PNEUMATIC AUTO FEED DRILLING MACHINE WITH INDEXING

MACHINE

SYNOPSIS
In small-scale industries and automatic maintenance shpes, there are frequent needs of tightening and
loosening in screws, drilling, boring, grinding machine. Huge and complicated designed parts cannot be machined in
ordinary machine. Futher for every operation separate machine is required. The increases the initial cost required,
large area requirement and large number of machine are required.
In a single machine all the above specified operation can be carried out, after drilling, the drill head is
removed from the barrel key and the required tools like grinding application of pneumatics, the pneumatic Cylinder
with is operated by an air compressor will give the successive action to operate this machine. by this we can achieve
our industrial requirements.

BLOCK DIAGRAM

GUIDE

SIGNATURE OF THE
PROJECT MONITORING MEMBER

HOD

PRINCIPAL

HEAD OF THE PROJECT

MONITORING COMMITTEE

CHAPTER-1

COMPONENTS AND DESCRIPTION

1. PNEUMATIC CYLINDER
2. 3/2 SOLENOID VALVE
3. FLOW CONTROL VALVE
4. HOSE COLLAR AND CONNECTOR
5. PUSH BUTTON

1.

PNEUMATIC CYLINDER:

Pneumatic cylinder consist of

A) PISTON

B) CYLINDER

The cylinder is a Single acting cylinder one, which means that

the air pressure operates forward and spring returns backward. The air
from the compressor is passed through the regulator which controls
the pressure to required amount by adjusting its knob.

A pressure gauge is attached to the regulator for showing the

line pressure.

Then the compressed air is passed through the

single acting 3/2 solenoid valve for supplying the air to one side of the
cylinder.

One hose take the output of the directional Control (Solenoid)

valve and they are attached to one end of the cylinder by means of
connectors.

One of the outputs from the directional control valve is

taken to the flow control valve from taken to the cylinder. The hose is
attached to each component of pneumatic system only by connectors.

CYLINDER TECHNICAL DATA:

Piston Rod:
M.S. hard Chrome plated

Seals:
Nitrile (Buna N) Elastomer

End Covers:
Cast iron graded fine grained from 25mm to 300mm

Piston:
-Aluminium.

Media:
-Air.

Temperature Range:
0^c to 85^c

Parts of Pneumatic Cylinder

Piston:

The piston is a cylindrical member of certain length which reciprocates inside the
cylinder. The diameter of the piston is slightly less than that of the cylinder bore diameter
and it is fitted to the top of the piston rod. It is one of the important parts which convert
the pressure energy into mechanical power.

The piston is equipped with a ring suitably proportioned and it is relatively soft
rubber which is capable of providing good sealing with low friction at the operating
pressure. The purpose of piston is to provide means of conveying the pressure of air
inside the cylinder to the piston of the oil cylinder.

Generally piston is made up of

Aluminium alloy-light and medium work.
Brass or bronze or CI-Heavy duty.

The piston is single acting spring returned type. The piston moves forward when
the high-pressure air is turned from the right side of cylinder. The piston moves backward
when the solenoid valve is in OFF condition. The piston should be as strong and rigid as
possible. The efficiency and economy of the machine primarily depends on the working
of the piston. It must operate in the cylinder with a minimum of friction and should be
able to withstand the high compressor force developed in the cylinder and also the shock
load during operation.

The piston should posses the following qualities.

a. The movement of the piston not creates much noise.

b. It should be frictionless.
c. It should withstand high pressure.

Piston Rod

The piston rod is circular in cross section. It connects piston with piston of other
cylinder. The piston rod is made of mild steel ground and polished. A high finish is
essential on the outer rod surface to minimize wear on the rod seals. The piston rod is
connected to the piston by mechanical fastening. The piston and the piston rod can be
separated if necessary.

