group CC [Autosaved].pptx in the field of engineering

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1. introduction , the novelty of this machine is that it provides an automated system to cut aluminum, mild steel, stainless steel sheet metal and among others, while making sure that the system is compact and portable, Pneumatics is employed in a variety of settings for example 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 for instance Pneumatic tubes can carry objects over distances. 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

2. pneumatic sheet metal cutting machine, is a mechanism designed to cut metal sheets at a quick speed, based on the inputs given by the operator, using a switch The machine consists of a cutter blade system, a double acting pneumatic cylinder held over the cutter blade system, an air compressor, a pneumatic valve to regulate the air flow to the pneumatic cylinder from the compressor, and a frame to hold the machine in position. Small and medium scale industries cannot tend to afford this technology

3. continued 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

4. PROBLEM STATEMENT. Current sheet metal cutting machines are either expensive, difficult to operate, or not portable. This makes them impractical for use in many industries and settings. Develop a pneumatic sheet cutting machine that is affordable, easy to use, and portable. This machine should be able to produce precise cuts in a variety of sheet metal materials efficiently.

5. Main objective. Main objective. To design a pneumatic sheet cutting machine that accurately and efficiently cut sheets of material using compressed air. Specific objectives. To reduce manual labor and improve production efficiency. To improve cutting accuracy and precision. To reduce production cost and losses. To improve safety during production.

6. RESEARCH QUESTIONS. What are the key design considerable parameters for a pneumatic sheet cutting machine? What are the effects of different sheet materials, sheet thickness and sheet hardness on the design of the cutting blade? What is the optimal cutting speed and cutting force for different sheet materials to optimize cutting process? What type and size of pneumatic cylinders are required to generate the required cutting force?

7. Contextual scope. A pneumatic sheet cutting machine uses compressed air to generate the force required to cut sheet metal. It has a frame which is a rigid structure that supports all the other components of the machine. The cutter blade system consists of an upper blade and a lower blade. The upper blade is movable, while the lower blade is fixed. The pneumatic cylinder is a piston-cylinder assembly that is used to generate the force required to move the upper blade. The air compressor supplies the compressed air to the pneumatic cylinder. The control valve is used to regulate the flow of compressed air to the pneumatic cylinder. When the sheet metal between the upper and lower blades. And the control valve is activated, compressed air is allowed to flow into the pneumatic cylinder. The pneumatic cylinder then extends, forcing the upper blade down onto the sheet metal. Once the upper blade has cut through the sheet metal, the control valve is deactivated, and the pneumatic cylinder retracts, raising the upper blad e

8. JUSTIFICATION. The need to significantly increase productivity in sheet metal production, since there are multiple pieces of sheet metal cut at the same time, with a high level of precision and accuracy. High labor cost calls for automating the sheet metal cutting process, a company can reduce the number of employees they need to hire and train. Inconsistent and inaccurate cuts by the manual methods, lead to increase in the number of defects in the finished product. The high risks of injuries from cuts, burns, and other hazards associated with manual cutting methods call for sheet metal cutting machines .

9. LIMITATIONS The machines will be expensive to purchase and maintain. It will be complex to operate and program, especially if you are new to them. The machines may be dangerous if not used properly. It is important to follow all safety precautions and wear appropriate safety gear when using it. The machine has a maximum material thickness that it will be cutting .

10. LITERATURE REVIEW 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 blades is very small, the plastic deformation takes place in the localized area and the metal adjacent to the cutting edges of the blade edges become slightly stressed, which causes fracture to start on both sides of the sheet as the deformation progresses and the sheet is sheared.

11. LITERATURE REVIEW Shearing machines are classified according to the following; Pneumatically operated Hydraulically operated Rack and pinion operated Spring operated HYDRAULICALLY OPERATED Hear the lowering and raising of the header is carried over using the hydraulic piston and cylinder arrangement. To actuate and piston and cylinder, the oil is lowered to enter the cylinder from the front or the back side of the piston. But the oil is compositely costlier and its leakage may cause so many problems.

