A

PROJECT REPORT

ON

Submitted By

Under the Guidance of

DEPARTMENT OF MECHANICAL ENGINEERING

WALCHAND COLLEGE OF ENGINEERING, SANGLI

2014-2015

CERTIFICATE This is to certify that the project report entitled

Submitted by

Of T. Y. Mechanical Engineering Branch

Is the report of their own work carried out by them for the award of

DIPLOMA IN MECHANICAL ENGINEERING

OF

M. S. B. T. E. MUMBAI

Under my guidance during the academic year

2014 2015

Date: /0 /2015 Place: WCE, Sangli.

Prof. H. N. TIKEKAR Prof. S. B. JALIHAL

(Guide) (HOD)

DEPARTMENT OF MECHANICAL ENGINEERING

WALCHAND COLLEGE OF ENGINEERING, SANGLI

2014-2015

ACKNOWLEDGEMENT

We are rather infused by the kind guidance of Prof. H. N.

Tikekar who put us in the cradle of our engineering studies and

evaluated us to this end and mean of our project without his

guidance, we are sure to be an orphan in the vast ocean of the

subject. Ultimately no tongue could describe the deep sense of co-

operation and ready nature to help us even in minute details of our

write up this project report.

Thanks and gratitude goes to Prof. S. B. Jalihal Head,

Department of Mechanical Engineering Polytechnic Wing, who made

very valuable guidance and co-operation during our project.

Further we are thankful to all the staff and non-teaching

members of Mechanical Engineering Department for the co-

operation during the project work. We are very grateful to those

who in the form of books had conveyed guidance in this project

work. Last but not the least we are thankful to our colleagues and

those helped us directly or indirectly throughout this project work.

Special thanks go to Mr. L. L. Kamble sir of machining

workshop.

Projects Associates:

Sr. No.

Topic Pg. No.

1. Synopsis 1 2. Introduction 3 3. Literature Survey 4 4. Prior Concepts 6 5. Construction 7 6. Design 8 7. Specifications 10 8. Drawings 12 9. Figures 18 10. Working 21 11. Process Sheet 26 12. Cost Sheet 28 13. Merits & Demerits 30 14. Future Scope 31 15. Conclusion 32 16. References 33 17. Photographs 34

Synopsis

The objective of the project is to prepare a machine which

cuts sheet metal without human efforts but operates

pneumatically. Compressed air is used as working media. The

compressed air moves the blades of machine to cut the sheet of

metal.

The idea of the project generated due to a manual sheet

metal sheering machine in workshop of our college. In that

machine sheet metal is placed in between the two sheering blades

of machine and the lever is pulled down to move the upper

movable blade and cut the work-piece.

But in that machine large force is required which can make

tire to a worker who continuously works on it for mass production

in large scale industry; so to reduce the human efforts pneumatic

machine should chose. Hence for some development of machine,

we have chosen this subject for our project. We hope that a good

idea will develop and we can use it in many industries in

surrounding and our practical knowledge, team-working skill,

leadership skills will be improved.

Figure: Concept Image for Project

Introduction

The formation of any business begins with someone

producing the initial idea for the project. The continued success of

an established business depends upon the number and quality of

the ideas fed into it. Without a continual flow of new ideas, a

business cannot function profitably or expand successfully and

must, therefore eventually fade into total obscurity.

Ideas for a new business project, a new product, a means of

reducing manufacturing costs or for solving industrial labour

problems, begin in the human mind. Most people conceive their

ideas unconsciously, and because they are unaware of the mental

mechanics that caused the idea to be produced, they cannot

repeat the ideation process to produce further profitable ideas at

will.

Fortunately, there are available established creative

techniques which, when used correctly, do enable a person to

produce a large number of first-class ideas at will. One such

creative technique, and probably the most widely used in American

industry, is brainstorming.

Literature survey

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 two

blades is very small, the plastic deformation takes place in a

localized area and the metal adjacent to the cutting edges of the

blade edges becomes highly stressed, which causes the fracture

to start on both sides of the sheet as the deformation progresses

and the sheet is sheared.

