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8/10/2019 (__)PNEUMATIC SHEET CUTTING MACHINE.doc
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PNEUMATIC SHEET CUTTING MACHINE
Submitted in partial fulfillment of the requirement for the award of
DIPLOMAIN
MECHANICAL ENGINEERINGBY
Under the guidance of --------------------------------
2004-2005
DEPARTMENT OF MECHANICAL ENGINEERING
CERTIFICATE
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Register number: _________________________
This is to certi! th"t the #ro$ect re#ort tit%e&
PNE'MATIC (HEET C'TTING MACHINE
submitte& b! the o%%o)ing stu&ents or the ")"r& o
the Di#%om" engineering is recor& o bon"*&e )or+
c"rrie& out b! them,
Done b!
Mr. / Ms_______________________________
In partial fl!ll"#nt $f t%# r#&ir#"#nt f$r t%# a'ar( $f(#)r## in
Di#%om" in Mech"nic"% EngineeringDuring The Ye"r-./001-/0023
44444444444444444 444444444444444He"& o De#"rtment Gui&e
C$i"*at$r# +4,+5,.at#:
(ubmitte& or the uni5ersit! e6"min"tion he%& on
44444444444
44444444444444444 4444444444444444Intern"% E6"miner E6tern"%E6"miner
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---------------------------------------------------------------------------------
AC7NO8LEDGEMENT---------------------------------------------------------------------------------
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ACN1EGEMENT
At this #%e"sing moment o h"5ing successu%%!
com#%ete& our #ro$ect9 )e )ish to con5e! our
sincere th"n+s "n& gr"titu&e to the m"n"gement
o our co%%ege "n& our be%o5e& ch"irm"n
)ho #ro5i&e& "%%
the "ci%ities to us,
8e )ou%& %i+e to e6#ress our sincere th"n+s toour #rinci#"% or
or)"r&ing us to &o our #ro$ect "n& o:ering
"&e;u"te &ur"tion in com#%eting our #ro$ect,
8e "re "%so gr"teu% to the He"& o
De#"rtment Pro, ,, or
her constructi5e suggestions < encour"gement
&uring our #ro$ect,
8ith &ee# sense o gr"titu&e9 )e e6ten& our
e"rnest < sincere th"n+s to our gui&e
,,9 De#"rtment
o Mech"nic"% or her +in& gui&"nce a9imum ;peration ressure = 1/ bar
ort si6e = + mm
! F(o /o"tro( (3e
Te/4"!/( Dt
ort si6e D /(!' 9 1/EF m
ressure D /-, 9 1/ 3AmF
>edia D )ir
Guantity D 1
2. Co""e/tor&
Te/4"!/( dt
>a9 wor&ing pressure D 1/ 9 1/ 3AmF
emperature D /-1// H "
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7luid media D )ir
>aterial D 0rass
5. Ho&e&
Te/4"!/( dte
>a9 pressure D 1/ 9 1/ 3AmF
;uter diameter D ( mm = ( 9 1/ Jm
Inner diameter D !' mm = !' 9 1/ Jm
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---------------------------------------------------------------------------------------
CHAPTE-6---------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------CMPNENTS AN
ESCIPTIN---------------------------------------------------------------------------------------
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CHAPTER-,
COMPONENTS AND DESCRIPTION
he ma4or components of these systems are5
"ompressor
neumatic "ylinder
Solenoid Bal*e
Cose and fitting
Seals
"ontrol imer "ircuit
7low control *al*e
COMPRESSOR$
he air under high pressure is gi*en by a compressor It is dri*en by an electric
motor he compressor deli*ers air to inlet of the cylinder )n air compressor as the same
indicates is a machine to compress the air and to raise its pressure he air compressor
suc&s air from the atmosphere5 compresses it and then deli*ers the same under a high
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pressure to a storage *essel from the storage *essel it may be con*eyed by a pipeline to a
place where the supply of compressed air is required
Since the compression of air requires some wor& to be done on it5 therefore
compressor must be dri*en by some prime mo*er
he compressed air is used for many purposes such as for operating pneumatic
drills5 ri*ets5 paint spraying and supercharging of internal combustion engines etc5 It is
also used in the operation of lifts5 rams5 pumps and *aricty of other de*ices in industry
"ompressed air is suc&ed for producing ballast of air in blast furnaces and bessemer
con*erter
C(&&!!/t!o" o A!r Com%re&&or
he air compressor may be classified in many ways but the following are
important of *iew
1 )ccording to wor&ing
a 8eciprocating "ompressor
b 8otary "ompressor
2 )ccording to action
a Single acting compressor
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b #ouble acting compressor
! )ccording to number of stages
a Single stage compressor
b >ulti stage compressor
RECIPROCATING COMPRESSOR$
