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FABRICATION OF PNEUMATIC

SHEET CUTTER

Mechanical engineeringSection A, Group no. A9

26th February, 2016Guided By: Prof. D.N Thatoi

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Ansita MohantyJyoti PandaBasundhara PradhanShubhendu VermaRohit RanjanSmurtipiyush Sahoo

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Mission Statement

Use of pneumatically controlled Sheet metal cutter in an efficient way.

Fabrication of pneumatic sheet cutting machine with minimization of cost as well as size.

Making the machine automatic and user friendly so that it will be easier for operation.

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Introduction What is a Sheet metal Sheet metal is simply a metal formed

into thin and flat pieces. The thickness of sheet is called its gauge. The thickness above 6mm falls in Plate category.

There are many metals that can be made into sheet metal like Aluminum, Brass, copper, steel, tin etc. For decorative uses sheet metals of Silver, gold, platinum are also used.

Sheet metals are used in Car bodies, medical tables, roofs for buildings etc.

Use of sheet metal are now days in furniture, shelves or cupboards.

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Schematic representation

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How Sheet Metal is cut: The cutting process is done by applying Shear Force Due to application of shear Force,

the stress in the material will exceed the ultimate shear strength and the material will fail and separate at the cut location.

Shearing force is applied by 2 blades one above and one belowthe sheet.

The upper blade delivers a quick downward blow to the sheetmetal that rests on the lower blade.

The upper tool penetrates on thesheet causing the shearing andmaterial failure.

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Pneumatically Operated

Sheet cutter

Hand Operated Sheet Metal

cutter

Pictures

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CUSTOMER SURVEY FORM

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Customer Name: Rabindra PradhanAddress: Ashirvad Furniture, Laxmi Sagar

Interviewer: SmrutiDate: 15/02/2016

Questions Customer Statement Interpreted Need Importance Typical Uses

Cutting of aluminum plates

Both Industrial and general purpose should be there

Very important

Cutting of mild steelCutting of thick paper in industry

LIKES

Handy in operation No laborious worker needed, also no use of manual work which ensures safety

Very importantNo skilled user needed

Easy to usePower consumption is lessUse of pneumatic control reduces Human effort

Ease of Operation Important

Reduced cost compared to Hydraulics

Suitable for small Industries

Genuine factor for small industries

Easy maintenance compared to spring operated and rack & pinion operated

Effectiveness throughout the year

Depends on the use

DISLIKES

Lesser Sheet Thickness Limitation of Sheet type i;e sheet metal is very thin

Much needed

Less width of sheet

Not suitable for large scale production or Batch production

Comparably less use for mass production industries

Not needed

Suggested Improvement

Safety should be ensured, Operation should be easy and it should cut the sheet effortlessly

Try to make the thickness more, obtain the cutting operation comfortably.

Important

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CUSTOMER NEEDS

No. Of Occurrences (Out of 20)

Weightage

Efficient Cutting 16 0.8Reduce Human effort 14 0.7

Occupy Less space 15 0.75Low Cost 13 0.65

Less Maintenance 10 0.5Automatic Operation 11 0.55

Reduce Power Consumption 7 0.35Safety During Machining 10 0.5

Portability 15 0.75More thickness of Sheet 9 0.45

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Customer Need Statements and Importance Ranking

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SELECTED NEEDS FOR REDESIGNThe following functions were selected for redesign:

Improvisation in Cutting Operational Suitability Portability Occupying Less space

PROBLEM DEFINITION (Our Objective)

A Pneumatic sheet cutter has to be designed and developed. In order to reduce human effort in manual operated machine our machine should ensure automatic operation, finer cutting. In addition to that the product should be small in size so that it is easier to carry the product from one place to another.

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FUNCTIONAL DECOMPOSITIONThe approaches for developing functions that were followed are Fast method

Objective: To relate one sub-function to another and so to increase the product value.

Subtract Operate Procedure MethodObjective: To disassemble each component from the product

and analyze the effect in a logical way. Activity diagram and Function structure method Objective: To describe the overall process description of customer from buying the product to operating it. Also to describe the flow paths from start of machine to end of the action. Functional hierarchical decomposition Objective: To trace the flow of energy, material and signals from the bottom to the top level.