One end of the piston rod is connected to the bottom of the piston. The other end
of the piston rod is connected to the other piston rod by means of coupling. The piston
transmits the working force to the oil cylinder through the piston rod. The piston rod is
designed to withstand the high compressive force. It should avoid bending and withstand
shock loads caused by the cutting force. The piston moves inside the rod seal fixed in the
bottom cover plate of the cylinder. The sealing arrangements prevent the leakage of air
from the bottom of the cylinder while the rod reciprocates through it.

Cylinder Cover Plates

The cylinder should be enclosed to get the applied pressure from the compressor
and act on the pinion. The cylinder is thus closed by the cover plates on both the ends
such that there is no leakage of air. An inlet port is provided on the top cover plate and an
outlet ports on the bottom cover plate. There is also a hole drilled for the movement of
the piston.

The cylinder cover plate protects the cylinder from dust and other particle and
maintains the same pressure that is taken from the compressor. The flange has to hold the
piston in both of its extreme positions. The piston hits the top plat during the return
stroke and hits the bottom plate during end of forward stroke. So the cover plates must
be strong enough to withstand the load.
Cylinder Mounting Plates:

It is attached to the cylinder cover plates and also to the carriage with the help of
L bends and bolts.
Cylinder Tube Materials:
LIGHT DUTY
DUTY

MEDIUM DUTY

HEAVY

1. Plastic

Hard drawn brass tube

2. Hard drawn

Aluminium

Aluminium tube

hard drawn brass tube.

Hard drawn steel tube

Castings

tube.

4. Hard drawn

Brass,

Bronze, Iron or
Brass

tube

Castings, welded steel tube

End Cover Materials:

LIGHT DUTY

MEDIUM DUTY

HEAVY DUTY

1. Aluminium stock

Aluminium stock

Hard

tensile
(Fabricated)

(Fabricated)

2. Brass stock

Brass stock

(Fabricated)

(Fabricated)

3. Aluminium

Aluminium, Brass,

Castings

Castings

iron or steel Castings.

Piston Materials:
LIGHT DUTY

MEDIUM DUTY

HEAVY DUTY

1.Aluminium

Aluminium Castings

Aluminium Forgings,

Brass (Fabricated)

Aluminium Castings.

2.

Bronze (Fabricated)

Bronze (Fabricated)

3.

Iron and Steel

Brass, Bronze, Iron or

Castings

Steel Castings.

MEDIUM DUTY

HEAVY DUTY

Aluminium, Brass

High Tensile

And Steel Castings

Steel Castings

Castings

Mount Materials:
LIGHT DUTY
1. Aluminium
Castings
2. Light Alloy

High Tensile

(Fabricated)

Steel Fabrication

Piston Rod Materials:

MATERIAL

FINISH

REMARKS

MILD STEEL

Ground and polished

Generally preferred

hardened, ground and

chrome plated

polished.
STAINLESS STEEL

Ground and Polished

Less scratch resistant

than chrome plated
piston rod

2. SOLENOID VALVE:

The directional valve is one of the important parts of a pneumatic system.

Commonly known as DCV, this valve is used to control the direction of air flow in the
pneumatic system. The directional valve does this by changing the position of its internal
movable parts.

This valve was selected for speedy operation and to reduce the manual effort and
also for the modification of the machine into automatic machine by means of using a
solenoid valve. A solenoid is an electrical device that converts electrical energy into
straight line motion and force. These are also used to operate a mechanical operation
which in turn operates the valve mechanism. Solenoids may be push type or pull type.
The push type solenoid is one in which the plunger is pushed when the solenoid is

energized electrically. The pull type solenoid is one is which the plunger is pulled when
the solenoid is energized.

The name of the parts of the solenoid should be learned so that they can be
recognized when called upon to make repairs, to do service work or to install them.