hey are a*ailable in great *ariety including special machine for unusual
requirements >a9imum compression compression ratio may be as high as 1/ per stage
wo stage compressors are a*ailable for compression ratios greater than eight
here different type of piston type reciprocating air compressor are a*ailable
hey are
1 Bertical
2 Cori6ontal
! 8adial
$
he most commonly used one is hori6ontal air cooled type reciprocating air
compressor for a pressure range ( to 12 KgAcm7
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Co"&tru/t!o"
It is similar to that of an internal combustion LI"M engine consisting of cost-iron or
aluminum body with an oil tan&5 the base piston with piston rings5 *al*es5 connecting
rods5 cran&s5 cran& shaft and bearing etc If the piston is mo*ing down air is suc&ed in
through the suction *al*e and a filter and is compressed in return stro&e
;il le*el gauges5 oil filling screw and oil outlet screw etc are also important parts
of an air compressor
he pressure switch is connected to the dri*ing motor and is set such that it
automatically trips off5 disconnecting the electrical connection to the motor as soon as the
recei*er achie*es the desired set pressure
he safety *al*e is set to the same pressure limit and in case of the pressure
e9ceeds this limit5 it automatically opens and e9cess pressure is e9hausted to the
atmosphere5 thus limiting the system pressure to the desired le*el he drain *al*e drains
off the condensate produced at the condenser and the recei*er piston rings are used
around the piston to ma&e it airtight
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he first stage cylinder is called the low-pressure cylinder LM where air is drawn
from the atmosphere and is compressed initially he second cylinder is called the
second-stage cylinder5 which is of smaller diameter and it is also called high-pressure
cylinder LCM Cere the initially compressed air from first cylinder is further
compressed to high pressure
%hen air is compressed5 considerable heat is generated5 this heat must be
dissipated at least in units5 where pressure e9ceeds 2 bar he main machine is cooled by
air circulation on water circulation
C4r/ter!&t!/& o Dou'(e /t!"+ /om%re&&or&
7or the same sped and cylinder *olume5 air deli*ery is double that of a single
acting compressor
hey are mostly suitable for large capacity
"ylinders are mostly water-cooled
hey are normally used for continuous and hea*y-duty wor&s
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Cigher speed of piston while reducing the si6e of the compressor may contribute
to greater wear of piston rings5 cylinder liners and pic&ings referable range of
piston speed ad*ocated
7or small capacity compressor !// mAmin
7or large capacity compressor-2'mAmin
ower discharge temperature Lmostly 2$/H" for single stage compressorsM
he ultimate choice of an air compressor is decided considering two main factors
hey areD
;ne should go for a small compressor for each machine LorM
Should one ha*e a centrali6ed compressor power houseN
he portable answer will depend on pipe line layout5 system requirement and the
distance of the user machine from the plant
PNEUMATIC CYLINDER$
"ylinder is a de*ice which con*erts fluid power into liner mechanical force and
motion hese cylinders are widely used in industrial pneumatic systems hese
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cylinders are also called as linear motors and reciprocating motors pneumatic cylinders
are designed for a *ariety of ser*ices
neumatic cylinders are designed for a *ariety of ser*ices neumatic cylinders
transforms the flow of pressured fluid into a push or pull of the piston rod since out
system uses double acting cylinders we shall see some details about them
#ouble acting cylinders are in one in which fluid force can be applied to the
mo*able element in two directories he force e9erted by the compressed air mo*es the
piston in two directories in a double acting cylinder hey are used particularly he
piston is required to perform wor& not only on the ad*ance mo*ement but also on the
return In principle5 the stro&e length is unlimited5 although buc&ing and bending must be
considered before we select a particular si6e of piston diameter5 rod length and stro&e
length
he main component of any pneumatic system is the cylinder5 which recei*ers air
under pressure and the pressuri6ed air helps to mo*e the piston to and fro he force
acting on the piston will be equal to the product of the pressure of air and the area of the
