K.L.E SOCEITY’S Smt.C.I.M.

POLYTECHNIC

VIDYANAGAR HUBLI-580031

PROJECT REPORT
DEPARTMENT OF MECHANICAL ENGINEERING
2016-17

PNEUMATIC SHEET CUTTING

MACHINE

UNDER THE GUIDANCE OF

THIS PROJECT REPORT IS SUBMITTED IN PARTIAL FULLFILLMENT OF THE

AWARD OF DIPLOMA IN MECHANICAL ENGINEERING OF BOARD OF
TECHNICAL EDUCATION BANGALORE
K.L.E SOCEITY’S Smt.C.I.M. POLYTECHNIC
VIDYANAGAR HUBLI-31

PROJECT REPORT

DEPARTMENT OF MECHANICAL
ENGINEERING
2016-2017
PNEUMATIC SHEET CUTTING
MACHINE

UNDER THE GUIDENCEOF

Sri
SUBMITTED BY

THIS PROJECT REPORT IS SUBMITTED IN PARTIAL FULLFILLMENT OF THE

AWARD OF DIPLOMA IN MECHANICAL ENGINEERING OF BOARD OF
TECHNICAL EDUCATION BANGLORE
COLLEGE ROLLNO: REGISTER NO:

K.L.E SOCEITY’S Smt.C.I.M. POLYTECHNIC

VIDYANAGAR HUBLI-31

CERTIFICATE
DEPARTMENT OF MECHANICAL
ENGINEERING

This is to certify that Mr. _____________________________And

his team has satisfactorily completed the project entitle
PNEUMATIC SHEET CUTTING MACHINE for the practical
fulfillment of Diploma Engineering in MECHANICAL
DEPARTMENT board of Technical Education Bangalore for the
year 2016-2017.

GUIDE HEAD OF DEPARTMENT PRINCIPAL

Signature of examiner:

1.______________ 2.__________________
 ACKNOWLEDGEMENT

Our first experience of project has been successfully

completed, thanks to the supporting staff, many friends
and colleagues with gratitude. We wish to
acknowledge all of them. However we wish to make
special mention of following.

First of all we are thankful of our project guide Sri

(Name) under whose guideline we were able to
complete our project. We are wholeheartedly thankful
to him for giving us his value able time and attention
and for providing us a systematic way for completing
our project in time.

We would thank to our H.O.D Sri. (Name)and all lab

maintenance staff for providing us assistance in
various h/w problem encountered during course of our
project

We are also very thankful to our beloved Principal

(NAME) who gave us an opportunity to present this
project.
 CONTENTS

CHAPTER NO TITLE PAGE No.

1 Introduction
2 Pneumatic system
3 Components and Description
4 Working principle
5 Design and drawings
6 Applications and Disadvantages
7 Advantages
8 List of materials
9 Conclusion
10 Photography

CHAPTER-1

INTRODUCTION
 This is an era of automation where it is broadly defined as replacement

of manual effort by mechanical power in all degrees of automation. The

operation remains an essential part of the system although with changing

demands on physical input as the degree of mechanization is increased.

Degrees of automation are of two types, viz.

Full automation.

Semi automation.

In semi automation a combination of manual effort and mechanical power is

required whereas in full automation human participation is very negligible.

Need For Automation

Automation can be achieved through computers, hydraulics, pneumatics,

robotics, etc., of these sources, pneumatics form an attractive medium for low

cost automation. The main advantages of all pneumatic systems are economy

and simplicity. Automation plays an important role in mass production.

 Reduction of lab our and material cost

 Reduction of overall cost

 Increased production
 Increased storage capacity

 Increased safety

 Reduction in fatigue

 Improved personnel comfort

CHAPTER-2

PNEUMATIC SYSTEM
 The subject of pneumatics might probably be termed as compressible

fluid mechanics. It deals with the use of pressurized gas as a source of power.

The pressure energy of gas is directly converted into force to do the required

work with high efficiencies of conversion.

The pneumatic cylinder utilizes a low pressure fluid. It has the

advantage that cylinder construction can be simplified reducing cost. It can be

used for high speed operations.