Parts of a Solenoid Valve

1. Coil

The solenoid coil is made of copper wire. The layers of wire are separated by
insulating layer. The entire solenoid coil is covered with an varnish that is not affected by
solvents, moisture, cutting oil or often fluids. Coils are rated in various voltages such as
115 volts AC, 230 volts AC, 460 volts AC, 575 Volts AC, 6 Volts DC, 12 Volts DC, 24
Volts DC, 115 Volts DC & 230 Volts DC. They are designed for such frequencies as 50
Hz to 60 Hz.

2. Frame
The solenoid frame serves several purposes. Since it is made of laminated sheets,
it is magnetized when the current passes through the coil. The magnetized coil attracts

the metal plunger to move. The frame has provisions for attaching the mounting. They
are usually bolted or welded to the frame. The frame has provisions for receivers, the
plunger. The wear strips are mounted to the solenoid frame, and are made of materials
such as metal or impregnated less fiber cloth.

3. Solenoid Plunger

The Solenoid plunger is the mover mechanism of the solenoid. The plunger is
made of steel laminations which are riveted together under high pressure, so that there
will be no movement of the lamination with respect to one another. At the top of the
plunger a pin hole is placed for making a connection to some device. The solenoid
plunger is moved by a magnetic force in one direction and is usually returned by spring
action. Solenoid operated valves are usually provided with cover over either the solenoid
or the entire valve. This protects the solenoid from dirt and other foreign matter, and
protects the actuator.

In many applications it is necessary to use explosion proof

solenoids.

WORKING OF 3/2 SINGLE ACTING SOLENOID (OR) CUT OFF

VALVE:

The control valve is used to control the flow direction is called

cut off valve or solenoid valve. This solenoid cut off valve is controlled
by the emergency push button. The 3/2 Single acting solenoid valve is
having one inlet port, one outlet port and one exhaust port. The
solenoid valve consists of electromagnetic coil, stem and spring. The
air enters to the pneumatic single acting solenoid valve when the push
button is in ON position.

Technical Data:

Size

Pressure

0 to 7 kg / cm2

Media

Air

Type

3/2

Applied Voltage

: 230V A.C

Frequency

: 50 Hz

3. . FLOW CONTROL VALVE:

1. Technical Data:

Size

Pressure

0 to 10 kg / cm2

Media

Air

(b) Purpose:
This valve is used to speed up the piston movement and
also it acts as an one way restriction valve which means that
the air can pass through only one way and it cant return back. By
using this valve the time consumption is reduced because of the
faster movement of the piston.

4. PU CONNECTIORS, REDUCER AND HOSECOLLAR:

In our pneumatic system there are two types of connectors

used; one is the hose connector and the other is the reducer.
Hose connectors normally comprise an adapter (connector) hose
nipple and cap nut. These types of connectors are made up of
brass or Aluminium or hardened steel. Reducers are used to
provide inter connection between two pipes or hoses of different
sizes.

They

may

be

fitted

straight,

tee,

or

other

configurations. These reducers are made up of gunmetal or other

materials like hardened steel etc.

CHAPTER-2

PNEUMATIC CYLINDER
Pneumatic cylinders (sometimes known as air cylinders) are
mechanical devices which use the power of compressed gas to produce a
force in a reciprocating linear motion.
Like hydraulic cylinders, pneumatic cylinders use the stored potential
energy of a fluid, in this case compressed air, and convert it into kinetic
energy as the air expands in an attempt to reach atmospheric pressure. This
air expansion forces a piston to move in the desired direction. The piston is a
disc or cylinder, and the piston rod transfers the force it develops to the
object to be moved. Engineers prefer to use pneumatics sometime because
they are quieter, cleaner, and do not require large amounts or space for fluid
storage.
Because the operating fluid is a gas, leakage from a pneumatic
cylinder will not drip out and contaminate the surroundings, making
pneumatics more desirable where cleanliness is a requirement. For example,
in the mechanical puppets of the DisneyTiki Room, pneumatics are used to
prevent fluid from dripping onto people below the puppet.