cylinder
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he amount of air deli*ered into the cylinder into the cylinder decides the rate of
doing wor& ) cylinder is a hollow circular section with the top and bottom flange
pro*ided to pre*ent the lea&age of air
he compressed air is used to actuate the piston In order to mo*e the piston to
and fro5 the air is supplied to the top and bottom of the cylinder alternati*ely
"ylinder is mainly classified into two types namely5
Single acting cylinder
#ouble acting cylinder
In single acting cylinder5 using the spring pro*ided around the piston rod attains
the return stro&e5 but it is not efficient So5 the double acting cylinder is used in which
the return stro&e is attained using compressed air
Dou'(e A/t!"+ C)(!"der
In this the force e9erted by the compressed air mo*es the piston in two directions
hey are used partially when the piston is required to perform wor& not only on the
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ad*ance mo*ement but also on the return stro&e his principle5 the stro&e length is
unlimited5 although buc&ing and bending must be considered before selecting the
particular si6e of piston diameter5 rod length and stro&e length
he different parts of double acting cylinder areD
1 0arrel
2 iston rod
! op "o*er
$ 0ottom "o*er
' %iper "o*er
( 8etaining ring
+ iston
, iston guide
. 0earing "ap
1/ O;@ ring for piston guide
11 Ce9agonal soc&et head screw
12"hec& nut
he double acting cylinder is made up of cast aluminium he inner and outer
surface of the cylinder should be machined accurately he internal diameter of the
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cylinder should be accurate in order to pro*ide a smooth surface for the pac&ing he
appearance of the outer diameter should be good
he outer most part of the bottom and top co*er contains internal threads for
inserting bolts to clamp the cylinder
In case of double acting cylinder a force is de*eloped in both the directions he
mo*ing member inside the cylinder is nothing but a piston which is found to be mo*ing
forward and bac&ward due to high-pressure air he cylinder top and lower plate are
flanged together by means of bolts and nuts he bottom of the cylinder is also flanged
with end co*ers for the mo*ement of the piston in reciprocating manner
he bottom end co*er has a bore in center whose diameter is slightly larger than
piston rod diameter he force during the return stro&e is less compared to that of the
forward stro&e because in the former5 the piston rod co*ers some area so that the air
cannot concentrate in the piston rod area
2.2.1. Prt& o P"eumt!/ C)(!"der
P!&to"
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he piston is a cylindrical member of certain length which reciprocates inside the
cylinder he diameter of the piston is slightly less than that of the cylinder bore diameter
and it is fitted to the top of the piston rod It is one of the important part which con*erts
the pressure energy into mechanical power
he piston is equipped with a ring suitably proportioned and it is relati*ely soft
rubber which is capable of pro*iding good sealing with low friction at the operating
pressure he purpose of piston is to pro*ide means of con*eying the pressure of air
inside the cylinder to the piston of the oil cylinder
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he efficiency and economy of the machine primarily depends on the wor&ing of
the piston It must operate in the cylinder with a minimum of friction and should be able
to withstand the high compressor force de*eloped in the cylinder and also the shoc& load
during operation
he piston should posses the following qualities
a he mo*ement of the piston not creates much noise
b It should be frictionless
c It should withstand high pressure
P!&to" Rod
he piston rod is circular in cross section It connects piston with piston of other
cylinder he piston rod is made of mild steel ground and polished ) high finish is
essential on the outer rod surface to minimi6e wear on the rod seals he piston rod is
connected to the piston by mechanical fastening he piston and the piston rod can be
separated if necessary
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;ne end of the piston rod is connected to the bottom of the piston he other end
of the piston rod is connected to the other piston rod by means of coupling he piston