Pneumatics is widely associated with low cost automation. It generally

offers the lowest initial and operating cost and simple, flexible control systems.

Though pneumatic system is the study properties of air other gases, we

are concerned with the study of air.

CHARACTERISTICS OF COMPRESSED AIR:

 The greatest advantage of pneumatic system is the availability of

working medium free of cost and it plentiful. Compressed air can also be

transported easily and can be easily stored in a reservoir.

Another notable advantage is the insensitiveness of compressed air to

temperature fluctuations. It ensures reliable operation even under extreme

conditions of temperature. Compressed air offers no risk of explosion; hence

no expensive protection cost is required. Compressed air is a very fast working

medium where speed and force ar infinitely variable.

CHARACTERISTICS OF PNEUMATICS:

1. Compressibility

A pneumatic fluid is compressible. Compressibility plays a major role

in the actuation of piston, i.e., opening a valve does not move the piston

immediately, rather sufficient fluid must flow into the volume to increase the

pressure until the force overcomes that on the other side.

Compressibility is the energy storage of a fluid. As it is possible to

store compressed fluids and transport them, pneumatics has the advantage of

transportability. Another advantage of the energy storage capacity is the small

compressor charging a tank can supply a system having high peak loads but

small average loads.

2. Leakage Sealing Problems

Several methods are used to minimize leakage. One is to use a low

operating pressure. Another method to prevent leakage is sealing. Good

sliding and rotating sealing are to obtain in pneumatics is because of low

viscosity of the fluids Diaphragms and bellows are used to avoid sliding seats.

3. Low Viscosity:

A highly encounted problem due to low viscosity is that of sealing.

They provide less viscous damping due to low viscosity hence sliding parts

wear considerably. This adds the necessity for external sources of lubrication.

Another problem is that the pneumatic cylinder should be thinner

enough to maintain a laminar flow inside.

1. Low Density

Fluids especially gases are usually of low density. Low density fluids

require large mechanical work and more time for high pressure build up.

2. Wide Range of Temperatures

The limitations often may lead to a view point that the use of pneumatic

equipment is coupled with high cost. It is proved to be false, however, since a

calculation of production cost includes not only the power cost but also all

other compared with wages, installation cost, and maintenance cost that they

are insignificant.

3.3. ADVANTAGES OF PNEUMATIC SYSTEM OVER OTHER

SYSTEM:

1. Output power of the pneumatic system can be easily controlled

2. Pneumatic system is not affected by over loading

3. The pneumatic system can be used at various working temperature

4. Air can be easily distributed through pipelines over very long distances

5. Pneumatic enables high working speeds

6. It is a maintenance free system

7. Pneumatic enables the application of force very gently which is not only

beneficial to pneumatic components but also the equipment which they

are installed.

8. The working fluid which is stored in the storage tank can be taken

through number of lines which eliminates the use of individual power

sources say electric motor and many other machine parts.

3.4 SPECIFICATION OF PNEUMATIC ELEMENTS:

 The various pneumatic elements are specified according to different

standards. The standard varies depending upon the manufacturers.

1. Double acting Cylinder:

Stroke length = 50 mm

Piston Diameter = 40 mm

Maximum Operating Pressure = 12 bar

Temperature range = 120C to +80C

Material = Aluminium alloy

Seals = Polyurethane

O’ ring = Nitrile

2. Solenoid Directional Control valve

We have used 5/2 solenoid valve as the directional control valve.

