DESIGN AND FABRICAT FABRICATION ION OF PNEUMATIC CONTROLLED SAND SLINGING MACHINE
Submitted in the partial fulfillment of the requirement for the award of
SUBMITTED BY:
1. R. VINO VINOT TH KUMA KUMAR R
4. S. SOLO SOLOMA MAN N RAJ RAJ
2. L. PRAMOSH
5. K. NEDUMARAN
3. C. N. SHANK HANKAR ARAN AN
6. S. SARA ARAVANAN NAN
Under guidance of
Mr. M.RAM PRABHU, M.E,.Ph.D M.E,.Ph .D OTOBE! "#$%&
DEPARTMENT OF MECHANICAL ENGINEERING VELTECH ENGINEERING COLLEGE CHENNAI – 600054
VELTECH ENGINEERING COLLEGE CHENNAI – 600054
DEPARTMENT OF MECHANICAL ENGINEERING
BONAFIDE CERTIFICATE CERTIFICATE Thi' i' to certif( that thi' )ro*ect wor+ on
“DESIGN AND FABRICATION OF PNEUMATIC CONTROLLED SAND SLINGING MACHINE ”
'ubmitted b( ,,,,,,,, ,,,,,& !eg& -o& ,,,,, Thi' i' the bonafide record of wor+ carried out b( him under our 'uper.i'ion during the (ear "#$% Submitted for the /i.a0.oce e1am held on ,,,,,&&
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ACKNOWLEDGEMENT 3t the out'et9 out'et9 we would would li+e to empha'ie empha'ie our 'incere 'incere than+' than+' to the Mr. ! !M.T M.TECH. ECH.!! encour )rincipal Mr. encourage agemen mentt and .aluab .aluable le
ad.ice&
we than+ our E'quired 2ead of Department Mr S S! ! A.M.I.E! M.E.! for pre'enting hi' felicitation' on u'&
;e are grateful on our Entourage'
Mr. ! M.E.! for
guiding in .ariou' a'pect' of the pro*ect ma+ing it a grand 'ucce''&
;e al'o al'o owe owe our our 'inc 'incer eree than than+' +' to all all 'taf 'tafff memb member er'' of the the Mechanical Engineering Department&
Ultimatel( Ultimatel(99 we e1tend e1tend our than+' than+' to all who had rendered rendered their their co0 operation for the 'ucce'' of the pro*ect&
CONTENTS
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TIT7E
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SY-O)SIS
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ABSTRACT
ABSTRCT To increa'e the producti.it( and to o.ercome '+illed labour 'hortage9 mo't of the manufacturi manufacturing ng indu'trie' indu'trie' are going for automati automation& on& The main arm for u' to 'elect the pro*ect wor+ i' to acquire practical +nowledge in the field of automation u'ing )-EUM3TI )-EUM3TI SYSTEM&
DESIGN AND AND ;e 'elect 'electedC edCDESIGN
FABRICA BRICAT TION OF PNEU PNEUMA MAT TIC
CONTROLLED SAND SLINGING MACHINE a' our pro*ect wor+ and we
u'ed principle' of Mechatronic' in de.eloping thi' pro*ect wor+9 the .ibrating mechan mechani'm i'm i' achie. achie.ed ed b( recipr reciproca ocatin ting g the double double acting acting c(lind c(linder' er' which which controlled b( 'olenoid operated ?" wa( D .al.e which i' actuated through the ontrol '('tem& The operating pre''ure required for thi' '('tem i' ? to % bar& The maintenance required for thi' '('tem i' le'' than the other '('tem'&
The pro*ect con'i't of $& "& <& >&
M&S& M&S& Sta Stand )neuma )neumatic tic control control '('tem '('tem /IB!3T /IB!3TI-6 plate with 'creen t(pe filter filter Elec Electr tric ic pan panel el
". M.S.STA M .S.STAND# ND# The M&S&Stand i' 'hown in figure& It i' made in 7 angle of "mm "mm thic thic+n +ne' e''' and and >?#8 >?#8 %## %## mm widt width h and and leng length th&& The The c(li c(lind nder er i' mounted at the top and connected to the .ibrating plate at the end of pi'ton rod&