Types of shearing Machine:

1) Pneumatically operated

2) Hydraulically operated

3) Rack and pinion operated

4) Spring operated

Brief description of all the types is as follows.

1) Pneumatically operated:-

Here the advancement of the header is carried out in the

upward and the downward direction using the 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.

2) Hydraulically operated:-

Here the lowering and raising of the header is carried over

using the hydraulic piston and cylinder arrangement. To actuate

the piston and cylinder, the oil is allowed to enter the cylinder from

front or the back side of the piston. But the oil is comparatively

costlier and its leakage may cause so many problems.

3) Rack and pinion operated:-

Here the lowering and the raising of the header are carried

out manually using the rack and pinion arrangement. In this case

the required pressure is applied manually using direct hand

pressure on the rack using pinion and lever arrangement. Since

the machine is robust and requires large pressure, hence it is not

suitable.

4) Spring operated:-

The working of spring operated machine is similar to the rack

and pinion operated machine but differs from it in construction.

Here the lowering and the raising of the heating handle are 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.

Prior concepts

Pneumatics, from the Greek (pneumatikos, coming from the

wind) is the use of pressurized gases to do work in science and

technology. Pneumatics was first documented by Hero of

Alexandria in 60 A.D., but the concept had existed before then.

Pneumatic products represent a multi-billion dollar industry today.

Pneumatic devices are used in many industrial applications.

Generally appropriate for applications involving less force than

hydraulic applications, and typically less expensive than electric

applications, most pneumatic devices are designed to use clean

dry air as an energy source. The actuator then converts that

compressed air into mechanical motion. The type of motion

produced depends on the design of the actuator. Pneumatics is

employed in a variety of settings.

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.

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.

Construction

Raw Material Used-

1. Mild Steel bars for base frame.

2. 35C8 material for shearing blades.