Voltage = 230 volts

Frequency = 50 Hz

Maximum Operation Pressure = 10 bar

Port size = 7 mm

3. Flow control Valve

Technical Data

Port size : 0.635 x 10 ֿ² m

 Pressure : 0-8 x 10 ⁵ N/m²

Media : Air

Quantity : 1

4. Connectors

Technical data

Max working pressure : 10 x 10 ⁵ N/m²

Temperature : 0-100 º C

Fluid media : Air

Material : Brass

5. Hoses

Technical date

Max pressure : 10 x 10 ⁵ N/m²

Outer diameter : 6 mm = 6 x 10 ˉ ³m

Inner diameter : 3.5 mm = 3.5 x 10 ˉ ³m

CHAPTER-3

COMPONENTS AND DESCRIPTION

 The major components of these systems are,

 Compressor

 Pneumatic Cylinder

 Solenoid Valve

 Hose and fitting

 Seals

 Control Timer Circuit

 Flow control valve

COMPRESSOR:

The air under high pressure is given by a compressor. It is driven by an

electric motor. The compressor delivers air to inlet of the cylinder. An air

compressor as the same indicates is a machine to compress the air and to raise

its pressure. The air compressor sucks air from the atmosphere, compresses it

and then delivers the same under a high pressure to a storage vessel from the

storage vessel it may be conveyed by a pipeline to a place where the supply of

compressed air is required.

Since the compression of air requires some work to be done on it,

therefore compressor must be driven by some prime mover.

 The compressed air is used for many purposes such as for operating

pneumatic drills, rivets, paint spraying and supercharging of internal

combustion engines etc., It is also used in the operation of lifts, rams, pumps

and variety of other devices in industry. Compressed air is sucked for

producing ballast of air in blast furnaces and Bessemer converter.

Classification of Air Compressor

The air compressor may be classified in many ways but the following

are important of view.

1. According to working

a. Reciprocating Compressor

b. Rotary Compressor

2. According to action

a. Single acting compressor

b. Double acting compressor

3. According to number of stages

a. Single stage compressor

b. Multi stage compressor

RECIPROCATING COMPRESSOR:

They are available in great variety including special machine for

unusual requirements Maximum compression compression ratio may be as

high as 10 per stage. Two stage compressors are available for compression

ratios greater than eight.

There different type of piston type reciprocating air compressor are

available. They are

1. Vertical

2. Horizontal

3. Radial

The most commonly used one is horizontal air cooled type reciprocating

air compressor for a pressure range 6 to 12 Kg/cm².

Construction
 It is similar to that of an internal combustion (IC) engine consisting of

cost-iron or aluminum body with an oil tank, the base piston with piston rings,

valves, connecting rods, cranks, crank shaft and bearing etc. If the piston is

moving down air is sucked in through the suction valve and a filter and is

compressed in return stroke.

Oil level gauges, oil filling screw and oil outlet screw etc are also

important parts of an air compressor.

The pressure switch is connected to the driving motor and is set such

that it automatically trips off, disconnecting the electrical connection to the

motor as soon as the receiver achieves the desired set pressure.

The safety valve is set to the same pressure limit and in case of the

pressure exceeds this limit, it automatically opens and excess pressure is

exhausted to the atmosphere, thus limiting the system pressure to the desired

level. The drain valve drains off the condensate produced at the condenser and

the receiver piston rings are used around the piston to make it airtight.

The first stage cylinder is called the low-pressure cylinder (LP) where

air is drawn from the atmosphere and is compressed initially. The second
cylinder is called the second-stage cylinder, which is of smaller diameter and it

is also called high-pressure cylinder (HP). Here the initially compressed air

from first LP cylinder is further compressed to high pressure.

When air is compressed, considerable heat is generated, this heat must

be dissipated at least in units, where pressure exceeds 2 bar. The main machine

is cooled by air circulation on water circulation.

Characteristics of Double acting compressors

 For the same sped and cylinder volume, air delivery is double that of a

single acting compressor.

 They are mostly suitable for large capacity.

 Cylinders are mostly water-cooled.

 They are normally used for continuous and heavy-duty works.

 Higher speed of piston while reducing the size of the compressor may

contribute to greater wear of piston rings, cylinder liners and pickings.

Preferable range of piston speed advocated.

 For small capacity compressor – 300 m/min

 For large capacity compressor-25m/min

 Lower discharge temperature (mostly 240ºC for single stage

compressors).
 The ultimate choice of an air compressor is decided considering two

main factors. They are:

One should go for a small compressor for each machine (or)

Should one have a centralized compressor “power house?”

