Design and fabrication of integrated hydraulic

paper cutting and punching machine

VEERESHGOUDA S NARAGUNDADVANCED MATERIALS TECHNOLOGY

U.V.C.E. BANGALORE

INTUITIION INTRODUCTION LITRATURE SURVEY EXISTING MACHINES OUR MACHINE THE DESIGN THE ENGINEERING PARTS DRAFTING AND ASSEMBLY THE FABRICATION ADVANTAGES AND APPLICATIONS CONCLUSION AND SCOPE FOR IMPROVEMENT COSTING REFERENCES

CONTENTS :

AREA: HYDRAULICS MANUAL OR MOTOR NEED FOR SMALL EFFICIENT PAPER CUTTING

AND PUNCHING MACHINE FOR THE XEROX SHOP AROUND COLLEGE AREA

INTUITION:

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.

INTRODUCTION

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.”

LITRATURE SURVEY

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.

There are four basic components:

Contd..

EXISTING MACHINES

OUR MACHINE

Manual pump

Hoses

Pressure gauge

Ram

Cutting and punching tool

Tooling

A Comparision

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 required Difficult for women

operators High initial and

maintenance cost Highly skilled

operators(programmers) Not affordable for small

shops Many machines are not

integrated to perform cutting and punching operations

Cylinder design:Cylinder specificationsCapacity=100 bar Diameter of piston=40mm Stroke=75mm A=πD2/4 =1256.6mm2

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

THE DESIGN

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*25 F=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).

Spring designContd..

Specifications and Materials4037 Alloy steel

303-316 Stainless steel Diameter of punch, D=6mm Length of punch, l=60mm

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

Yield strength, σ0 =758MPa

Shear 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)

Tool design:

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).

THE ENGINEERING

PARTS DRAFTING AND ASSEMBLY

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

THE FABRICATION

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.

ADVANTAGES AND APPLICATIONS

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.

CONCLUSION AND SCOPE FOR IMPROVEMENT

COSTING- Materials cost

COSTING- Processing cost

Total cost of the project=Material cost + process cost=13,200+850= Rs. 14,050

Total Cost

Closer tolerance in punch and die hole.

Problems and troubleshooting while project

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.

REFERENCES

Thank you