12. SHEARING MACHINES RACK AND PINION OPERATED Here the lowering and raising of the header is carried out manually using the rack and pinion arrangement. In this case the required pressure is applied manually using direct and hand pressure on the rack using the pinion and leaver arrangement. Since the machine is robust and requires large pressure, hence it is not suitable. SPRING OPERATED The working of spring-operated machine is similar to rack and pinion operated machine but differs from in construction. Here the lowering and raising of the heating handle is 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.

13. PNEUMATICALLY OPERATED Heart the advertisement of the header is carried out in the upward and downward direction using 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 Advantages 1-Like hydraulics, pneumatics is a type of fluid power application where instead of an incompressible liquid, pneumatics employ gas in their system. The air used in pneumatic devices is dried and free from moisture so that it does not create any problem to the internal parts of the system. 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.

14. Advantages Mass production techniques can be adopted to produce pneumatic systems, which not only save money but save time too -Initial cost is less; hydraulics equipment cost as much as twice the price of pneumatic equipment. For opening and closing valves, pneumatic systems work well because they can sustain overload pressure conditions. Pneumatic actuators also have long life and perform well with negligible maintenance requirement throughout their life cycle. 10-Very suitable for power transmission when distance of transmission is more Also, hydraulic systems are dirtier than pneumatic systems.  

15. DESIGN OF SYSTEM Statement for design The Pneumatic Shearing machine is to be designed to operate at the maximum pressure of 7 bar and the lever operating force required is 150N, with the operating temperature of 2000 degrees Celsius Cylinder Sizing Design Parameters Bore diameter:  Stroke length:  Rod diameter:  Pressure rating:  Cylinder thrust: Theoretical air consumption: Stripping force Sheet metal cutting force Material: Aluminum Mount type: Flange mount End caps: Aluminum Piston seals: Rubber Rod seals: Polyurethane

16. Components of pneumatic shearing machine Different components of pneumatic sheet metal cutting machine are; Shearing blade Pneumatic cylinder 5/3 direction control valve Air circulating device Frame

17. PNEUMATIC CYLINDER Cylinder is a device used to convert pneumatic power into linear mechanical force and motion. These cylinders are widely used in industrial pneumatic systems. These cylinders are also called liner motion and reciprocating motors pneumatic cylinder designers are designed for variety of service Classifications of cylinders Single acting cylinder Double acting cylinder

18. Solenoid valve In a pneumatic sheet metal cutting machine, the solenoid valve plays a crucial role in controlling the flow of compressed air that drives the cutting process. Its operation relies on the principles of electromagnetism to convert electrical signals into mechanical motion.

19. Solid works

20. Design requirement Easy inspection, operation, serviceability and maintenance of the machine. Ability to address labor scarcity Dimensions, tolerances and units. Economic considerations metal Factor of safety:

21. DESIGN SPECIFICATIONS Cylinder thrust Theoretical air consumption Sheet metal cutting force- Stripping Force Cutting force = 𝐿 × t× 𝑇𝑚𝑎𝑥

22. MATERIAL SELECTION. Construction materials were selected basing on; their availability, cost, durability, corrosion resistance and suitability of the material for the working conditions in service. They were also being selected basing on the type of force that will be acting on them, work expected to perform and their chemical and mechanical properties. In particular mild steel material was used due to its numerous properties.

23. Reasons for selection of different materials r eadily available in market It is economical to use It is available in standard sizes It has good mechanical properties i.e. it is easily machinable Proposed Work It has moderate factor of safety, because factor of safety results in unnecessary wastage of material and heavy selection. Low factor of safety results in unnecessary risk of failure It has high tensile strength Low co-efficient of thermal expansion

24. WORKING MECHANISM OF A PNEUMATIC SHEET METAL CUTTING MACHINE The working mechanism of a pneumatic sheet metal cutting machine is as follows: The operator positions the sheet metal on the machine and secures it in place. The operator activates the foot pedal or hand lever, which opens the control valve. Compressed air flows into the cylinder, which forces the piston to move forward. The piston moves the upper blade down, which cuts the sheet metal. The operator releases the foot pedal or hand lever, which closes the control valve. The piston retracts, and the upper blade returns to its starting position.

