DEPARTMENT OF MECHANICAL ENGINEERING WALCHAND COLLEGE OF ENGINEERING, SANGLI 2014-2015
This is to certify that the project report entitled
Is the report of their own work carried out by them for the award of
Under my guidance during the academic year 2014 – 2015 2015 Date:
/0 /2015
Place: WCE, Sangli.
Prof. H. N. TIKEKAR
Prof. S. B. JALIHAL
(Guide)
(HOD)
DEPARTMENT OF MECHANICAL ENGINEERING WALCHAND COLLEGE OF ENGINEERING, SANGLI 2014-2015
ACKNOWLEDGEMENT We are rather infused by the kind guidance of Prof. H. N. Tikekar who put us in the cradle of our engineering studies and Tikekar evaluated us to this end and mean of our project without his guidance, we are sure to be an orphan in the vast ocean of the subject. Ultimately no tongue could describe the deep sense of cooperation and ready nature to help us even in minute details of our write up this project report. Thanks and gratitude goes to Prof. S. B. Jalihal Jalihal Head, Department of Mechanical Engineering Polytechnic Wing, who made very valuable guidance and co-operation during our project. Further we are thankful to all the staff and non-teaching members of Mechanical Engineering Department for the cooperation during the project work. We are very grateful to those who in the form of books had conveyed guidance in this project work. Last but not the least we are thankful to our colleagues and those helped us directly or indirectly throughout this project work. Special thanks go to Mr. L. L. Kamble Kamble sir of machining workshop.
Projects Associates:
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Synopsis Introduction Literature Survey Prior Concepts Construction Design Specifications Drawings Figures Working Process Sheet Cost Sheet Merits & Demerits Future Scope Conclusion References Photographs
1 3 4 6 7 8 10 12 18 21 26 28 30 31 32 33 34
Synopsis The objective of the project is to prepare a machine which cuts
sheet
metal
without
human
efforts
but
operates
pneumatically. Compressed air is used as working media. The compressed air moves the blades of machine to cut the sheet of metal. The idea of the project generated due to a manual sheet metal sheering machine in workshop of our college. In that machine sheet metal is placed in between the two sheering blades of machine and the lever is pulled down to move the upper movable blade and cut the work-piece. But in that machine large force is required which can make tire to a worker who continuously works on it for mass production in large scale industry; so to reduce the human efforts pneumatic machine should chose. Hence for some development of machine, we have chosen this subject for our project. We hope that a good idea will develop and we can use it in many industries in surrounding and our practical knowledge, team-working skill, leadership skills will be improved.
Introduction The formation of any business begins with someone producing the initial idea for the project. The continued success of an established business depends upon the number and quality of the ideas fed into it. Without a continual flow of new ideas, a business cannot function profitably or expand successfully and must, therefore eventually fade into total obscurity. Ideas for a new business project, a new product, a means of reducing manufacturing costs or for solving industrial labour problems, begin in the human mind. Most people conceive their ideas unconsciously, and because they are unaware of the mental mechanics that caused the ‘idea’ to be produced, produced, they cannot repeat the ideation process to produce further profitable ideas at will. Fortunately,
there
are
available
established
creative
techniques which, when used correctly, do enable a person to produce a large number of first-class ideas at will. One such creative technique, and probably the most widely used in American industry, is ’brainstorming’.
Literature survey In shearing or cutting operation as or blade descends upon the metal, the pressure exerted by the blade first cause the plastic deformation of the metal. Since the clearance between the two blades is very small, the plastic deformation takes place in a localized area and the metal adjacent to the cutting edges of the blade edges becomes highly stressed, which causes the fracture to start on both sides of the sheet as the deformation progresses and the sheet is sheared.
1) Pneumatically operated 2) Hydraulically operated 3) Rack and pinion operated 4) Spring operated Brief description of all the types is as follows.
Here the advancement of the header is carried out in the upward and the downward direction using the pneumatic double acting piston and cylinder unit arrangement along with the foot operated direction control valve. In this type of machine high pressure air is used as the working fluid for the transfer of power and the motion.
Here the lowering and raising of the header is carried over using the hydraulic piston and cylinder arrangement. To actuate the piston and cylinder, the oil is allowed to enter the cylinder from front or the back side of the piston. But the oil is comparatively costlier and its leakage may cause so many problems.
Here the lowering and the raising of the header are carried out manually using the rack and pinion arrangement. In this case the required pressure is applied manually using direct hand pressure on the rack using pinion and lever arrangement. Since the machine is robust and requires large pressure, hence it is not suitable.
The working of spring operated machine is similar to the rack and pinion operated machine but differs from it in construction. Here the lowering and the raising of the heating handle are carried out manually and it requires too much pressure for its operation and also there is possibility of having damage to the work piece if not handled carefully.
Prior concepts Pneumatics, from the Greek (pneumatikos, coming from the wind) is the use of pressurized gases to do work in science and technology.
