pneumatic punching Machine

About the Design and fabrication of pneumatic punching machine

1. DESIGN AND FABRICATION OF PNEUMATIC PUNCHING MACHINE By SYED LUQMAN ZUHAIR (160717736306) MOHAMMED ABDUL KALEEM (160717736309) MOHAMMED AMER SOHAIL (160717736310) UNDER THE GUIDANCE: MR. V DURGESH (ASSISTANT PROFESSOR)

2. CONTENT Overview Literature review Problem definition Objectives Working principle and methodology Components required Construction and assembly Calculations Results Conclusion Futurescope

3. INTRODUCTION Pneumatic punching helps to make the hole in sheet metal by using compressed air. Pneumatic actuators controlled energy to the punch, so the operator needs to provide only modest effort regardless of conditions. Pneumatic punching machine helps to make hole in various size by changing tool. As well, pneumatic punch provides some feedback of forces acting on the sheet and hole can made in sheet metal.

4. Why we choose the pneumatic system ? High effectiveness High durability and reliability Simple design Economical Easy selection of speed and pressure

5. Types of punching machines

6. Literature survey S.NO AUTHOR PROJECT TITLE FINDINGS 1 Viraj N. Suryawanshi Nilesh V.Wakade Design and Development of Pneumatic Punching Machine Experimental set up of the machine 2 Utkarsh Sharma et. al. designed and fabricated an automatic pneumatic hole punching machine About solidworks Modeling 3 A. K. Gupta P. Bharadwaj S. Sahgal Experimental Investigation and Fabrication of Pneumatic Punch fabrication of blanking of thin sheet

7. 4 Girish Gharat Aniket Patil Harshal Mhatre Sandesh Satvi Design and Fabrication of Pneumatic Punching and Bending Machine Working of a machine and components

8. PROBLEM STATEMENT This project will focus on build of low force punching tool with using a pneumatic system. It is because, in the real industry, most company needs to buy a hydraulic machine whether they only need a small force to punch. Whether hydraulic machine can used for low or high force, high cost of machine and maintenance are needed. Therefore, this pneumatic punch also can help small company to use semi auto puncher than using manual puncher. Pneumatic punching machine give us high accuracy with before time completion and second most important, it is not dangerous.

9. SCOPE AND OBJECTIVES The main objectives of this project study are to design and fabricate a simple punching tool that used pneumatic system. i ) To design mechanical system of a punching tool. ii)To fabricate a pneumatic punching tool machine through several fabrication techniques To design and develop such a pneumatic punching machine which uses compressed air to generate high pressure to be applied on piston and this high-pressure air fed to punch, forces it on the material. And thus punching operation is performed.

10. Methodology Figure shows the procedure for Modeling and Fabrication of the machine. The system uses a 3D solid modeling system as the core, and applies the feature base parametric modeling method.

11. COMPONENTS USED compressor Pneumatic cylinder Direction control valve Air circulating device Frame Polyurethane tubes Hose and fitting Seals

12. Pneumatic cylinder The cylinders convert the energy of the compressed air into linear motion which extend or retract the piston rod.

13. Technical data of pneumatic cylinder Stroke length : 26 0mm Piston rod : 20 mm Quantity : 1 Temperature : 0-80 º C Pressure Range : 6-10 bar

14. Direction control valve To control the to and fro motion of a pneumatic cylinder, the air energy has to be regulated, controlled, and reversed with a predetermined sequence in a pneumatic system. Size : 0.635 x 10 ˉ² m Part size : 0.635 x 10 ˉ² m Max pressure range : 0 - 9 x 10 ⁵ N/m² Quantity : 1

15. Frame It forms the support to stand the machine vertically. It holds the weight of the vertical post and supports. It is made of mild steel channels of rectangular base with the vertical post and the horizontal channel. Material : mild steel Thickness : 1.2 mm

16. Polyurethene tubes Polyurethene tubes are used for transmission of pneumatic fluid i.e. compressed air. Polyurethene combines the best properties of both plastic and rubber. It offers abrasion and tear resistance, high tensile and elongation values, and low compression set.