$. PNEUMATIC S%STEM# In pneumatic '('tem9 the pi'ton rod in c(linder i' mo.ed b( the 'uppl( of compre''ed air which i' 'upplied through the ?" wa( 'olenoid operated directional control .al.e& The c(linder 3 and and B port' are connected to the ?" wa( D&& /al.e with %Amm )/ tube& The %mm connector i' u'ed to connect thi' c(linder port and D& .al.e& The minimum air pre''ure
required i' ? to %bar& The figure 'how' the cro'' 'ection .iew of double acting c(linder&
4. VIBRATING PLATE& The figure 'how' the /ibrating plate &
The .ibrating plate & i' made in mild 'teel material& material& Thi' i' connected to the the end rod of the the double acting acting c(linder& c(linder&
4. ELECTRICAL PANEL: 3 ">/ D& Suppl( i' required to operate thi' 'olenoid .al.e& 4or thi' 'eparate 'witch i' pro.ided to O-O44 thi' 'olenoid .al.e&
WORKING PRINCIPLE VIBRATING MACHINE The )neumatic )neumatic circuit circuit diagram i' 'hown in below
Before 'tarting the machine 'et the pre''ure ? Bar in the 4!7 unit and connect air 'uppl( to the ?" wa( Solenoid operated directional control .al.e at the pre''ure port& WORKING PRINCIPLE' ()*r+,)- /+1)-23
The The doub double le acti acting ng c(li c(lind nder er i' actu actuat ated ed b( a ?" ?" 'ole 'oleno noid id operated directional control .al.e9 which i' controlled FO- GO44H through the contr controll oller er&& The The
'oleno 'olenoid id .al.e .al.e coil coil
i' opera operatin ting g at $".dc $".dc which which i'
connected to O-O44 rela( controller '('tem &
;hen the pu'h button i' pre''ed9 then the 'ignal i' 'end to the input of the O- O44 control !E73Y input9 which actuate the ?" 'olenoid coil which in turn actuate actuate the .al.e po'ition to to direct the air to the c(linder& c(linder& The c(linder pi'ton rod reciprocate' to and fro& ;hen the 'etting time i' reached9 the po'ition of the .al.e changed and pi'ton will be mo.e bac+ to it' initial po'ition&
2ere there i' no mechanical or electrical timer i' u'ed to return the pi'ton&
Specifcation o te co!ponent" #"e
%$JU3-TIT -3ME O4 T2E )3 )3!TS !TS
SIE Y
$& Doub Double le actin acting g c(li c(linde nder r
"& Solenoid ?" wa( D /al.e al.e
"?mm1$##mm
$".dc 1$> inch
$
$
'ie0 <& S7I-6E! )73TE
>##mm1>##mm
>& )O;E! SU))7Y $"/D
$".dc$ amp'
?& M&S& B3SE ST3-D
@?#mm 1 >##mm
%& /al.e /al.e onnector Fquic+ fi1ing t(peH
Steel
? no'
@& )la'tic tube
% 1 > mm
< meter'
A& Electrical on off rela( control
$".dc
$
$ $
$ no
POWER SUPPL% 5V DC AND "$V DC&
3 $" K# / 'tep down down tran'former tran'former i' u'ed to 'tepdown 'tepdown "<#/ 3 3 to $"/ 3 &Thi' $"/ 3 'uppl( i' con.erted to $"/ D u'ing four rectifier diode'& The .oltage from the rectifier 'ection i' regulated to $"/ D u'ing @A$" I & 4rom $"/ D D the @A#? I i' u'ed u'ed for regulating regulating ?/ D for the power 'uppl( of 7ED& The The power 'uppl( circuit i' 'hown in fig&
INTRODUCTION#
3ll the electronic component' 'tarting from diode to Intel IL' onl( wor+ with a D 'uppl( ranging from ?/ to $"/& $"/& ;e are utiliing for the 'ame9 the cheape't and commonl( a.ailable energ( 'ource of "<#/0?#2 and 'tepping down9 rectif(ing9 filtering and regulating the .oltage& STEP DOWN TRANSFORMER#