Pneumatics
was
first
documented
by
Hero
of
Alexandria in 60 A.D., but the concept had existed before then. Pneumatic products represent a multi-billion dollar industry today. Pneumatic devices are used in many industrial applications. Generally appropriate for applications involving less force than hydraulic applications, and typically less expensive than electric applications, most pneumatic devices are designed to use clean dry air as an energy source. The actuator then converts that compressed air into mechanical motion. The type of motion produced depends on the design of the actuator. Pneumatics is employed in a variety of settings. In dentistry applications, pneumatic drills are lighter, faster and simpler than an electric drill of the same power rating, because the prime mover, the compressor, is separate from the drill and pumped air is capable of rotating the drill bit at extremely high rpm. Pneumatic transfer systems are employed in many industries to move powders and pellets. Pneumatic devices are also used where electric motors cannot be used for safety reasons, such as mining applications where rock drills are powered by air motors to preclude the need for electric motors deep in the mine where explosive gases may be present.
Construction
1. Mild Steel bars for base frame. 2. 35C8 material for shearing blades. 3. Cylinder fittings like fork end, base plates, support links. 4. Angle section for blade fitting. 5. Connecting link. 6. Blade link.
1. Pneumatic double acting cylinder. 2. Direction & flow control valves. 3. Pneumatic pipe & pipe fittings. 4. Bolts & nuts. 5. Antirust coat & paint.
1. Cutting Machine. 2. Hacksaw Cutting Machine. 3. Sensitive Drilling Machine. 4. Horizontal Milling Machine. 5. Electric Arc Welding Machine. 6. Table Grinder. 7. Hand Grinder. 8. Surface Grinding Machine. 9. Tap & Tap Holder.
Design 1.
Base FrameQuantity: 1 Height: 300mm Length: 900mm Width: 300mm Weight: 5kg
2.
Shearing BladeQuantity: 2 Length: 300mm Height: 60mm Thickness: 15mm Blade Angle: 15o Weight: 3.5kg
3.
Base PlateQuantity: 1 Height: 65mm Width: 65mm Thickness: 6mm
4.
Fork EndQuantity: 1 Length: 75mm Width: 20mm Thickness: 5mm
5.
Angle SectionQuantity: 1 Height: 45mm Length: 300mm Width: 45mm Thickness: 7mm Weight: 0.5kg
6.
Connecting LinkQuantity: 1 Length: 360mm Thickness: 5mm Height: 25mm Weight: 0.3kg
7.
Support LinksQuantity: 2 Height: 90mm Width: 25 Thickness: 5
8.
Blade LinkQuantity: 1 Height: 90mm Width: 20mm Thickness: 5mm Welded Length: 30mm
Specifications 1.
Pneumatic CylinderQuantity: 1 Total Length: 375mm Bore: 40mm Stroke: 200mm Piston Rod Diameter: 20mm Max Working Pressure: 8 bar Weight: 3kg
2.
DC ValveQuantity: 1 Operation: Manual Type: Hand Lever, Detent Type Number of Ports: 5 Number of Positions: 3 Construction: Sliding spool type
3.
Pneumatic PipeQuantity: 3000mm Diameter: 8mm Thickness: 1mm
4.
Fork End NutQuantity: 2 Length: 16mm Size: M16
5.
Cylinder Base Plate BoltsQuantity: 4 Length: 32mm Size: M6
6.
Blade Fixing BoltsQuantity: 3 Length: 25mm Size: M10
7.
Connecting Link BoltsQuantity: 2 Length: 45mm Size: M6
Drawings
Figures
Working The following figure shows general layout for the machine.
Initially the air-compressor is started and allowed the receiver tank air pressure to reach up to 8 bar. The supply air is then passed to the manifold through FRL unit to condition the air and eligible to industrial use. From the manifold a separate supply for the machine is taken out and given to ON-OFF switch, so as to operate the machine at will without interrupting the running of compressor. Then the pipe carries compressed air first to machine’s Direction Control Valve. At position ‘A’ shows the non-actuated non-actuated circuit diagram. At this position the piston is steady and locked. All ports are in closed condition.
At position ‘B’ ‘B’,, the DC valve is at left hand position as shown in figure. The cap end port & pressure port get connected to each other and the rod end port gets connected to the exhaust port. The compressed air comes in the cap end of the cylinder and pushes the pistons outwards. The air already present in the rod end side is pushed out of the cylinder. When the piston moves outwards, the force is transmitted through the connecting link and the upper blade moves downwards. Before the actuating DC valve the sheet is inserted in between the upper & lower blades. As upper blade moves downwards, the stress is generated in the sheet metal and goes beyond ultimate shear stress of sheet metal. And thus the shearing action takes place. Now the DC valve is operated to come at position ‘C’, as shown in figure. The rod end port & pressure port get connected to each other and the cap end port gets connected to the exhaust port. The compressed air comes in the rod end of the cylinder and pushes the pistons inwards. The air already present in the cap end side is pushed out of the cylinder. The sheet metal is either again inserted for further cutting in case of large pieces; the small cut pieces are removed and the next sheet is inserted to cut.
Process sheet Part No.