17. Hose and Fittings Hose and Fittings : It is provided for the passage of compressed air from the compressor outlet to the operating valve. Technical data Max pressure : 10 x 10 ⁵ N/m² Outer diameter : 8 mm = 8 x 10 ˉ ³m Inner diameter : 5.5 mm = 5.5 x 10ˉ ³m

18. Design of pneumatic cylinder 1.Design of piston rod Diameter of the Piston (d) = 40 mm = 4cm Pressure acting (p) = 6 kgf /cm² Material used for rod = C 45 Yield stress ( σ y) = 56 kgf /mm² Assuming factor of safety = 2 Force acting on the rod (P) = Pressure x Area = p x ( Π d² / 4) = 753.6 kgf Design Stress ( σ d ) = σ y / Fos d = √ 4 p / Π [ σ y ] = 5.85mm Minimum diameter of rod required for the load = 5.85mm We assume diameter of the rod = 20 mm

19. 2. Length of piston rod Approach stroke = 230 mm Extra length due to front cover = 12 Extra length of accommodate head = 20 mm Total length of the piston rod = 23 0 + 12 + 20 = 262mm By standardizing, length of the piston rod = 260mm

20. M odeling Solid works is a computer graphics system for modeling various mechanical designs for performing related design and manufacturing operations. The system uses a 3D solid modeling system as the core, and applies the feature base parametric modeling method. Solid works is a feature based parametric solid modeling system with many extended design and manufacturing application.

21. Modeling of components pneumatic piston Piston Rod Direction control valve Nut and Bolt

22. Working principle The compressed air from the compressor at the pressure of 5 to 10 bar is passed through a pipe connected to the manual control valve with one input. the manual control valve has two outputs and one input. The compressed air from the compressor is used as the force medium for this operation. In one position, air enters to the top of the cylinder and pushes the piston so that the punching is done. In next position, air enters to the bottom of the cylinder and pushes the piston return back, so that the return stroke is obtained.

23. Calculations CUTTING FORCE Cutting force = 𝐿 × t × 𝑇 𝑚𝑎𝑥 Stripping force =10% of cutting force 𝐿 = Length of periphery to be cut in mm 𝑆 = Sheet thickness in mm 𝑇 𝑚𝑎𝑥 = 80 % of tensile strength The formula to calculate the press force is as follows- Press force = cutting force + stripping force The punch force required to punch a piece of sheet metal can be estimated from the following equation F = L x t x Ultimate tensile stress. Where: t is the sheet metal thickness,  L is the total length UTS is the ultimate tensile strength of the material.

24. Calculation of Force after punching CALCULATION FOR ALUMINIUM If total length , L = 15.7 mm. Sheet thickness, T = 0.2 mm. Maximum tensile strength of aluminum , T max . = 140 N/mm2 Total cutting force = 𝐿 × 𝑇 × 𝑇 𝑚𝑎𝑥 . = 15.7 × 0.2 × 140 = 439.6N Stripping force = 10% of the cutting force = 43.9N Pressure force = Cutting force + Stripping force =439.6+43.9=483.5N

25. CALCULATION FOR PLASTIC If total length , L = 15.7 mm. Sheet thickness, T = 0.2 mm. Maximum tensile strength , T max . = 90 N/mm2 Total cutting force = 𝐿 × 𝑇 × 𝑇 𝑚𝑎𝑥 . = 15.7 × 0.2 × 72 = 226.08N Stripping force = 10-15% of cutting force = 22.6N Pressure force = Cutting force + Stripping force = 225.08 + 22.6 = 247.6N

26. Results And Discussions For Aluminium punching force = 483.5N For plastic punching force = 247.6N Aluminium Plastic Punch force 483.5N 247.6N

27. conclusion It is observed that pneumatic machines are cheaper than hydraulic machines. Cost of maintenance is also low as compared to hydraulic machines since compressed air is the working fluid. The force required for punching and shearing machines and the tool wear can be controlled by changing the process variables like clearance and angle. We tested our project by punching the sheet metal. As our project is based on manufacturing of pneumatic punching further modifications can be done and increase its applications.

28. Future extension We contemplate the following future features which can be incorporated into this project:- 1) Automation of pneumatic punching machine 2) Improvements in pneumatic machine by adding components like timers, silencers, etc. 3) Accident avoiding systems by adding LDR sensors

29. References Design and development of pneumatic punching machine , anand kumar singh,ijtre,volume4,issue 11,july2017 design and fabrication of pneumatic punching and bending machine, 2015,ijsrd,vol.3,issue02,2015 viraj n. suryawanshi , nilesh v.wakade , prof. prashant a. narwade “design and development of pneumatic punching machine” international research journal of engineering and technology ( irjet ) e- issn : 2395-0056 volume: 06 issue: 05 | may 2019 p- issn : 2395-0072 Madhukumar v, arun kumar n, harsha b s, navin kumar k n, nagaraja t.k.2 international journal of engineering research and advanced technology ( ijerat ) issn : 2454-6135 [special volume. 02 issue, 01, may-2016]. p.goyal,g.shrivastava,r.singh,n.singh “review on pneumatic punching machine and modification in punch tool to reduce punching force requirement”,international journal of engineering technology science and research volume 2,pp 129-135 issue 2,february 2015 issn:2394- 3386