The portable answer will depend on pipe line layout, system

requirement and the distance of the user machine from the plant.

PNEUMATIC CYLINDER:

Cylinder is a device which converts fluid power into liner mechanical

force and motion. These cylinders are widely used in industrial pneumatic

systems. These cylinders are also called as linear motors and reciprocating

motors pneumatic cylinders are designed for a variety of services.

Pneumatic cylinders are designed for a variety of services. Pneumatic

cylinders transforms the flow of pressured fluid into a push or pull of the piston

rod since out system uses double acting cylinders we shall see some details

about them.
 Double acting cylinders are in one in which fluid force can be applied to

the movable element in two directories. The force exerted by the compressed

air moves the piston in two directories in a double acting cylinder. They are

used particularly. The piston is required to perform work not only on the

advance movement but also on the return. In principle, the stroke length is

unlimited, although bucking and bending must be considered before we select a

particular size of piston diameter, rod length and stroke length.

The main component of any pneumatic system is the cylinder, which

receivers air under pressure and the pressurized air helps to move the piston to

and fro. The force acting on the piston will be equal to the product of the

pressure of air and the area of the cylinder.

The amount of air delivered into the cylinder into the cylinder decides

the rate of doing work. A cylinder is a hollow circular section with the top and

bottom flange provided to prevent the leakage of air.

The compressed air is used to actuate the piston. In order to move the

piston to and fro, the air is supplied to the top and bottom of the cylinder

alternatively.
 Cylinder is mainly classified into two types namely,

 Single acting cylinder.

 Double acting cylinder.

In single acting cylinder, using the spring provided around the piston

rod attains the return stroke, but it is not efficient. So, the double acting

cylinder is used in which the return stroke is attained using compressed air.

Double Acting Cylinder

In this the force exerted by the compressed air moves the piston in two

directions. They are used partially when the piston is required to perform work

not only on the advance movement but also on the return stroke. This

principle, the stroke length is unlimited, although bucking and bending must be

considered before selecting the particular size of piston diameter, rod length

and stroke length.

The different parts of double acting cylinder are:

1. Barrel

2. Piston rod
 3. Top Cover

4. Bottom Cover

5. Wiper Cover

6. Retaining ring

7. Piston

8. Piston guide

9. Bearing Cap

10. ‘O’ ring for piston guide

11. Hexagonal socket head screw

12. Check nut

The double acting cylinder is made up of cast aluminium. The inner

and outer surface of the cylinder should be machined accurately. The internal

diameter of the cylinder should be accurate in order to provide a smooth

surface for the packing. The appearance of the outer diameter should be good.

The outer most part of the bottom and top cover contains internal

threads for inserting bolts to clamp the cylinder.

In case of double acting cylinder a force is developed in both the

directions. The moving member inside the cylinder is nothing but a piston

which is found to be moving forward and backward due to high-pressure air.

The cylinder top and lower plate are flanged together by means of bolts and
nuts. The bottom of the cylinder is also flanged with end covers for the

movement of the piston in reciprocating manner.

The bottom end cover has a bore in center whose diameter is slightly

larger than piston rod diameter. The force during the return stroke is less

compared to that of the forward stroke because in the former, the piston rod

covers some area so that the air cannot concentrate in the piston rod area.

4.4.1. 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 double acting type. The piston moves forward when the

high-pressure air is turned from the right side of cylinder. The piston moves

backward when high pressure acts on the piston from the left side of the

cylinder. 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.

CONTROL VALVE:
 Various types of control valves are used to regulate, control and monitor

the air energy for control of direction pressure, flow, etc.

Pneumatic energy is regulated and controlled by pneumatic valves.

Functionally valves are divided into four major groups.

 Direction Control

 Flow Control

In our project electrically actuated solenoid operated 5/2 DC valves are

used.

Solenoid is another name for an electromagnet. Direction control valves

are very often actuated by electromagnets. An electromagnet is a temporary

magnet. A magnetic force is developed in an electromagnet when electrical

current passes through it and force drops down as soon as it is de energized.

This electromagnet is commonly termed as solenoid. The proper

working of a solenoid operated valve depends on the reliability of the

electromagnets.