transmits the wor&ing force to the oil cylinder through the piston rod he piston rod is
designed to withstand the high compressi*e force It should a*oid bending and withstand
shoc& loads caused by the cutting force he piston mo*es inside the rod seal fi9ed in the
bottom co*er plate of the cylinder he sealing arrangements pre*ent the lea&age of air
from the bottom of the cylinder while the rod reciprocates through it
C)(!"der Co3er P(te&
he cylinder should be enclosed to get the applied pressure from the compressor
and act on the pinion he cylinder is thus closed by the co*er plates on both the ends
such that there is no lea&age of air )n inlet port is pro*ided on the top co*er plate and an
outlet ports on the bottom co*er plate here is also a hole drilled for the mo*ement of
the piston
he cylinder co*er plate protects the cylinder from dust and other particle and
maintains the same pressure that is ta&en from the compressor he flange has to hold the
piston in both of its e9treme positions he piston hits the top plat during the return
stro&e and hits the bottom plate during end of forward stro&e So the co*er plates must
be strong enough to withstand the load
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C)(!"der Mou"t!"+ P(te&$
It is attached to the cylinder co*er plates and also to the carriage with the help of
O@ bends and bolts
CONTROL ALE$
Barious types of control *al*es are used to regulate5 control and monitor the air
energy for control of direction pressure5 flow5 etc
neumatic energy is regulated and controlled by pneumatic *al*es 7unctionally
*al*es are di*ided into four ma4or groups
#irection "ontrol
7low "ontrol
In our pro4ect electrically actuated solenoid operated 'A2 #" *al*es are used
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Solenoid is another name for an electromagnet #irection control *al*es are *ery
often actuated by electromagnets )n electromagnet is a temporary magnet ) magnetic
force is de*eloped in an electromagnet when electrical current passes through it and force
drops down as soon as it is de energi6ed
his electromagnet is commonly termed as solenoid he proper wor&ing of a
solenoid operated *al*e depends on the reliability of the electromagnets
It ensures
Guic& and sure action
ong life
Pasy maintenance
ess wastage of energy
So(e"o!d (3e
he directional *al*e is one of the important parts of a pneumatic system
"ommonly &nown as #"B5 this *al*e is used to control the direction of air flow in the
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pneumatic system he directional *al*e does this by changing the position of its internal
mo*able parts
his *al*e was selected for speedy operation and to reduce the manual effort and
also for the modification of the machine into automatic machine by means of using a
solenoid *al*e ) solenoid is an electrical de*ice that con*erts electrical energy into
straight line motion and force hese are also used to operate a mechanical operation
which in turn operates the *al*e mechanism
Solenoids may be push type or pull type he push type solenoid is one in which
the plunger is pushed when the solenoid is energi6ed electrically he pull type solenoid
is one is which the plunger is pulled when the solenoid is energi6ed
he name of the parts of the solenoid should be learned so that they can be
recogni6ed when called upon to ma&e repairs5 to do ser*ice wor& or to install them
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2.5.1. Prt& o So(e"o!d (3e
1. Co!(
he solenoid coil is made of copper wire he layers of wire are separated by
insulating layer he entire solenoid coil is co*ered with an *arnish that is not affected by
sol*ents5 moisture5 cutting oil or often fluids "oils are rated in *arious *oltages such as
11' *olts )"5 2!/ *olts )"5 $(/ *olts )"5 '+' Bolts )"5 ( Bolts #"5 12 Bolts #"5 2$
Bolts #"5 11' Bolts #" Q 2!/ Bolts #" hey are designed for such frequencies as '/
C6 to (/ C6
#. Frme
he solenoid frame ser*es se*eral purposes Since it is made of laminated sheets5
it is magneti6ed when the current passes through the coil he magneti6ed coil attract the
metal plunger to mo*e he frame has pro*isions for attaching the mounting hey are
usually bolted or welded to the frame he frame has pro*isions for recei*ers5 the
plunger he wear strips are mounted to the solenoid frame5 and are made of materials
such as metal or impregnated less fiber cloth
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,. So(e"o!d P(u"+er
he Solenoid plunger is the mo*er mechanism of the solenoid he plunger is
