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05/01/2023 1
FABRICATION OF PNEUMATIC SHEET CUTTERAnsita Mohanty
Jyoti Panda
Basundhara Pradhan
Shubhendu Verma
Rohit Ranjan
Smurtipiyush Sahoo
Mechanical engineeringSection A, Group no. A9
14th May, 2016
Guided By: Dr. D.N Thatoi
Asst. Prof. Sasanka Choudhary
05/01/2023 2
Mission Statement
• Use of pneumatically controlled Sheet metal cutter in an efficient way.
• Fabrication of pneumatic sheet cutting machine with minimization of cost as well as size.
• Making the machine automatic and user friendly so that it will be easier for operation.
• Determine the maximum out put from our model and make it satisfactory to the customer as well.
• Finally gain experience through individual and team performance.
05/01/2023 3
Introduction
What is a Sheet metal• Sheet metal is simply a metal formed into thin
and flat pieces. The thickness of sheet is calledits gauge. The thickness above 6mm falls in Plate category.
• There are many metals that can be made into sheet metal like Aluminum, Brass, copper, steel, tin etc. For decorative uses sheet metals of Silver, gold, platinum are also used.
• Sheet metals are used in Car bodies, medical tables, roofs for buildings etc. Use of sheet metal are now days in furniture, shelves or cupboards.
Schematic representation
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How Sheet Metal is cut:• The cutting process is done by applying Shear Force• Due to application of shear Force, the stress in the
material will exceed the ultimate shear strength and the material will fail and separate at the cut location.
• Shearing force is applied by 2 blades one above and one below the sheet.
• The upper blade delivers a quick downward blow to thesheet metal that rests on the lower blade.
• The upper tool penetrates on the sheet causing the shearing and material failure.
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Customer Need Statement and Importance Ranking
CUSTOMER NEEDS No. Of Occurrences (Out of 20) Weightage
Efficient Cutting 16 0.8
Reduce Human effort 14 0.7
Occupy Less space 15 0.75
Low Cost 13 0.65
Less Maintenance 10 0.5
Automatic Operation 11 0.55
Reduce Power Consumption 7 0.35
Safety During Machining 10 0.5
Portability 15 0.75
More thickness of Sheet 9 0.45
05/01/2023 6
SMOOTH OPERATION
TRANSMITMECHANICAL
ENERGY
PRODUCE CUTTING FORCE
PISTON CYLINDER
COMPRESS IT PNEUMATICALLY
LUBRICATIONDAMP VIBRATIONS
TRANSMIT FORCE TO CUTTING BLADE
ALIGNMENT OF WORK PIECE
LOCOMOTION OF CUTTING BLADE
OVER SHEET METAL
CUT THE SHEET
PROVIDE AIR
GENERATE NOISE
HOW? WHY?
REDUCE NOISE
ELIMINATELEAKAGE
FAST Method
PORTABILITY LINEAR SMOOTH OPERATION
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Function Structure
Open SystemClose System Support
Cutting blades
Execute Cutting
Store the split sheet Raw Metal sheet
Pressure force
AirSheet uncut
Cutting force
Release air
Sheared metal sheet
Provide elect. to compressor
Generation of compressed air
Stores compressed air
Flow of air to FRL unit
Compression & storage
Release into pneumatic cylinder
Cut the sheet
FRL Unit Expansion of air inside cylinder
Motion of connecting rod to
movement of blade
Shearing over the sheet
Electrical energy
Compressed air pressure
Air
Uncut Sheet
Sheared metal
K.E of blade
Cutting of metal as required
Desired cut
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Bill Of Material FormProject Name: Design and fabrication of Pneumatic Sheet cutter
Engineers ANSITA MOHANTY, JYOTI PANDA, BASUNDHARA PRADHAN, SHUBHENDU VERMA, ROHIT RANJAN, SMRUTIPIYUSH SAHOO
Date 04.03.2016
Part No
Name Qty Functional Analysis DFM Cost Analysis
Function Flows in Flows out Manuf. Process
Manuf. Cost
(In Rupees)
Dimensions Mass Material Finish
1 Shearing Blades
assembly
2 Cut the Sheet Metal sheet
Sheared sheet
Machining 320 L=200 mm, B=55 mm, t=12mm
2kg High Speed Steel
Smooth
2 Pneumatic cylinder assembly
1 Provide force to the blades
Compressed air
Expanded air
Available in market
2449 Stroke=200mm, D=50mm, Pr.=10bar
2.5kg High Carbon Steel
Smooth
3 Base frame
assembly
1 Support the blades and
cylinder
Sheet metal
Sheet metal
Wood cutting
NA As required 2kg Wood Rough
4 Nuts and bolts
As require
d
Tightening ------- -------- 80 As required Mild steel Rough
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Efficient cutting 1
Reduce human effort 2
Less space to occupy 3
Portability 4
Low cost 5
3 5 1 3 4
N cm2 kg bar Rs
562 1500 10 8 3000
570 1500 NA 10.3 4200
566 1350 NA 8 3500
Max
. cut
ting
Forc
e
Are
a of
bas
e
Wei
ght t
o ca
rry
Max
. Air
pres
sure
Equ
ipm
ent c
ost
Technical Difficulty
Measurement Unit
Object Target Value
Objective Measures
FIBER 500
Reference model