;hen 3 i' applied to the primar( winding of the power tran'former9 it can either be 'tepped down or 'tepped up depending on the .alue of D needed& In our circuit the tran'former of "<#/$?0#0$?/ i' u'ed to perform the 'tep down operation where a "<#/ 3 appear' a' $?/ 3 acro'' the 'econdar( 'econdar( winding& winding& 3part 3part from 'tepping down .oltage'9 .oltage'9 it gi.e' i'olation i'olation between the power 'ource and power 'uppl( circuitrie'& circuitrie'& RECTIFIER UNIT#
In the power 'uppl( unit9 rectification i' normall( achie.ed u'ing a 'olid 'tate diode& Diode ha' the propert( that will will let the electron flow ea'il( ea'il( in one direction at proper proper bia'ing condition& 3' 3 i' applied applied to the diode9 electron' onl( flow when when the anode and cathode i' negati.e& negati.e& !e.er'ing the
polarit( of .oltage will not permit electron flow& 3 commonl( u'ed circuit for 'uppl(ing 'uppl(ing large amount' amount' of Dpower i' the bridge rectifier& rectifier& 3 bridge bridge rect rectif ifie ierr of four four diod diode' e' F> 1 I-># I->##@ #@HH are are u'ed u'ed to achi achie. e.ee full full wa.e wa.e rectificati rectification& on& Two diode' diode' will conduct conduct during the negati.e negati.e c(cle and the other two will conduct during the po'iti.e half c(cle9 and onl( one diode conduct'& conduct'& 3t the 'ame 'ame time one of the other two diode' diode' conduct' conduct' for the negati.e .oltage that i' applied from the bottom winding due to the forward bia' for that diode& In thi' circuit due to po'iti.e half c(cle D$ G D" will conduct to gi.e #&A/ pul'ating D& The D output ha' a ripple frequenc( of $##2& Since each alteration produce' a re'ulting output pul'e9 frequenc( frequenc( N " 1 ?# 2& The output obtained obtained i' not a pure D and therefore filtration filtration ha' to be done& The D .oltage appearing acro'' the output terminal' of the bridge rectifier will be 'omewhat 'omewhat le'' than # # of the applied applied rm' .alue& -ormall( one alteration of the input .oltage will will re.er'e the polaritie'& polaritie'& Oppo'ite end' of the tran'former will therefore alwa(' be $A# degree out of pha'e with each other& other& 4or a po'iti.e c(cle9 c(cle9 two diode' diode' are connected connected to the po'iti.e .oltage at the top winding& FILTERING FILTERING CIRCUIT#
4ilter circuit' which i' u'uall( capacitor acting a' a 'urge arre'ter alwa(' follow the rectifier unit& Thi' capacitor capacitor i' al'o called a' a decoupling capacitor or a b(pa''ing capacitor9 i' u'ed not onl( to P'hortL the ripple with frequenc( of $"#2 to ground but al'o to lea.e the frequenc( of the D to appear appear at the output& 3 load re'i'tor re'i'tor !$ i' connected connected 'o that a reference reference to the ground i' maintained& maintained& $9 !$ i' for b(pa''ing b(pa''ing ripple'& "9 !" i' u'ed a' a low pa'' filter9 i&e& it pa''e' onl( low frequenc( 'ignal' and b(pa''e' high frequenc( 'ignal'& The load re'i'tor 'hould 'hould be $ to "&? of the load& $###µf"?/ : for the reduction of ripple' from the pul'ating $#µf"?/ f"?/
: for mainta maintaini ining ng the the 'tabil 'tabilit( it( of the .olta .oltage ge at at the the load load 'ide 'ide&&
#&$µf
: for b(pa''ing the high frequenc( di'turbance'
BLOCK DIAGRAM FOR POWER SUPPLY
STE) DO;-
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23!6E 3)3ITO!
?/ !E6U73TO!
$"/D !E6U73TO!