made of steel laminations which are ri*eted together under high pressure5 so that there
will be no mo*ement of the lamination with respect to one another )t the top of the
plunger a pin hole is placed for ma&ing a connection to some de*ice he solenoid
plunger is mo*ed by a magnetic force in one direction and is usually returned by spring
action
Solenoid operated *al*es are usually pro*ided with co*er o*er either the solenoid
or the entire *al*e his protects the solenoid from dirt and other foreign matter5 and
protects the actuator In many applications it is necessary to use e9plosion proof
solenoids
2.5.#. 0or*!"+ o So(e"o!d (3e
he solenoid *al*e has ' openings his ensure easy e9hausting of 'A2 *al*e he
spool of the 'A2 *al*e slide inside the main bore according to spool position: the ports get
connected and disconnected he wor&ing principle is as follows
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Po&!t!o"-1
%hen the spool is actuated towards outer direction port O@ gets connected to O0@
and OS@ remains closed while O)@ gets connected to O8@
Po!&!t!o"-#
%hen the spool is pushed in the inner direction port O@ and O)@ gets connected to
each other and O0@ to OS@ while port O8@ remains closed
HOUSE AND FITINGS$
It is pro*ided for the passage of compressed air from the compressor outlet to the
operating *al*e
wo separate pipes also connect the operating *al*e with the wor&ing cylinder
pressure drop through and air line depends on the flow rate5 pipe diameter5 pipe length
and pipe geometry It can be determined directly for straight pipes of any gi*en length
) small chaining bore si6e can ha*e mar&ed effect on pressure drop5 where as e*en
doubling the pipe length5 will only result in doubling the pressure drop
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ressure drop through bends and fittings can only be determined by empirical
tests5 since it is specific to the internal geometry in*ol*ed 8igid pipes howe*er are less
manipulated through remain form of bends with arrangements increase and *ariable air
ha*e to flow and the flow itself may be of fluctuating or pulsating nature In this case it
is thus normally based on practical recommendation
SEALS$
Seal is an important component of a pneumatic system and is used to pre*ent the
air lea&age through the 4oint
his pro4ect passes the static seal which are used to pre*ent the lea&age through
the stationary surface
>aterial of the seal is eflon tape eflon has the following properties
%ithstand the system pressure and temperature without any damage
8esist the wear and abrasion
8eco*er from deformation
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8esists the ad*erse effects such as deterioration and shrin&ing
caused by the system air
Seals are de*ices for closing gaps to pre*ent lea&age or ma&e pressure 4oints and
also to pre*ent the entry of air and dirt from outside into the system he material of seal
must be compatible with the fluid medium It is a circular ring made of synthetic rubber
It is used for pro*iding tight sealing between the piston and the cylinder wall It pre*ents
air lea&age from the top and bottom of the cylinder
Seals for air cylinder and *al*es are not normally called upon to seal pressure
higher than about 2 bars Since the fluid to be seated is a gas5 Lin our case airM rubbing
speeds tends to be high and the seal the seal may ha*e to be operated under dry
conditions with minimal lubrication
CONTROL TIMER CIRCUIT$
Need or T!mer C!r/u!t$
>ain purpose to timer circuit is to actuate the solenoid *al*e at regular inter*al of
time to achie*e proper lubrication at the desired inter*al
ELECTRONIC CONTROL TIMING UNIT$-
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2 6
7 IC
555
8 ,
# 1
18
,
2917 #
12
2
1, 6
Cere the ''' I" has been used as a multi *ibrator he output of I" ''' is fed to
the input pin Lpin no 1$M of "# $/1+ continues counting
he output of the I" becomes a*ailable at pin 3os !5 2 and $ he output pulse of
any one of output pin triggers Luts ;3M the riac and current starts flowing across the
load connected his process continues on other pins at different time inter*als and the
cycle continues he frequency inter*al LimeM of the cycle can be ad4usted by the pre-set
loo& connected to pin ( of ''' imer I"
2A-#,9 : ,
27;
L1
TRIAC : ,
1N2997 : ,
L#
19; L,
199=F 1N2997 : 2
1N2997
1999=F
#,9
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1 ,
2 + IC
NE 555
! (
$ '
#,9 A//?