25. Conceptual design

26. Frame calculations Calculation of Bending Moment and Stress: Calculation of Shear Force and Stress: Deflection Calculation: ). Material Properties: Factor of Safety:

27. Design of pneumatic cylinder Calculation of Force: Calculation of Stroke: Calculation of Speed: Calculation of Rod Strength: Calculation of Piston Seal Pressure: Bore diameter and rod diameter

28. Design of the control valves Flow Rate Calculation: Response Time Calculation: Pressure Regulation Calculation :

29. Design of a foot pedal or hand lever ). Force Calculation: Pedal or Lever Angle Calculation: Travel Distance Calculation: Pedal or Lever Stiffness Calculation:

30. Design cutting blade and stationary blade Shear Strength Calculation: Blade Angle Calculation: Blade Clearance Calculation: Blade Material Selection: Compressive Strength Calculation:

31. DESIGN OF SYSTEM Statement for design The Pneumatic Shearing machine is to be designed to operate at the maximum pressure of 7 bar and the lever operating force required is 150N, with the operating temperature of 2000 degrees Celsius

32. Design parameters Design Parameters Bore diameter:  Stroke length:  Rod diameter:  Pressure rating:  Cylinder thrust: Theoretical air consumption: Stripping force Sheet metal cutting force Material: Aluminum Mount type: Flange mount End caps: Aluminum Piston seals: Rubber Rod seals: Polyurethane Porting: Side porting Valuing: Solenoid operated Blade dimensions Speed control: Flow control valve

33. Sizing Calculations Bore diameter = (4 * Force / (π * Pressure)) D= (π D=14.14 mm d=0.6 d=9.6mm  

34. continued Cylinder thrust; Cylinder thrust for double acting in forward stroke 𝐹 = (𝜋 /4) × (𝐷 – 𝑑) ^2 × 𝑃, F= (𝜋 /4) × (0.016-0.01) × (7×10^5) F=3298.672N Stripping force This is the force that is required to overcome friction and retract the piston. It is typically 20-30% of the operating force Fs= 0.25×F Fs=0.25*150N Fs=37.5N

35. continued Flow Rate = (Force * Stroke Length) / (Pressure * Time Area of piston (Ap) = π ×(D/2) ² shear stress for cutting the sheet metal: Blade thickness Blade width Bending Moment (M) Allowable Bending Stress (σ-allowable) Required Section Modulus (S)

36. continued Cross-Sectional Dimensions The cross-sectional dimensions of the rectangular frame member can be determined by relating the section modulus to the width (b) and height (h) of the rectangle: Section modulus (S) = (b * h^2) / 6

37. Frame Deflection The deflection of the frame member was calculated using the following equation: Deflection (Δ) = (Output force (F-out) * Lever arm length^3 (L-lever^3)) / (48 * Modulus of elasticity (E) * Section modulus (S)) Deflection=FL^3/48ES

38. Kinematic and dynamic analysis of the machine Refer to the report work

39. CONCLUSION: T his project work has provided us an excellent opportunity and experience, to use limited knowledge. We gained a lot of practical knowledge regarding planning, designing and drawing, purchasing, computing and machining while doing this project work. We feel that a project work is a solution to bridge the gates between institution and industries.

40. FURTHER SCOPE OF WORK Since old age, man is always trying to gain more and more luxurious and is always trying to develop more and more modified techniques with increasing the authentic look and economic considerations hence there is always more and more scope. But being the degree engineer 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 modifications. A pneumatic sheet cutting machine is very versatile machine and has a lot of application because of its flexibility and ease of doing operation. This machine can be converted into different modification; It can be made to run a bottle cap sealing machine It can be made hydraulically power operated. It can be made rack and pinion operated.