1)
2)
3)
Part Name
Frame
Blades
Angle Section
Material Quantity
Mild Steel
35C8
Mild Steel
1
2
1
Process
Equipment
Time
Cutting
Cutting Machine
80
Grinding
Table Grinder
40
Welding
Electric Arc Welding Machine
100
Grinding
Hand Grinder
10
Anti-rust Coating
Hand Brush
20
Colour Painting
Hand Brush
35
Cutting
Hacksaw Cutting Machine
15
Drilling
Sensitive Drilling Machine
15
Tapping
3/8" BSW Tap & Holder
15
Surface Grinding
Surface Grinding Machine
80
Angular Milling
Horizontal Milling Machine
90
Filing
File
20
Greasing
Grease
5
Cutting
Cutting Machine
10
Grinding
Table Grinder
5
Drilling
Sensitive Drilling Machine
15
Welding
Electric Arc Welding Machine
10
4)
5)
6)
7)
8)
Connecting Link
Fork End
Cylinder Base Plate
Cylinder Support Links
Blade Link
Mild Steel
Mild Steel
Mild Steel
Mild Steel
Mild Steel
1
1
1
Cutting
Cutting Machine
10
Grinding
Table Grinder
5
Drilling
Sensitive Drilling Machine
5
Cutting
Cutting Machine
5
Grinding
Table Grinder
5
Drilling
Sensitive Drilling Machine
10
Welding
Electric Arc Welding Machine
15
Cutting
Cutting Machine
5
Grinding
Table Grinder
5
Drilling
Sensitive Drilling Machine
10
Welding
Electric Arc Welding Machine
5
Cutting
Cutting Machine
8
Grinding
Table Grinder
5
Drilling
Sensitive Drilling Machine
7
Tapping
3/8" BSW Tap & Holder
10
Welding
Electric Arc Welding Machine
15
Cutting
Cutting Machine
5
Grinding
Table Grinder
5
Drilling
Sensitive Drilling Machine
5
Welding
Electric Arc Welding Machine
10
2
1
Total Process Time (in Minutes)
715
Cost sheet Sr. No.
Part Name
1]
Main Frame
2]
Angle Section
Mild Steel Mild Steel
3]
Cylinder Base Plate
4]
Material
Quantity
Material Machining Cost Cost
Total Cost
20 Feet
600
500
1100
1
50
50
100
Mild Steel
1
30
30
60
Support Links
Mild Steel
2
30
30
60
5]
Double Acting Cylinder
Plain Carbon Steel
1
4000
-
4000
6]
Flow Control Valve
Cast Steel
2
850
-
850
7]
Pipe
PVC
3m
120
-
120
8]
Direction Control Valve
Alloy Steel
1
700
-
700
9]
Pipe Fitting Connections
Cast Steel
3
150
-
150
10]
Shearing Blades
35C8
2
300
400
700
11]
Blade Link
Mild Steel
1
20
30
50
12]
Connecting Link
Mild Steel
1
30
30
60
13]
Fork End
Mild Steel
1
50
50
100
Antirust Coat
Alloy Steel Alloy Steel -
Paint
-
14]
Bolts
15]
Nuts
16] 17]
11
80
-
80
3
10
-
10
100 mL
20
-
20
100 mL
40
-
40
7080
1120
Grand Total Cost (in Rupees)
Merits & Demerits
1.
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.
2.
Moreover, to avoid corrosive actions, oil or lubricants are added so that friction effects can be reduced.
3.
Compressed air is used in most of the machines and in some cases compressed carbon dioxide, whereas cutting process is become easy.
4.
Fast cutting action is carried out.
5.
Cutting without bending is achieved.
1.
Sheet more than 2 mm thickness cannot cut easily.
2.
Compressed air is must.
3.
Foundation is required also safety major must be taken.
Future Scope Since old age man is always trying to gain more and more luxurious. Man is always trying to develop more and more modified technique with increasing the aesthetic look and economic consideration. Hence there is always more and more scope. But being the Diploma Engineers and having the ability to think and plan. But due to some time constraints, and also due to lack of funds, we only have thought and put in the report the following future modifications1. It can be made hydraulically power operated by installing the gear oil pump at the place of air compressor and pneumatic cylinder arrangement. 2. It can be made rack and pinion operated or spring and lever operated, by replacing the pneumatic circuit by rack and the pinion arrangement by the square threaded screw and nut arrangement. 3. The place where there is scarcity of the electricity the electric motor operate compressor is replaced by an I.C. Engine installed compressor. Thus in future there are so many modifications, which we can make to survive the huge global world of competition.
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.
References 1. Machine Design by R.S. Khurmi. 2. Manufacturing Process by O. P. Khanna and Lal. 3. Workshop Technology by R.K. Jain. 4. Pneumatic
System:
Principle
&
Maintenance
Mujumdar. 5. Machine Tool Design Handbook. 6. P.S.G. Design Data Book. 7. Internet sitesa) http://www.google.com/ b) http://www.engineersedge.com/ c) http://www.efunda.com/ d) http://www.mechanicalengineeringblog.com/
by
S.R.
Photographs