TRIGGER DISCHARGE
OUTPUT THERSOLD
RESET CONTROL
PIN NO$ 1
It is ground terminal
PIN NO$ #
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he trigger *oltage to the lower comparator is applied It has constant *oltage
that is atleast one third of the supply *oltage5 when trigger *oltage falls below this le*el
the flip-flop changes its state and output becomes high
PIN NO$ ,
It is the output
terminal5 in low state output is equal to
6ero and when at higher state output is
equal to Bcc
PIN NO$ 2
It controls the flip
flop directly It turns the de*ice to its
original position when reset pin is
connected to ground the output is
appro9imately equal to 6ero %hen reset is not used it is connected to Bcc
PIN NO$ 5
It is the control *oltage terminal It is connected to ground through a capacitor of //1
R7 )ny e9ternal *oltage at pinD ' will change both the threshold *oltage and the trigger
*oltage reference le*el
PIN NO$ 8
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hreshold *oltage of upper comparator is applied from this terminal he resistor 8t
connected to Bcc and pinD ( is grounded by an e9ternal capacitor he output is high
capacitor charges by resistor 8t %hen the capacitor changes to the threshold le*el5 the
output becomes low
PIN NO$ 7
It is the discharge pin for e9ternal capacitor Usually pinD + is connected with pinD (
directly to by a resistor %hen the output becomes low then the e9ternal capacitor
discharges by internal discharge transistor remains at cut-off and the e9ternal capacitor
charges to Bcc
PIN NO$ 6
It is the positi*e supply terminal ) dc *oltage from ?' to ? 1' can be applied
T4e !m%ort"t eture& o IC555 /" 'e &ummr!@ed & o((o&.
1 iming range from microseconds to hours
2 >ono-stable and )stable operation is possible through I"'''
! he duty cycle can be ad4usted according to our necessity
$ It has the ability to operate from a wide range of supply Boltage
IC 555 SPECIFICATION
Supply Boltage LBccM = $' to 1'B
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Supply "urrent LBcc='BA2M = ! to (m)
Supply "urrent LBcc=2'BA2M = 1/ to 1'm)
;utput "urrent = 2//m) Lma9imumM
ower dissipation = (//mw
FLO0 CONTROL ALE$
7low "ontrol Bal*es are fitted to all the distribution tubes his *al*e is made of
brass 0oth the ends ha*e stepped surface to insert hoses ) handle is pro*ided to control
the flow of oil in e*ery *al*e
>? Te/4"!/( Dt$
Si6e D
ressure D / to 1/ &g A cm2
>edia D )ir
> ' ? Pur%o&e$
his *al*e is used to speed up the piston mo*ement and also it acts as an one way
restriction *al*e which means that the air can pass through only one way and it can@t
return bac&
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0y using this *al*e the time consumption is reduced because of the faster
mo*ement of the piston
---------------------------------------------------------------------------------------
CHAPTE-4---------------------------------------------------------------------------------------
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---------------------------------------------------------------------------------------
ING PINCIP1E---------------------------------------------------------------------------------------
CHAPTER-2
0OR;ING PRINCIPLE
he compressed air from the compressor is used as the force medium for this
operation here are pneumatic double acting cylinders5 solenoid *al*e: flow control
*al*e and timer unit used he arm from the compressor enters to the floe control Bal*e
he controlled air from the flow control *al*e enters to the solenoid *al*e he
function of solenoid *al*es all of air correct time inter*al he 'A2 solenoid *al*e is used
In one position air enter to the cylinder and pusses the piston5 so that the cutting stro&e is
obtained
he ne9t position air enters to the other side of cylinder and pusses the piston
return bac&5 so that the releasing stro&e is obtained he speed of the cutting and releasing