It ensures

 Quick and sure action

 Long life.
  Easy maintenance.

 Less wastage of energy.

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.
4.5.1. 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 attract 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.

4.5.2. Working of Solenoid Valve

The solenoid valve has 5 openings. This ensure easy exhausting of 5/2 valve.

The spool of the 5/2 valve slide inside the main bore according to spool position; the

ports get connected and disconnected. The working principle is as follows.

Position-1

When the spool is actuated towards outer direction port ‘P’ gets connected to ‘B’

and ‘S’ remains closed while ‘A’ gets connected to ‘R’

Poisition-2

When the spool is pushed in the inner direction port ‘P’ and ‘A’ gets connected to

each other and ‘B’ to ‘S’ while port ‘R’ remains closed.

HOUSE AND FITINGS:

It is provided for the passage of compressed air from the compressor outlet to the

operating valve.

Two separate pipes also connect the operating valve with the working cylinder

pressure drop through and air line depends on the flow rate, pipe diameter, pipe length

and pipe geometry. It can be determined directly for straight pipes of any given length.

A small chaining bore size can have marked effect on pressure drop, where as even

doubling the pipe length, will only result in doubling the pressure drop.
 Pressure drop through bends and fittings can only be determined by empirical

tests, since it is specific to the internal geometry involved. Rigid pipes however are less

manipulated through remain form of bends with arrangements increase and variable air

have to flow and the flow itself may be of fluctuating or pulsating nature. In this case it

is thus normally based on practical recommendation.

SEALS:

Seal is an important component of a pneumatic system and is used to prevent the

air leakage through the joint.

This project passes the static seal which are used to prevent the leakage through

the stationary surface.

Material of the seal is Teflon tape. Teflon has the following properties

 Withstand the system pressure and temperature without any damage.

 Resist the wear and abrasion.

 Recover from deformation.

 Resists the adverse effects such as deterioration and shrinking

caused by the system air.

 Seals are devices for closing gaps to prevent leakage or make pressure joints and

also to prevent the entry of air and dirt from outside into the system. The material of seal

must be compatible with the fluid medium. It is a circular ring made of synthetic rubber.

It is used for providing tight sealing between the piston and the cylinder wall. It prevents

air leakage from the top and bottom of the cylinder.

Seals for air cylinder and valves are not normally called upon to seal pressure

higher than about 2 bars. Since the fluid to be seated is a gas, (in our case air) rubbing

speeds tends to be high and the seal the seal may have to be operated under dry

conditions with minimal lubrication.

CONTROL TIMER CIRCUIT:

Need for a Timer Circuit:

Main purpose to timer circuit is to actuate the solenoid valve at regular interval of

time to achieve proper lubrication at the desired interval.

ELECTRONIC CONTROL TIMING UNIT:-

Here the 555 IC has been used as a multi vibrator. The output of IC 555 is fed to

the input pin (pin no 14) of CD 4017 continues counting.

 The output of the IC becomes available at pin Nos. 3, 2 and 4. The output pulse of

any one of output pin triggers (Puts ON) the Triac and current starts flowing across the

load connected. This process continues on other pins at different time intervals and the

cycle continues. The frequency interval (Time) of the cycle can be adjusted by the pre-set

look connected to pin 6 of 555 Timer IC.

4A-230V X 3
47K

L1
TRIAC X 3
4 8 16 1N4007 X 3
3 L2
7 IC 4017
555 2
10K 6 3 14
L3
2 1 4
13 8

100µF 1N4007 X 4

1N4007
1000µF

230/9V

230V A/C I/P

IC 555 TIMER

The IC SE / NE 555 monolithic circuit is a highly stable controller capable of

producing accurate time delays or oscillations. Additional terminals are provided for

triggering or resetting if desired. In the timing operations, the time is precisely controlled

by one external resistor and a capacitor, by the operation as an oscillator, the free running

frequency and the duty cycle are both accurately contributed with the external RC

constants.