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SMOOTH OPERATION

TRANSMITMECHANICAL

ENERGY

PRODUCE CUTTING FORCE

PISTON CYLINDER

COMPRESS IT PNEUMATICALLY

LUBRICATIONDAMP

VIBRATIONS

TRANSMIT FORCE TO

CUTTING BLADE

ALIGNMENT OF WORK PIECE

LOCOMOTION OF CUTTING BLADE

OVER SHEET METAL

CUT THE SHEET

PROVIDE AIR

GENERATE NOISE

HOW? WHY?

REDUCE NOISE

ELIMINATELEAKAGE

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PORTABILITY LINEAR SMOOTH OPERATION

FAST Method

AIR COMPRESSOR FRL CONTROL UNIT PNEUMATIC CYLINDER

CUTTER BLADE ASSEMBLY

Compressed Air can’t be Generated

Compressed air flow can’t be regulated

Pressurized air can’t be expanded

No up-down motion of blade for cutting

Main source of energy i;e Compressed air Pressure can’t be given to Cylinder

The FRL (Filtration- Regulation- Lubrication) process can’t be performed

As expansion wont take place, piston movement can’t occur

Moving blade can’t be pushed down

Energy can’t be stored in the Cylinder to perform mechanical work

Connecting rod can’t Reciprocate

Shearing operation can’t take place

The Rod can’t push the Upper blade

Also no support arms to hold and secure the sheet

SUBTRACT AND OPERATE APPLIED TO THE PNEUMATIC SHEET CUTTER

Cut The Metal Sheet

Input Metal Sheet

Input Air Pressure Hold

Reciprocate Connecting

Rod

Permit Finer Cut

Fix the Metal Under Cutter

Provide Indication for Cutting

Accept it through FRL Control Unit

Transmit Pressure to Connecting

Rod

Support the Pneumatic

Cylinder

Convert Compressed

Air Pressure to Mechanical

work

Reciprocation of Cylinder

Rod

Movement of the Blade

Fix The Pneumatic Cylinder On

the Machine

SOP Diagram

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Purchase Transport in Package

Unpackaged

Main Frame for Support

StorePrepare to Cut the Sheet

Flow of compressed

air to the Cylinder

Motion of connecting

rod

Cutting of Sheet metal

Throw away Debris

Process descriptions as Activity Diagrams for Sheet cutter product

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Open System

Close System

Support Cutting blades

Execute Cutting

Store the split sheet Raw Metal sheet

Pressure force

AirSheet uncut

Cutting force

Release air

Sheared metal sheet

Provide elect. to compressor

Generation of compressed

air

Stores compressed

air

Flow of air to FRL unit

Compression & storage

Release into pneumatic

cylinderCut the sheet

FRL UnitExpansion of

air inside cylinder

Motion of connecting

rod to movement of

blade

Shearing over the sheet

Electrical energy

Compressed air pressure

Air

Uncut Sheet

Sheared metal

K.E of blade

Cutting of metal as required

Desired cut

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Cut the metal sheet

Supply power

Use electricity

Supplyelectricity

Generate compressed

air

Automatic work

Use different sheets

Accept sheets Hold sheets

Movement of upper

blade

Feel easier operation

Use regulating

switch

Convert elet. To

compressed air

Apply K.E to blade

Reciprocate connecting

rod

Convert air Pr. to K.E Expansion of

compressed air in cylinder

Regulate air flow

Withstand air flow

Motion of connecting

rod

Use FRL control unit

Use tubes to allow air

flow

Provide compressed air

Hierarchical Decomposition

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Conclusion Thus our concept is complying to the demands of the

customer whose use the products as well as those who are new.

The latent needs of customers, which they were not able to reciprocate properly is estimated successfully.

The individual functions were studied thoroughly and were evaluated by each group member.

Further study will involve more analysis about the product and comparison of similar products available in the market.

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References Ajit Kumar Singh, Harpreet Singh and Dharmendra Sharma, “Design and

Fabrication of Pneumatic Auto Sheet Metal Cutting Machine Using Solar Energy”, International Journal of Engineering Research & Technology (IJERT): ISSN: 2278-0181: Vol. 4 Issue 03, March-2015

A.S. Aditya Polapragada & K. Sri Varsha , “Pneumatic Auto Feed Punching, cutting and Riveting Machine “, International Journal of Engineering Research & Technology (IJERT) Vol. 1 Issue 7, September - 2012 ISSN: 2278-0181.

P.M.Pradhan, “Experimental Investigation and Fabrication of Pneumatic Cutting tool”, International Journal of Innovative Research in Science, Engineering and Technology, Vol. 2, Issue 6, June 2013.

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