Strong Relationship
Medium RelationshipWeak Relationship
House of Quality
4 3
4 3
3 4
4 4
3 3
FIB
ER
50
0
Ref
eren
ce m
odel
05/01/2023 10
Sheet Metal Cutting
Human
Cutter alignment
Use of removable
cutterUse of single type of metal
sheet cutter
Expectation
Well trained
Analogies
Use of FRL unit
Use of solenoid
Use of regulating switch
Material alignment
Use of single variant of sheet
metal
Thickness within the limit
Manual application
Replacement of effort
application method
Hydraulic application
Pneumatic application
Mind Map Function
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PUGH CHARTWeightage
ConceptsOption # 1 Option #2 Option #3 Option #4 Option
#5
Use of Pneumatic Cylinder
Use of shear blades instead of scissor blades
Electronic sensor for air flow regulation
FRL regulating switch for air flow
Use less base area for sheet cutting
CRITERIA
Efficient Cutting 4 1 1 S S S
Reduced Human effort 3 S S 1 1 1
Less space to occupy 3 S S 1 S 1
Portability 4 S S S S 1Low cost 3 1 -1 -1 1 S ∑+ 2 1 2 2 3
∑- 0 -1 -1 0 0
∑ 2 0 1 2 3
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Part Models
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Assembly
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Mathematical Equations and numerical calculation for Sheet metal cutter
For Aluminum Sheet of Thickness “1mm”
Thickness = 1 mmLength of cut = 30mmMaximum Shear Strength of Aluminum = 30 N/mm2
Force Calculation:
Force required to cut the sheet =
This is the force required to cut the sheet. However, initially the force required will be 140-150 % of calculated value.(We have taken this from reference)
Hence, required force
The Compressor pressure should be max 10 bar.But our Base structure is made up of wood, so it can’t withstand such pressure when applied continuously.
So we have taken iterations of 8 bar, 6 bar and 4 bar respectively. Out of which 8 bar pressure gives us the cylinder diameter of minimum size.
Design of cylinder:Since max force required to cut the sheet= 1350N Applied Max pressure= 10bar, we will let the pressure at 8 bar.Converting the unit 1 bar= So, Force applied by the cylinder,
Therefore, diameter of the cylinder is ~50mm (This is taken basing upon the dimensions available in the market)
maxtL
30130 FN900
1350%150900 mmd
d
35.46
1084
1350 12
PdF 2
4
1260%140900
05/01/2023 15
Solid Works Simulation
Fixtures and Load
Fixture name Fixture Image Fixture Details
Fixed-1
Entities:3 face(s)
Type:Fixed Geometry
Resultant Forces
Components X Y Z ResultantReaction force(N) -0.490486 5.69331 1.44239 5.89362
Reaction Moment(N.m) 0 0 0 0
Load name Load Image Load Details
Force-1
Entities:1 face(s)Type: Apply normal forceValue: 675 N
05/01/2023 16
Dynamic Analysis of stress
Name Type MinMax
Stress1 VON: von Mises Stress at Step No: 100(1 Seconds)
2.20596 N/m^2Node: 6434
7.90995e+007 N/m^2Node: 1727
Assembly3-Dynamic 3-Stress-Stress1
05/01/2023 17
Displacement analysis
Name Type Min
Max
Displacement1 URES: Resultant Displacement at Step No: 100(1 Seconds)
0 mmNode: 1725
0.373107 mmNode: 10603
Assembly3-Dynamic 3-Displacement-Displacement1
05/01/2023 18
FMEA of Sheet metal cutter productProduct Name: Pneumatic sheet metal cutterMetal Cutting System
Devel. Team: Ansita, Jyoti, Basundhara, Shubhendu, Rohit, Smruti
Page No. 1 of 1 Date: 21.03.2016
Part No & Functions
Potential Failure Mode
Potential Effect(s) of Failure
SEVERE(S)
Potential Cause(s)/ Mechanism(s) of Failure
OCCUR(O)
Current Design Controls/ Tests
DETECT(D)
Recommended Actions
RPN
Blade Tool breakage and edge breakage
Deteriorated cutting operation
8 Incorrect clearance angle and blade angle during manufacturing Misalignment of lower blade and upper blade
3 Prototype test and analysis
7 Regular maintenance and checking for contact surface erosion
168
Cylinder Decrease of air pressure within the cylinder
Insufficient cutting force to the blade
4 Leaks in tubing and connections
6 Prototype test and analysis
8 Secure the valves and check the tubing regularly
192
Piston Damage in Piston head
In appropriate motion
6 Maximum usage and mfg. defects
5 NA 8 Maintenance service 240
Connecting Rod
Fracture of connecting rod
Disengagement of blade w.r.t. pneumatic cylinder
9 Failure due to sudden change in pressure of inlet air
2 Check for material strength during prototype simulation
9 To maintain a near constant pressure output from the compressor
162
05/01/2023 19
Material selection for pneumatic sheet metal cutter
• Base frame: To choose the material for the ‘Base frame’ would be ‘Wood’. The kind of wood available in local area is mostly Teak.The Base of the frame would be made up of ‘Plywood’ as it provides High strength and it is available in large sheets.