3. Cylinder fittings like fork end, base plates, support links.

4. Angle section for blade fitting.

5. Connecting link.

6. Blade link.

Ready Items Used-

1. Pneumatic double acting cylinder.

2. Direction & flow control valves.

3. Pneumatic pipe & pipe fittings.

4. Bolts & nuts.

5. Antirust coat & paint.

Machines & Tools Used-

1. Cutting Machine.

2. Hacksaw Cutting Machine.

3. Sensitive Drilling Machine.

4. Horizontal Milling Machine.

5. Electric Arc Welding Machine.

6. Table Grinder.

7. Hand Grinder.

8. Surface Grinding Machine.

9. Tap & Tap Holder.

Design

1. Base Frame-

Quantity: 1

Height: 300mm

Length: 900mm

Width: 300mm

Weight: 5kg

2. Shearing Blade-

Quantity: 2

Length: 300mm

Height: 60mm

Thickness: 15mm

Blade Angle: 15o

Weight: 3.5kg

3. Base Plate-

Quantity: 1

Height: 65mm

Width: 65mm

Thickness: 6mm

4. Fork End-

Quantity: 1

Length: 75mm

Width: 20mm

Thickness: 5mm

5. Angle Section-

Quantity: 1

Height: 45mm

Length: 300mm

Width: 45mm

Thickness: 7mm

Weight: 0.5kg

6. Connecting Link-

Quantity: 1

Length: 360mm

Thickness: 5mm

Height: 25mm

Weight: 0.3kg

7. Support Links-

Quantity: 2

Height: 90mm

Width: 25

Thickness: 5

8. Blade Link-

Quantity: 1

Height: 90mm

Width: 20mm

Thickness: 5mm

Welded Length: 30mm

Specifications

1. Pneumatic Cylinder-

Quantity: 1

Total Length: 375mm

Bore: 40mm

Stroke: 200mm

Piston Rod Diameter: 20mm

Max Working Pressure: 8 bar

Weight: 3kg

2. DC Valve-

Quantity: 1

Operation: Manual

Type: Hand Lever, Detent Type

Number of Ports: 5

Number of Positions: 3

Construction: Sliding spool type

3. Pneumatic Pipe-

Quantity: 3000mm

Diameter: 8mm

Thickness: 1mm

4. Fork End Nut-

Quantity: 2

Length: 16mm

Size: M16

5. Cylinder Base Plate Bolts-

Quantity: 4

Length: 32mm

Size: M6

6. Blade Fixing Bolts-

Quantity: 3

Length: 25mm

Size: M10

7. Connecting Link Bolts-

Quantity: 2

Length: 45mm

Size: M6

Drawings

BASE FRAME

Shearing Blades & Blade Link

Angle Section

Connecting Link

Base Plate

Support Links

Fork End

Figures

Pneumatic Cylinder

Direction Control Valve

Flow Control Valve

Working

The following figure shows general layout for the machine.

Figure: General Layout

Initially the air-compressor is started and allowed the receiver

tank air pressure to reach up to 8 bar. The supply air is then

passed to the manifold through FRL unit to condition the air and

eligible to industrial use.

From the manifold a separate supply for the machine is

taken out and given to ON-OFF switch, so as to operate the

machine at will without interrupting the running of compressor.

Then the pipe carries compressed air first to machines

Direction Control Valve. At position A shows the non-actuated

circuit diagram. At this position the piston is steady and locked. All

ports are in closed condition.

Position A

At position B, the DC valve is at left hand position as shown

in figure. The cap end port & pressure port get connected to each

other and the rod end port gets connected to the exhaust port. The

compressed air comes in the cap end of the cylinder and pushes

the pistons outwards. The air already present in the rod end side is

pushed out of the cylinder.

When the piston moves outwards, the force is transmitted

through the connecting link and the upper blade moves

downwards. Before the actuating DC valve the sheet is inserted in

between the upper & lower blades. As upper blade moves

downwards, the stress is generated in the sheet metal and goes

beyond ultimate shear stress of sheet metal. And thus the

shearing action takes place.

Now the DC valve is operated to come at position C, as

shown in figure. The rod end port & pressure port get connected to

each other and the cap end port gets connected to the exhaust

port. The compressed air comes in the rod end of the cylinder and

pushes the pistons inwards. The air already present in the cap end

side is pushed out of the cylinder.

The sheet metal is either again inserted for further cutting in

case of large pieces; the small cut pieces are removed and the

next sheet is inserted to cut.

Position B

Position C

Process sheet

Part

No.

Part

Name Material Quantity Process Equipment Time

1) Frame Mild

Steel 1

Cutting Cutting Machine 80

Grinding Table Grinder 40

Welding Electric Arc

Welding Machine 100

Grinding Hand Grinder 10

Anti-rust

Coating Hand Brush 20

Colour

Painting Hand Brush 35

2) Blades 35C8 2

Cutting Hacksaw Cutting

Machine 15

Drilling Sensitive Drilling

Machine 15

Tapping 3/8" BSW Tap &

Holder 15

Surface

Grinding

Surface Grinding

Machine 80

Angular

Milling

Horizontal Milling

Machine 90

Filing File 20

Greasing Grease 5

3) Angle

Section

Mild

Steel 1

Cutting Cutting Machine 10

Grinding Table Grinder 5

Drilling Sensitive Drilling

Machine 15

Welding Electric Arc

Welding Machine 10

4) Connecting

Link

Mild

Steel 1

Cutting Cutting Machine 10

Grinding Table Grinder 5

Drilling Sensitive Drilling

Machine 5

5) Fork End Mild

Steel 1

Cutting Cutting Machine 5

Grinding Table Grinder 5

Drilling Sensitive Drilling

Machine 10

Welding Electric Arc

Welding Machine 15

6) Cylinder

Base Plate

Mild

Steel 1

Cutting Cutting Machine 5

Grinding Table Grinder 5

Drilling Sensitive Drilling

Machine 10

Welding Electric Arc

Welding Machine 5

7)

Cylinder

Support

Links

Mild

Steel 2

Cutting Cutting Machine 8

Grinding Table Grinder 5

Drilling Sensitive Drilling

Machine 7

Tapping 3/8" BSW Tap &

Holder 10

Welding Electric Arc

Welding Machine 15

8) Blade Link Mild

Steel 1

Cutting Cutting Machine 5

Grinding Table Grinder 5

Drilling Sensitive Drilling

Machine 5

Welding Electric Arc

Welding Machine 10

Total Process Time (in Minutes) 715

Cost sheet

Sr.