Figure (i)

SELECTION OF PNEUMATICS

Mechanization is broadly defined as the replacement of manual effort by

mechanical power.

Pneumatics is an attractive medium for low cost

mechanization particularly for sequential or repetitive operations. Many factories

and plants already have a compressed air system, which is capable of providing
both the power or energy requirements and the control system (although equally
pneumatic control systems may be economic and can be advantageously applied to
other forms of power).

The main advantages of an all-pneumatic system are

usually economy and simplicity, the latter reducing maintenance
to a low level. It can also have out standing advantages in terms
of safety.

PNEUMATIC COMPONENTS AND ITS DESCRIPTION

The pneumatic bearing press consists of the following

components to fulfil the requirements of complete operation of
the machine (Fig 1)

i.

Pneumatic cylinder

ii.

Hand operated valve

iii.

Flow control value

iv.

Regulator or pressure control valve

v.

Pressure gauge

vi.

Connectors and

vii.

Hoses

1. CYLINDER:

The cylinder is a double acting cylinder one, which means

that

the

air

pressure

operates

alternatively

(forward

and

backward). The air from the compressor is passed through the

regulator which controls the pressure to required amount by

adjusting its knob. A pressure gauge is attached to the regulator

for showing the line pressure.

Then the compressed air is passed through the directional

control valve for supplying the air alternatively to either sides of
the cylinder. Two hoses take the output of the directional
Control valve and they are attached to two ends of the cylinder
by means of connectors. One of the outputs from the directional
control valve is taken to the flow control valve from taken to the
cylinder.

TWO WAY DIRECTIONAL VALVE

A two-way directional valve consists of two ports connected to each other
withpassages, which are connected and disconnected. In one extreme spool
position, portA is open to port B; the flow path through the valve is open. In
the other extreme,the large diameter of the spool closes the path between A
and B; the flow path isblocked. A two-way directional valve gives an on-off
function.
(Flow path open and Flow path closed).

Figure (iii)

HIGH SPEED STEEL BLADE:

A blade is used to cut the sheet metal in a desired dimension. Here we are
using high speed steel blades to cut the sheet metal.

7
7. MATERIALS

7.1.Stainless steel:
The three most common stainless steel grades available in sheet metal are 304, 316, and
410.

Grade 304 is the most common of the three grades. It offers good
corrosion resistance while maintaining formability and weldability.
Available finishes are #2B, #3, and #4. Note that grade 303 is not
available in sheet form.

Grade 316 offers more corrosion resistance and strength at

elevated temperatures than 304. It is commonly used for pumps,
valves, chemical equipment, and marine applications. Available
finishes are #2B, #3, and #4.

Grade 410 is a heat treatable stainless steel, but does not offer as
good corrosion resistance. It is commonly used in cutlery. The only
available finish is dull.

8. SHEARED EDGE
A varietyof cutting processes that utilize shearing forces exist to separate or
remove material from a piece of sheet stock in different ways. Each process
is capable of forming a specific type of cut, some with an open path to
separate portion of material and some with a closed path to cut out and
remove that material. By using many of these processes together, sheet metal
parts can be fabricated with cut outs and profiles of any 2D geometry. Such
cutting process include the following

 Shearing Separating material into two parts

Blanking Removing material to use for parts
Conventional blanking
Fine blanking
Punching Removing material as scrap
Piercing
Slotting
Perforating
Notching
Nibbling
Lancing
Slitting
Parting
Cutoff
Trimming
Shaving
Dinking

Figure (iv)