• Shearing Blade: To choose the material for ‘Shearing blade’ would be ‘High speed steel (H 13)’.This type of hot work steel provides better Toughness and resistance to Thermal Fatigue cracking.
• Connecting Link: The material for ‘Connecting Link’ would be ‘Mild steel’. The connecting link should provide high strength during to and fro motion of the connecting rod.Also the connecting Link needs to be welded properly with the Upper blade to make a linkage as shown in the figure.
• Pneumatic cylinder: The material for ‘Pneumatic Cylinder’ would be ‘High carbon steel’. As we are not manufacturing this cylinder, we don’t focus on what material it is based on.
Component Manufacturing process
Shearing blade
(1 )Milling, (2) Hardening and tempering, (3) Surface grinding. (4) Drilling, (5) Welding
Base Frame (1)Ply cutting, (2) Wood cutting, (3) Fastening, (4) Drilling
Connecting Link
(1)Drilling, (2) Filing, (3) Welding
Manufacturing Process
Pneumatic Cylinder-Frame: Assembled by Drilling.
Upper Blade and Lower Blade: Bolt and nut tightening at the hinge point so that Upper blade can rotate smoothly.
Connecting Link-Upper Blade: They were Joined by welding and bolt nut tightening.
Connecting Link-Cylinder: There was a threading at the end of Connecting Rod of Cylinder. So The connecting Link was tightened with Nuts and Bolts to the Connecting Rod.
Assembling Process
05/01/2023 20
05/01/2023 21
Our Fabricated Model
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Merits and Demerits
Hydraulics present certain advantages over pneumatics, but in a given application, pneumatic powered equipment is more suitable, particularly in industries where the factory units are plumbed for compressed air.
Moreover, to avoid corrosive actions, oil or lubricants are added so that friction effects can be reduced.
Compressed air is used in most of the machines and in some cases compressed carbon dioxide, whereas cutting process is become easy.
Fast cutting action is carried out.
Cutting without bending is achieved.
Sheet more than 1 mm thickness cannot cut easily.
Compressed air is
must.
Foundation is required also safety measurer must be taken.
05/01/2023 23
Conclusion
Now we know that Pneumatic Shearing machine is very cheap as compared to hydraulic shearing machine. The range of the cutting thickness can be increased by arranging a high pressure compressor and installing more hardened blades. This machine is advantageous to small sheet metal cutting industries as they cannot afford the expensive hydraulic shearing machine.
Thus we can say that our Product was up to the mark and it hold a good running condition for a sheet of 1 mm thickness.
The Team performed in all activities in the project and gave their optimum values in dedication. We learnt the basics and established a well capable model that can fulfill our customer demand and satisfy their needs.
05/01/2023 24
References
Ajit Kumar Singh, Harpreet Singh and Dharmendra Sharma, “Design and Fabrication of Pneumatic Auto Sheet Metal Cutting Machine Using Solar Energy”, International Journal of Engineering Research & Technology (IJERT): ISSN: 2278-0181: Vol. 4 Issue 03, March-2015
A.S. Aditya Polapragada & K. Sri Varsha , “Pneumatic Auto Feed Punching, cutting and Riveting Machine “, International Journal of Engineering Research & Technology (IJERT) Vol. 1 Issue 7, September - 2012 ISSN: 2278-0181.
P.M.Pradhan, “Experimental Investigation and Fabrication of Pneumatic Cutting tool”, International Journal of Innovative Research in Science, Engineering and Technology, Vol. 2, Issue 6, June 2013.