LED LE
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VOLTAGE VOLTAGE REGULATO REGUL ATOR# R#
The .oltage regulator' pla( an important role in an( power 'uppl( unit& unit& The The primar primar( ( purpo' purpo'ee of a regula regulator tor i' to aid the rectifi rectifier er and filter filter circuit circuit in pro.iding pro.iding a con'tant D .oltage .oltage to the de.ice& )ower 'upplie' 'upplie' without regulator' ha.e an inherent problem of changing D .oltage .alue' due to .ariation' in the load or due to fluctuation' in the 3 linear .oltage& ;ith a regulator connected to the D output9 the .oltage can be maintained within within a clo'e tolerant tolerant region region of the de'ired de'ired output& output& I@A$" I@A$" and @$" i' u'ed in thi' pro*ect for pro.iding $"/ and $"/ D 'uppl(&
DESCRIPTION OF PNEUMATIC COMPONENTS $& Double Double acting acting air air c(linder c(linder with with pi'ton pi'ton arrangemen arrangement& t& "& Spool .al.e F" po'iti po'ition on ? port' .al.eH .al.eH <& )neu )neuma mati ticc fitt fittin ing' g' a& Bul+ Bul+ head head unio union n b& 4le1ible ho'e' c& 3ir 3ir com compr pre' e''o 'or' r'
DOUBLE ACTING AIR C%LINDER WITH PISTON ARRANGEMENT#
It con'i't' of a pi'ton in'ide a c(lindrical hou'ing called a barrel& 3ttached to one end of the pi'ton i' a rod which the rod end ha' one port&
Thi' rod end port i' u'ed for entrance of air and e1tend' out'ide one end of the c(linder& c(linder& 3t another another end i' a port for e1it of air& air& Double acting c(linder can be e1tended and retracted pneumaticall(& The 'malle't bore 'ie of a double acting acting c(linder i' $ $A inch& The pi'ton9 which i' made of ductile Iron9 contain' u0cup pac+ing to 'eal again't lea+age
between the pi'ton and barrel& The port' are located in the end cap'9 which are 'ecured to the barrel b( bolt' and nut'&
SPOOL SPO OL VALVE# VALVE#
The 'pool i' rod in ?" .alue'9 'o that ?" .al.e i' called C'pool .al.e& It u'ed to change the path of flow of air&
DIRECTING CONTROL VALVES#
3 direction control .al.e i' u'ed to change the direction of airflow a' and when required b( b( the '('tem for re.er'ing re.er'ing the machine tool tool de.ice'& 3 direction control .al.e ma( be cla''ified9 according to the con'truction of the internal mo.ing part'9 a'
$& !ota !otar( r( 'poo 'pooll T( T(pe& pe& "& Slidin Sliding g Spoo Spooll T(pe& (pe& <& Soleno Solenoid id operat operated ed .al.e' .al.e'
SOLENOID OPERATED VALVES#
Sole Soleno noid id .al. .al.e' e' are are elec electr trom omec echa hani nica call de.i de.ice ce'' li+e li+e rela rela(' (' and and contractor'& contractor'& 3 'olen 'olenoid oid .al.e i' u'ed to obtain obtain mechanical mechanical mo.ement mo.ement in machin machiner( er( b( utiliin utiliing g fluid or air pre''u pre''ure& re& The The fluid fluid or air pre''ur pre''uree i' applied to the c(linder pi'ton through a .al.e operated b( a c(lindrical electrical coil& The electrical coil along with with it' frame and plunger plunger i' +nown a' the 'olenoid and the a''embl( of 'olenoid and mechanical .al.e i' +nown a' 'ole 'oleno noid id .al. .al.e& e&
The 'ole 'oleno noid id .al. .al.ee i' thu' thu' anot anothe herr impo import rtan antt
electromechanical de.ice de.ice u'ed in control of machine'& Solenoid .al.e' .al.e' are of two t(pe'9 $& Single Single 'olenoid 'olenoid 'pring 'pring return return operatin operating g .al.e9F? .al.e9F?"H "H "& Double Double 'olen 'olenoid oid opera operatin ting g .al.e& .al.e&
In fig $ i' 'hown a 'ingle 'olenoid 'pring return .al.e in it' de0energied condition& The '(mbol '(mbol for the the 'olenoid 'olenoid and the return are al'o 'hown& The 'olenoid .al.e i' 'hown connected to the c(linder to help reader' under'tand the 'olenoid .al.e action& action& In the de energied energied condition9 the plunger plunger and the .al.e 'pool po'ition a' 'hown in figure $&