PIN DIAGRAM:
GROUND SUPPLY (Vcc)
1 8

TRIGGER DISCHARGE
2 7
IC
OUTPUT NE 555 THERSOLD
3 6

RESET CONTROL
4 5

PIN NO: 1
It is ground terminal.

PIN NO: 2
 The trigger voltage to the lower comparator is applied. It has constant voltage

that is atleast one third of the supply voltage, when trigger voltage falls below this level

the flip-flop changes its state and output becomes high.

PIN NO: 3

It is the output

terminal, in low state output is equal to

zero and when at higher state output is

equal to Vcc.

PIN NO: 4

It controls the flip

flop directly. It turns the device to its

original position when reset pin is

connected to ground the output is

approximately equal to zero. When reset is not used it is connected to Vcc.

PIN NO: 5

It is the control voltage terminal. It is connected to ground through a capacitor of 0.01

μF. Any external voltage at pin: 5 will change both the threshold voltage and the trigger

voltage reference level.

PIN NO: 6
 Threshold voltage of upper comparator is applied from this terminal. The resistor Rt

connected to Vcc and pin: 6 is grounded by an external capacitor. The output is high

capacitor charges by resistor Rt. When the capacitor changes to the threshold level, the

output becomes low.

PIN NO: 7

It is the discharge pin for external capacitor. Usually pin: 7 is connected with pin: 6

directly to by a resistor. When the output becomes low then the external capacitor

discharges by internal discharge transistor remains at cut-off and the external capacitor

charges to Vcc.

PIN NO: 8

It is the positive supply terminal. A dc voltage from +5 to + 15 can be applied.

The important features of IC555 can be summarized as follows.

1. Timing range from microseconds to hours.

2. Mono-stable and Astable operation is possible through IC555.

3. The duty cycle can be adjusted according to our necessity.

4. It has the ability to operate from a wide range of supply Voltage.

IC 555 SPECIFICATION

Supply Voltage (Vcc) = 4.5 to 15V

 Supply Current (Vcc=5V/2) = 3 to 6mA

Supply Current (Vcc=25V/2) = 10 to 15mA

Output Current = 200mA (maximum)

Power dissipation = 600mw

FLOW CONTROL VALVE:

Flow Control Valves are fitted to all the distribution tubes. This valve is made of

brass. Both the ends have stepped surface to insert hoses. A handle is provided to

control the flow of oil in every valve.

(a) Technical Data:

Size : ¼”

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 can’t

return back.
 By using this valve the time consumption is reduced because of the faster

movement of the piston.

CHAPTER-4

WORKING PRINCIPLE

The compressed air from the compressor is used as the force medium for this

operation. There are pneumatic double acting cylinders, solenoid valve; flow control

valve and timer unit used .The arm from the compressor enters to the floe control Valve.

The controlled air from the flow control valve enters to the solenoid valve. The

function of solenoid valves all of air correct time interval. The 5/2 solenoid valve is used.

In one position air enter to the cylinder and pusses the piston, so that the cutting stroke is

obtained.

The next position air enters to the other side of cylinder and pusses the piston

return back, so that the releasing stroke is obtained. The speed of the cutting and

releasing stroke is varied by the timer control unit circuit.

 CHAPTER-5

DESIGN AND DRAWINGS

PNEUMATIC CYLINDER

Design of Piston rod:

Load due to air Pressure.

Diameter of the Piston (d) = 40 mm

Pressure acting (p) = 6 kgf/cm²

Material used for rod = C 45

Yield stress (σy) = 36 kgf/mm²

Assuming factor of safety = 2

Force acting on the rod (P) = Pressure x Area

= p x (Πd² / 4)

= 6 x {( Π x 4² ) / 4 }
 P = 73.36 Kgf

Design Stress(σy) = σy / F0 S

= 36 / 2 = 18 Kgf/mm²

= P / (Π d² / 4 )

∴d = √ 4 p / Π [ σy ]

= √ 4 x 75.36 / {Π x 18}

= √ 5.33 = 2.3 mm

∴ Minimum diameter of rod required for the load = 2.3 mm

We assume diameter of the rod = 15 mm

Design of cylinder thickness:

