design and fabrication of integrated hydraulic paper cutting

VEERESHGOUDA S NARAGUNDADVANCED MATERIALS TECHNOLOGY

U.V.C.E. BANGALORE

INTUITIIONINTRODUCTIONLITRATURE SURVEYEXISTING MACHINESOUR MACHINETHE DESIGNTHE ENGINEERINGPARTS DRAFTING AND ASSEMBLYTHE FABRICATIONADVANTAGES AND APPLICATIONSCONCLUSION AND SCOPE FOR IMPROVEMENTCOSTINGREFERENCES

AREA: HYDRAULICS

MANUAL OR MOTOR

NEED FOR SMALL EFFICIENT PAPER CUTTING AND PUNCHING MACHINE FOR THE XEROX SHOP AROUND COLLEGE AREA

The conventional machines used for binding works occupy more than half a room and are more costly. And are difficult for transportation and even consume more power.This hydraulic paper cutting and punching machine will overcome these disadvantages effectively. This also reduces cost, power and working space.This project is an integration of both cutting and punching operations. And hence meet the requirement of both small and large capacity binding operation based on hydraulic system design.

Definition: Hydraulics is a branch of engineering concerned mainly with moving liquids. The term is applied commonly to the study of the mechanical properties of water, other liquids, and even gases when the effects of compressibility are small. Hydraulics can be divided into two areas, hydrostatics and hydrokinetics.

“Pascal’s law states that when a confined fluid is placed under pressure, the pressure is transmitted equally in all directions and directed normal on all faces of the container.”

1. A reservoir to hold the fluid.

2. A pump to force the fluid through the system.

3. Valves to control the flow.

4. An actuator to convert the fluid energy into mechanical force to do the work.

Contd..

Manual pump

Hoses

Pressure gauge

Ram

Cutting and punching tool

Our machine Other machine

Less floor area required

Integration of cutting and punching operations

Ease of repair as it has removable tools

Low initial and maintenance cost

Can be used in small shops

No need of skilled operators

Large floor space is requiredDifficult for women operatorsHigh initial and maintenance cost Highly skilled operators(programmers)Not affordable for small shopsMany machines are not integrated to perform cutting and punching operations

Cylinder design:Cylinder specificationsCapacity=100 bar

Diameter of piston=40mm

Stroke=75mmA=πD2/4=1256.6mm2

100*(105) =F/(1256.6*10^6F =12.566KN

Formula from design data hand book

Where, C=D/di

D= (Outside dia. + Inside dia.)/2= (22+25)/2

D=23.5mm, l=60mmdi =22mm

C= =1.068Now,

K =12.60 N/mm

Where,F=K*x

F=12.60*25F=300N

For two springs,F=600N

Then,Total force on each punch=

(12566-600)/7 =1708.37 N/punch

(Square and ground end spring is used).

Contd..

Specifications and Materials4037 Alloy steel

303-316 Stainless steelDiameter of punch, D=6mmLength of punch, l=60mm

Surface hardness, RC-60minimumCore hardness, RC-47minimum

Yield strength, σ0 =758MPaShear stress in one paper, τ = shear

force/shear area= s

f/3.142*d*t=700*10-

3/(3.14*6*.137)

=0.271066 N/mm2

Shear stress for 15 papers = 15*0.271066

= 4.066N/mm2

Shear yield strength of Punch = σ0/ 2=758 / 2

= 379 N/mm2 > shear strength for 15 papers

Hence design is safe.

Punch design: The thickness of paper is which is typically given in thousandths

of an inch.[10] Paper may be between 0.07 millimetres (0.0028 in) and 0.18

millimetres (0.0071 in) thick. The density of paper ranges from 250 kg/m3 (16 lb/cu ft) for tissue

paper to 1,500 kg/m3 (94 lb/cu ft) for some speciality paper. Printing paper is

about 800 kg/m3 (50 lb/cu ft)

Contd..

Use of standard hydraulic power pack

(ϕ 40 mm * 75 mm stroke)

Use of polished ms supporting plates

(50 mm width*16mm thickness*280 mm length)

Use of standard diameter punches (ϕ6mm*60mm length)

Use of springs (di=22mm*60 mm length)

Use of standard guide rods (ϕ20mm*150mm length)

Use of en8 cutting tool material (80mm w*10 mm t*280mm l).

Punch drawing

Supporting plate drawing

Die plate drawing

Guide rod drawing.

Spring drawing

Tool assemblies drawing

Drilling on supporting plates for guide rods (ϕ20.5mm)

Drilling on punch plate (ϕ6 mm)

Thread cutting on guide rod and tapping on die plate (M16)

Counter sinking on punch plate for brazing operation (45° *2mm)

Brazing operations

Advantages

Less floor area required

Integration of cutting and punching operations

Ease of repair as it has removable tools

Low initial and maintenance cost

Can be used in small shops

No need of skilled operators

Applications of our machine

The machine can be used by binders and Xerox shops.

Any other hydraulic press operations as it have removable tooling.

It can perform cutting and punching operations at once.

It can also be used as simple hydraulic clamping device.

Conclusion of the project

The hydraulic paper cutting and punching machine with removable tooling, which can be removed and repaired easily.

Simple design using hydraulic press makes it economical and efficient.

SCOPE FOR IMPROVEMENT

The hydraulic system used is of small capacity and uses manual pump so this can be further improved by using large capacity power pack and automatic pump so that even large pressing operations can be performed.

Even three side cutting and one side punching operations can be performed by further improvements.

Design analysis and optimization using any FEA Package

Process simulation of cutting and punching using simulation software.

Total cost of the project

=Material cost + process cost

=13,200+850

= Rs. 14,050

Closer tolerance in punch and die hole.

Stephen Timoshenko, strength of materials, 3rd edition,cbs publishers and distributors pvt.ltd.2002.K.Mahadevan and K.Balaveera reddy, Design data handbook, 3rd edition,cbs publishers and distributors pvt.ltd.2010.Esposite Anthony, fluid power with applications, PHI publications 4th edition 2004.R.S.khurmi and J.K.gupta, a text book of machine design, Eurasia publications.

Thank you