?" ;3Y /37/E
In thi' po'ition of 'pool9 port ) i' connected to port 3 and port B i' connected to tan+ or e1hau't Fi&e& atmo'phereH atmo'phereH if air i' u'ed& Spring pre''ure FSH +eep' the 'pool in thi' condition a' long a' the coil i' de energied& 4luid pre''ure from port ) through port 3 i' applied to the left 'ide of the c(linder pi'ton& Thu' Thu' the c(linder pi'ton mo.e' mo.e' in the right direction& direction& -ow when the 'olenoid coil i' energied9 plunger i' attracted and it pu'he' the 'pool again't 'pring pre''ure& The new po'ition of plunger and 'pool are 'hown in fig "&
In thi' po'ition of 'pool9 port 3 get' connected to tan+ and port ) get' connected connected to port B& Thu' pre''ure pre''ure i' applied applied to the c(linder c(linder pi'ton pi'ton from right and mo.e' the pi'ton rod to the left& left& 3t the 'ame time fluid in the the other 'ide i' drained out to the tan+& ;hen the 'olenoid coil i' again de energied9 energied9 the 'pring FSH will mo.e the 'pool to it' original po'ition a' 'hown in figure $& Thu'9 Thu'9 normall normall( ( when when the 'oleno 'olenoid id coil i' de energi energied ed the pi'ton pi'ton rod remain' e1tended&
PNE&MATIC FITTING
PNEUMATIC FITTINGS#
There are no nut' to tighten the tube to the fitting' a' in the con.entional t(pe of of metallic fitting'& The tube i' connected connected to the fitting b( b( a 'imple pu'h en'uring lea+ proof connection and can be relea'ed b( pre''ing the cap and doe' not not require an( 'pecial tooling tooling li+e 'panner to connect ForH di'connect the tube from the fitting&
SPECIFICATION OF THE FITTING#
Bod( Material ollectThread -ipple Seal 4luid U'ed Ma1& Operating )re''ure
0 )la'tic 0 Bra'' 0 -itrate !ubber 0 3ir 0 @ Bar
Tolera leranc ncee on on OD OD of of the the tube tube''
0 ± $ mm
Min& in& ;a ;all thi thic+ c+n ne'' e'' of of tu tube' be'
0 $ mm& mm&
FLEXIBLE HOSES:
The )neumatic ho'e'9 which i' u'ed when pneumatic component' 'uch a' actuator' are 'ub*ected to to mo.ement& 2o'e i' fabricated in la(er la(er of Ela'tomer or '(nthetic rubber9 which permit' operation at high pre''ure& The 'tandard out'ide diameter diameter of tubing i' $$% inch& inch& If the ho'e i' 'ub*ected to rubbing9 it 'hould be enca'ed in a protecti.e 'lee.e&
ADVA ADVANTA NTAGES AND AND LIMITA LIMITATIONS
ADVANTAGES#
♦ The )neumatic arm i' more efficient in the technical field ♦ Juic+ re'pon'e i' achie.ed ♦ Simple in con'truction' ♦ Ea'( to maintain and repair ♦ o't of the unit i' le'' when compared to other robotic' ♦ -o fire haard problem due to to o.er loading ♦ omparati.el( the operation co't i' le'' ♦ The operation of arm i' fa'ter becau'e the media to operate i' air ♦ ontinuou' operation i' po''ible without 'topping .
LIMITATIONS# ♦ 2igh torque cannot be obtained& ♦ 7oad arr(ing capacit( of thi' unit i' not .er( high F< K ? +g'H ♦ Silencer ma( be u'ed9 to reduce the noi'e of compre''ed air
3))7I3TIO"3 DISCHARG DISCHARGE E OF WORKPIE WORKPIECE# CE#
The arm fed ha' wide applicat application ion in low co't automat automation& ion& It can be u'ed u'ed in automa automated ted a''emb a''embl( l( line' line' to pic+0u pic+0up p the fini'h fini'hed ed produc productt from wor+'tatio wor+'tation n and place them in the bin'& bin'& It can al'o be u'ed to pic+0up pic+0up the raw material and place them on the con.e(or belt' and .ice .er'a& $3 OB OB CLA CLAMP MPIN ING# G#