No. Part Name Material Quantity

Material

Cost

Machining

Cost

Total

Cost

A) Base Frame

1] Main Frame Mild

Steel 20 Feet 600 500 1100

2] Angle

Section

Mild

Steel 1 50 50 100

3] Cylinder

Base Plate

Mild

Steel 1 30 30 60

4] Support

Links

Mild

Steel 2 30 30 60

B) Pneumatic Circuit Components

5]

Double

Acting

Cylinder

Plain

Carbon

Steel

1 4000 - 4000

6] Flow Control

Valve

Cast

Steel 2 850 - 850

7] Pipe PVC 3 m 120 - 120

8] Direction

Control Valve

Alloy

Steel 1 700 - 700

9] Pipe Fitting

Connections

Cast

Steel 3 150 - 150

C) Blades & Accessories

10] Shearing

Blades 35C8 2 300 400 700

11] Blade Link Mild

Steel 1 20 30 50

12] Connecting

Link

Mild

Steel 1 30 30 60

13] Fork End Mild

Steel 1 50 50 100

D) Others

14] Bolts Alloy

Steel 11 80 - 80

15] Nuts Alloy

Steel 3 10 - 10

16] Antirust Coat - 100 mL 20 - 20

17] Paint - 100 mL 40 - 40

Grand Total Cost (in Rupees) 7080 1120 8200

Merits & Demerits

Merits-

1. Hydraulics present certain advantages over pneumatics, but

in a given application, pneumatic powered equipment is more

suitable, particularly in industries where the factory units are

plumbed for compressed air.

2. Moreover, to avoid corrosive actions, oil or lubricants are

added so that friction effects can be reduced.

3. Compressed air is used in most of the machines and in some

cases compressed carbon dioxide, whereas cutting process is

become easy.

4. Fast cutting action is carried out.

5. Cutting without bending is achieved.

Demerits-

1. Sheet more than 2 mm thickness cannot cut easily.

2. Compressed air is must.

3. Foundation is required also safety major must be taken.

Future Scope

Since old age man is always trying to gain more and more

luxurious. Man is always trying to develop more and more modified

technique with increasing the aesthetic look and economic

consideration. Hence there is always more and more scope. But

being the Diploma Engineers 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-

1. It can be made hydraulically power operated by installing the

gear oil pump at the place of air compressor and pneumatic

cylinder arrangement.

2. It can be made rack and pinion operated or spring and lever

operated, by replacing the pneumatic circuit by rack and the

pinion arrangement by the square threaded screw and nut

arrangement.

3. The place where there is scarcity of the electricity the electric

motor operate compressor is replaced by an I.C. Engine

installed compressor.

Thus in future there are so many modifications, which we can

make to survive the huge global world of competition.

Conclusion

Now we know that Pneumatic Shearing machine is very

cheap as compared to hydraulic shearing machine.

The range of the cutting thickness can be increased by

arranging a high pressure compressor and installing more

hardened blades. This machine is advantageous to small sheet

metal cutting industries as they cannot afford the expensive

hydraulic shearing machine.

References

1. Machine Design by R.S. Khurmi.

2. Manufacturing Process by O. P. Khanna and Lal.

3. Workshop Technology by R.K. Jain.

4. Pneumatic System: Principle & Maintenance by S.R.

Mujumdar.

5. Machine Tool Design Handbook.

6. P.S.G. Design Data Book.

7. Internet sites-

a) http://www.google.com/

b) http://www.engineersedge.com/

c) http://www.efunda.com/

d) http://www.mechanicalengineeringblog.com/

Photographs