stro&e is *aried by the timer control unit circuit
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CHAPTE-5---------------------------------------------------------------------------------------
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ESIGN AN AINGS---------------------------------------------------------------------------------------
CHAPTER-5
DESIGN AND DRA0INGS
PNEUMATIC CYLINDER
De&!+" o P!&to" rod$
oad due to air ressure
#iameter of the iston LdM = $/ mm
ressure acting LpM = ( &gfAcm7
>aterial used for rod = " $'
Tield stress L8yM = !( &gfAmm7
)ssuming factor of safety = 2
7orce acting on the rod LM = ressure 9 )rea
= p 9 L9d7A $M
= ( 9 L 99 $7 A $ V
= +!!( Kgf
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#esign StressL8yM = 8y A 7/ S
= !( A 2 = 1, KgfAmm7
= A L9d7A $ M
;d = inimum diameter of rod required for the load = 2! mm
%e assume diameter of the rod = 1' mm
De&!+" o /)(!"der t4!/*"e&&$
>aterial used = "ast iron
)ssuming internal diameter of the cylinder = $/ mm
Ultimate tensile stress = 2'/ 3Amm7 = 2'// gfAmm7
%or&ing Stress = Ultimate tensile stress A factor of safety
)ssuming factor of safety = $
%or&ing stress L ftM = 2'// A $ = (2' KgfAcm7
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)ccording to O)>PS PGU)I;3@
>inimum thic&ness of cylinder L t M = ri < Lft? pM A Lft p M -1 V
%here5
ri = inner radius of cylinder in cm
ft = %or&ing stress LKgfAcm7M
p = %or&ing pressure in KgfAcm7
;Substituting *alues we get5
t = 2/ < L(2' ? (M A L (2' (M -1V
t = //1. cm = /1. mm
%e assume thic&ness of cylinder = 2' mm
Inner diameter of barrel = $/ mm
;uter diameter of barrel = $/ ? 2t
= $/ ? L 2 9 2' M = $' mm
De&!+" o P!&to" rod$
D!meter o P!&to" Rod$
7orce of piston 8od LM = ressure 9 area = p 9 9/4Ld7M
= ( 9 L9A $M 9 L$M7
= +!!( Kgf
)lso5 force on piston rod LM = L9A$M LdpM79 ft
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= LYA$M 9 LdpM7 9 (2'
+!!( = LYA$M 9 LdpM79 (2'
;dp7 = +!!( 9 L$AYM 9 L1A(2'M
= /1'
dp = /!, cm = !, mm
0y standardi6ing dp = 1' mm
Le"+t4 o %!&to" rod$
)pproach stro&e = 1(/ mm
ength of threads = 2 9 2/ = $/mm
P9tra length due to front co*er = 12 mm
P9tra length of accommodate head = 2/ mm
otal length of the piston rod = 1(/ ? $/ ? 12 ? 2/
= 2!2 mm
0y standardi6ing5 length of the piston rod = 2!/ mm
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CHAPTE-+---------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------APP1ICATINS =
ISA>ANTAGES---------------------------------------------------------------------------------------
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CHAPTER-8
APPLICATIONS AND DISADANTAGES
APPLICATIONS$-
his machine is *ery useful for small scale industries
his machine is used to cut the roller sheet metal
)ll Industrial )pplication
DISADANTAGES$-
%hile wor&ing5 the compressed air produces noise therefore a silencer may
be used
Cigh torque can not be obtained
oad carrying capacity of this unit is not *ery highLZ'/ 3M
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CHAPTER-7
ADANTAGES
he pneumatic is more efficient in the technical field
Guic& response is achie*ed
Simple in construction
Pasy to maintain and repair
"ost of the unit is less when compared to other machine
3o fire ha6ard problem due to o*er loading
"omparati*ely the operation cost is less
he operation of cutting is faster because the medium used to operate is air
"ontinuous operation is possible without stopping
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---------------------------------------------------------------------------------------
CHAPTE-@---------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------
1IST MATEIA1S---------------------------------------------------------------------------------------
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CHAPTER-6
LIST OF MATERIALS
S(.