Thi' unit can al'o be u'ed in clamping operation' in certain area' of ma'' production' where clamping and unclamping ha.e to be done at high 'peed'& The application of of thi' unit i' limited to to operation'9 which in.ol.e' moderate clamping force'&
3 TRANSFER OF OBS BETWEEN BETWEEN WORK WORK STA STATIONS# TIONS#
The gripping method u'ed in a low co't automation to mo.e the wor+ piece from one wor+'tation to another& The combination of an angular rotar( motion motion i' the principl principlee behind thi' thi' method& method& The gripper gripper hold' the wor+ rigidl( rigidl(&& The to and fro motion i' achie.ed achie.ed b( mean' of the actuating actuating c(linder& 43 TO TOOL OL CHANGING CHANGING APPL APPLICA ICATI TION# ON#
;hen the pneumatic arm' are made 'maller in 'ie the( can be u'ed in auto automa mati ticc tool tool chan change gerr in - - turn turnin ing g and and dril drilli ling ng mach machin ine' e'99 b( attaching 'uitable tool holding de.ice to the rotar( c(linder&
FEAT&RES OF THE VIBRATING MACHINE
FEATURES FEATURES OF THE VIBRATING VIBRATING MACHINE MAC HINE
It i' compact in 'ie
It can be mo.e
The electrical power con'umption i' .er( low
It can be utilied at our wor+ 'hop
It i' 'imple in con'truction
7ow co't
7e'' weight and ea'( to handle
It reduce' the man power
It i' u'ed in ma'' production
5OB )!E)3!3TIO-Q Before welding9 remo.e an( bend in the 7 angle with the 'ludge hammer on the an.il bloc+& Then it i' cut to the required length with the hac+'aw blade and fabricated to required dimen'ional 'hape with arc welding&
4I-IS2I-6 O)E!3TIO- BE4O!E )3I-TI-6Q
3fter welding9 an( 'lag on the welded area i' remo.ed with the chipping hammer and cleaned with the metal wire bru'h& Then all the 'urface' are rubbed with the emer( emer( 'heet& 'heet&
Metal primer i' applied on the 'urface' with the bru'h &3fter dr(ing the
metal primer9 the 'econd coating i' applied with the paint&
o't in !' -3ME O4 T2E )3 )3!TS !TS
"& Double Double acting acting c(lind c(linder er
$%##0
"& Solenoid ?" wa( D /al.e
$"##0
<& /IB!3TI-6 )73TE
@##0
>& )O;E! SU))7Y $"/D
>##0
?& M&S& ST3-D
$"##0
%& /al.e onnector F?-o'& 1 >#&##H
"##0
@& )la'tic tube F? meter'H "?metre
"##0
A& rela( control
?##0 %###0
;e ma+e thi' pro*ect pro*ect entirel( entirel( different different from other other pro*ect'& pro*ect'& Since concept' in.ol.ed in our pro*ect i' entirel( different that a 'ingle unit i' u'ed to .ariou' purpo'e' which i' not de.eloped b( an( of other team member'& B( doing thi' pro*ect we gained the +nowledge of pneumatic '('tem i' how automati automation on can be effec effecti. ti.el( el( done done with with the help of pneuma pneumatic tic '('tem&
It i' concluded that an( automation '('tem can be done with the help of pneumatic '('tem& ;e ha ha.e 'u 'ucce cce''fu ''full ll( ( com complet pleteed the the pro pro*ect *ect wor wor+ + on u'in u'ing g )neumatic' '('tem at our In'titute& B( doing thi' pro*ect wor+9 we under'tood the wor+ing principle and u'e' of .ariou' (linder'9 /al.e'9 etc& & It will be of no doubt that )neumatic' will be an integrated part of an( proce'' in indu'tr( in the near future and we de.eloped de.eloped a through +nowledge +nowledge in 3utomation with )nematic' Once again we e1pre'' our 'incere than+' to our 'taff member'&
Ban'al9 !&=&9 C4luid C4luid Mechanic' and 2(draulic' Machine' Machine' F?th editionH9 7a1mi publication' F)H ltd9 -ew Delhi9 $?&
!amamirtham9S&9 !amamirtham9S&9 C4luid Mechanic' and 2(draulic' and 4luid Machine'9 Dhanpat !ai and Son'9 Delhi9 $A&
)&& Sharma9 C3 Te1t Boo+ of )roduction Engineering9 S& hand and o<d9 I/ edition9 $<&
2a*ra houdr(9 CElement' of wor+ 'hop Technolog( K /ol& II Media )romoter'& "##"&
Ma*undar '&r&9 C)neumatic '('tem' K )rinciple' and Maintenance9 tata Mc6raw hill9 $?&
PHOTOVIEW