Material used = Cast iron

Assuming internal diameter of the cylinder = 40 mm

Ultimate tensile stress = 250 N/mm² = 2500 gf/mm²

Working Stress = Ultimate tensile stress / factor of safety

Assuming factor of safety = 4

 Working stress ( ft ) = 2500 / 4 = 625 Kgf/cm²

According to ‘LAMES EQUATION’

Minimum thickness of cylinder ( t ) = ri {√ (ft + p) / (ft – p ) -1 }

Where,

ri = inner radius of cylinder in cm.

ft = Working stress (Kgf/cm²)

p = Working pressure in Kgf/cm²

∴ Substituting values we get,

t = 2.0 { √ (625 + 6) / ( 625 – 6) -1}

t = 0.019 cm = 0.19 mm

We assume thickness of cylinder = 2.5 mm

Inner diameter of barrel = 40 mm

Outer diameter of barrel = 40 + 2t

= 40 + ( 2 x 2.5 ) = 45 mm

Design of Piston rod:

Diameter of Piston Rod:

Force of piston Rod (P) = Pressure x area = p x Π/4 (d²)

= 6 x (Π / 4) x (4)²

= 73.36 Kgf

Also, force on piston rod (P) = (Π/4) (dp)² x ft

P = (Π/4) x (dp)² x 625

73.36 = (Π/4) x (dp)² x 625

∴ dp² = 73.36 x (4/Π) x (1/625)

= 0.15

dp = 0.38 cm = 3.8 mm

By standardizing dp = 15 mm

Length of piston rod:

Approach stroke = 160 mm

Length of threads = 2 x 20 = 40mm

Extra length due to front cover = 12 mm

Extra length of accommodate head = 20 mm

Total length of the piston rod = 160 + 40 + 12 + 20

= 232 mm
By standardizing, length of the piston rod = 230 mm
 CHAPTER-6

APPLICATIONS AND DISADVANTAGES

APPLICATIONS:-

This machine is very useful for small scale industries

This machine is used to cut the roller sheet metal

All Industrial Application

DISADVANTAGES:-

 While working, the compressed air produces noise therefore a silencer may

be used.

 High torque can not be obtained

 Load carrying capacity of this unit is not very high.(<50 N)

 CHAPTER-7

ADVANTAGES

 The pneumatic is more efficient in the technical field

 Quick response is achieved

 Simple in construction

 Easy to maintain and repair

 Cost of the unit is less when compared to other machine

 No fire hazard problem due to over loading

 Comparatively the operation cost is less

 The operation of cutting is faster because the medium used to operate is air

 Continuous operation is possible without stopping

 CHAPTER-8
LIST OF MATERIALS

Sl. Description Qty. MATERIAL

No.
01. Double acting cylinder 1 No. EN8
02. Solenoid Valve 1 No. ALU.
03. Timer 1 No. ELECTRONIC
04. Flow Control Valves 1 No. ALU.
05. Hoses 2M POLYURETENE
06. Wire 2M -
07. Stand 1 No. MS
08. Base Board 1 No. MS
9 Hose Collar 6 NO. BRASS.
10. Reducer 1 NO. BRASS
11. Fixed cutting plate 1 NO. S.S
12. Moving Cutting Plate 1 NO. S.S
 CHAPTER-9

CONCLUSION

This project work has provided us an excellent opportunity and experience, to use

our limited knowledge. We gained a lot of practical knowledge regarding, planning,

designing drawing, purchasing, computing and machining while doing this project work.

We feel that the project work is a good solution to bridge the gates between institution

industries.
 We are proud that we have completed the work with the limited time successfully.

The machine is working with satisfactory conditions. We are able to understand the

difficulties in maintaining the tolerances and also quality. We have done to our ability

and skill making maximum use of available facilities.

In conclusion remarks of our project work, let us add a few more lines about our

impression project work.

The chief advantage of our system is that, it cutting speed is varied. The fast

operation is done by the timer unit. This project is a low cost automation project.

CHAPTER-9

PHOTOGRAPHY