10

8.1. SHEARING
As mentioned above, several cutting processes exist that utilize shearing
force to cut sheet metal. However, the term shearing by itself refers to a
specific cutting process that produces straight line cuts to separate a piece of
sheet metal. Most commonly, shearing is used to cut a sheet parallel to an
existing edge which is held square, but angled cuts can be made as well. For
this reason, shearing is primarily used to cut sheet stock into amaller sizes in
preparation for other processes. Shearing has the following capabilities
Sheet thickness: 0.005 0.25 inches
Tolerence: 0.1 inches
The shearing is performed on a shear machine, often called
asquaring shear or power shear, that can be operated manually or by
hydraulic, pneumatic, or electric power. A typical shear machine includes a
table with support arms to hold the sheet, stops or guides to secure the sheet,
upper and lower straight - edge blades, a gauging device to precisely
position the sheet. The sheet is placed between the upper and the lower
blade, which are then forced together against the sheet, cutting the material.
In most devices, the lower blades remain stationary while the upper blade is
forced downward. The upper blade is slightly offset from the lower blade,
approximately 5 10% of the sheet thickness. Also the upper blade is
usually angled so that the cut progresses from one end to the other, thus
reducing the required force. The knife edge and are available in different
materials, such as low alloy steel and high carbon steel.

11

9. PNEUMATIC TRANSMISSION OF ENERGY:

The reason for using pneumatics, or any other type of energy transmission
on amachine, is to perform work. The accomplishment of work requires the
applicationof kinetic energy to a resisting object resulting in the object
moving through adistance. In a pneumatic system, energy is stored in a
potential state under the formof compressed air. Working energy (kinetic
energy and pressure) results in apneumatic system when the compressed air
is allowed to expand. For example, atank is charged to 100 PSIA with
compressed air. When the valve at the tank outletis opened, the air inside the
tank expands until the pressure inside the tank equals theatmospheric
pressure. Air expansion takes the form of airflow.
To perform any applicable amount of work then, a device is needed which
cansupply an air tank with a sufficient amount of air at a desired pressure.
This deviceis positive displacement compressor.
What a Positive Displacement Compressor Consists of
A positive displacement compressor basically consists of a movable member
insidea housing. The compressor has a piston for a movable member. The
piston isconnected to a crankshaft, which is in turn connected to a prime
mover (electricmotor, internal combustion engine). At inlet and outlet ports,
valves allow air toenter and exit the chamber.
How a Positive Displacement Compressor Works:

As the crankshaft pulls the piston down, an increasing volume is formed

within thehousing. This action causes the trapped air in the piston bore to
expand, reducing itspressure. When pressure differential becomes high
enough, the inlet valve opens,allowing atmospheric air to flow in. With the
piston at the bottom of its stroke, inletvalve closes. The piston starts its
upward movement to reduce the air volume whichconsequently increases its
pressure and temperature. When pressure differentialbetween the compressor
chamber and discharge line is high enough, the dischargevalve opens,
allowing air to pass into an air receiver tank for storage.

12
9.1. Control of Pneumatic Energy:
Working energy transmitted pneumatically must be directed and under
completecontrol at all times. If not under control, useful work will not be
done and machineryor machine operators might be harmed. One of the
advantages of transmittingenergy pneumatically is that energy can be
controlled relatively easily by usingvalves.
9.2. Control of Pressure:
Pressure in a pneumatic system must be controlled at two points - after
thecompressor and after the air receiver tank. Control of pressure is required
after thecompressor as a safety for the system. Control of pressure after an
air receiver tankis necessary so that an actuator receives a steady pressure
source without wastingenergy.
9.3. Control of Pressure after a Compressor:
In a pneumatic system, energy delivered by a compressor is not generally
usedimmediately, but is stored as potential energy in air receiver tank in the
form ofcompressed air.

In most instances, a compressor is designed into a system so that it operates

intermittently. A compressor usually delivers compressed air to a receiver
tank untilhigh pressure is reached, then it is shut down. When air pressure in
the tankdecreases, the compressor cuts in and recharges the tank.
Intermittent compressoroperation in this manner is a power saving benefit
for the system.
A common way of sensing tank pressure and controlling actuation and deactuationof relatively small (2-15 HP) compressors, is with a pressure
switch.
CHAPTER-3