No.
De&/r!%t!o" t). MATERIAL
/1
/2
/!
/$
/'
/(
/+
/,
.
1/
11
12
#ouble acting cylinder
Solenoid Bal*e
imer
7low "ontrol Bal*es
Coses
%ire
Stand
0ase 0oard
Cose "ollar
8educer
7i9ed cutting plate
>o*ing "utting late
1 3o
1 3o
1 3o
1 3o
2 >
2>
1 3o
1 3o
( 3;
1 3;
1 3;
1 3;
P3,
)U
PP"8;3I"
)U
;TU8PP3P
-
>S
>S
08)SS
08)SS
SS
SS
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---------------------------------------------------------------------------------------
CHAPTE-B---------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------
CST ESTIMATIN---------------------------------------------------------------------------------------
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CHAPTER-=
COST ESTIMATION
1. MATERIAL COST$
S(.
No.
De&/r!%t!o" t). MATERIAL COST >RS?
/1
/2
/!
/$
/'
/(
/+
/,
.
1/
11
12
#ouble acting cylinder
Solenoid Bal*e
imer
7low "ontrol Bal*es
Coses
%ire
Stand
0ase 0oard
Cose "ollar
8educer
7i9ed cutting plate
>o*ing "utting late
1 3o
1 3o
1 3o
1 3o
2 >
2>
1 3o
1 3o
( 3;
1 3;
1 3;
1 3;
P3,
)U
PP"8;3I"
)U
;TU8PP3P
-
>S
>S
08)SS
08)SS
SS
SS
TOTAL B
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#. LAOUR COST
)CP5 #8II3aterial "ost ? abour cost
=
=
;*erhead "harges = 2/[ of the manufacturing cost
=
TOTAL COST
otal cost = >aterial "ost ? abour cost ? ;*erhead "harges
==
otal cost for this pro4ect =
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---------------------------------------------------------------------------------------
CHAPTE-,0---------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------
CNC1USIN---------------------------------------------------------------------------------------
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CHAPTER-19
CONCLUSION
his pro4ect wor& has pro*ided us an e9cellent opportunity and e9perience5 to use
our limited &nowledge %e gained a lot of practical &nowledge regarding5 planning5
designing drawing5 purchasing5 computing and machining while doing this pro4ect wor&
%e feel that the pro4ect wor& is a good solution to bridge the gates between institution
industries
%e are proud that we ha*e completed the wor& with the limited time successfully
he machine is wor&ing with satisfactory conditions %e are able to understand the
difficulties in maintaining the tolerances and also quality %e ha*e done to our ability
and s&ill ma&ing ma9imum use of a*ailable facilities
In conclusion remar&s of our pro4ect wor&5 let us add a few more lines about our
impression pro4ect wor&
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he chief ad*antage of our system is that5 it cutting speed is *aried he fast
operation is done by the timer unit his pro4ect is a low cost automation pro4ect
---------------------------------------------------------------------------------------
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I1IGAPH3---------------------------------------------------------------------------------------
ILIOGRAPHY
1 ) e9t 0oo& of >achine #esign----8SKhurmi Q \Kc
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, neumatic System---->a4umdhar5 3ew )ge India International LM td
ublishers5 1..+
. Strength of >aterials----S 8amamurtham Q 8 3arayanan5 #hanpat 8ai
ublishing "orporation5 1..,
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