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Automatic Reveting Machine Report
Automatic Reveting Machine Report
Automatic Reveting Machine Report
Guided by
Dr. Gajanan G. Waghmare
CERTIFICATE
This is to certify that Mr. Mangesh Vasant Chaudhari, Mr.
Akash Subhash Barde, Mr. Riddhish Chetan Bhamre, Mr.
Jay Hasmukh Kapadia has successfully completed the Project
Stage-1 entitled “Semi-Automatic Riveting Machine” under
my supervision, in the partial fulfilment of Bachelor of
Engineering – Mechanical Engineering of University of Pune.
Date:
Place:
Dr. G.G. Waghmare
Project Guide Internal Examiner
Date:
The success of any manufacturing sector depends upon the quality of its product. The
riveting is one of the important joining methods to permanently fasten two thin-
walled sheet metal parts. The existing Spin Riveting machine is manually operated
by the operator and the cycle time of this machine is 6sec and the output is 600
products per hour. In Spin riveting machine, the punch rotates about its axis at the
angle of 50, so as it rotates damage occurs to the component to which it is riveted
and ejection done in this is manual. The main purpose of our project is to develop a
semi-automatic press riveting machine. In this, by Application of Pneumatics
Actuators the fixture sliding track in which the fixture blocks move automatically
by PLC and after riveting the ejection of the component is done automatically by
Pneumatics.
The outcomes of this machine are that cycle time is reduced from 6 sec to 4 sec and
the output is increase from 600 to 900 products per hour. There will be no damage
to the component as the riveting is done automatically and hence rejection is
approximately equal to zero. By designing this machine, better joint strength is
provided and it improves quality and productivity by minimizing the cycle time.
INTRODUCTION
JOINING:
1. Bolting: In this metal joining process, the metallic parts are joined together by
means of bolt or screw. This process is widely used in assembling of parts that
are to be joined temporarily or joints which require periodic maintenance.
2. Welding: In this metal joining process, the two parts that are to be welded are
fused together by application of heat and pressure. Permanent fusion happens
between joining metals. The various types of welding process are: a) Gas
welding b) Arc welding c) Resistance welding d) Solid state welding e)
Thermo-Chemical Welding f) Radiant Energy welding.
3. Brazing: Brazing is a metal joining process in which the filler material or
alloy is heated to a temperature above 450°C and melted. Only filler metal
melts and deposits fusing the work-piece. Work-piece doesn’t melts. Base
metal is heated and distributed between two close fitting parts by capillary
action. Filler materials: Aluminium-Silicon, copper, brass, nickel alloy, etc.
4. Soldering: Soldering is a metal joining process in which the filler material or
alloy is heated to a temperature below 450°C and melted. Solder is an alloy of
Tin (63%) and Lead (37%).Only filler metal melts and deposits fusing the
work- piece. Used in electronics and jewellery industry.
5. Clinching: Clinching is a bulk sheet metal forming process aimed at joining
thin metal sheet without additional components, using special tools to
plastically form an interlock between two or more sheets.
Riveting: Riveting is a forging process that may be used to join parts together by
way of a metal part called a rivet. In this process, the metallic parts to be joined
undergo change in their physical structure. The rivet acts to join the parts through
adjacent surfaces. A straight metal piece is connected through the parts. Then both
ends are formed over the connection, joining the parts securely. The metal work piece
used to form the connection may be hollow or it may be solid. Rivets have many uses,
such as in the construction and sheet metal industries. Riveting is used widely in
automobile, electrical and aerospace industry and many other applications where we
require permanent or semi-permanent bonding and where bolting and welding is not
an option.
Types of Riveting:
2. Spin riveting machine: Spin riveting is, in comparison with impact riveting,
a closely controlled process whereby two or more components are joined
using one or more separate hollow or solid rivets.
3. Impact riveting machine: Impact riveting machines set the rivet by driving
the rivet downwards, through the materials to be joined and on into a forming
tool (known as a roll set). This action causes the end of the rivet to roll over
in the
roll set which causes the end of the rivet to flare out and thus join the
materials together.
LITERATURE REVIEW
ZHANG Et al [1] have discussed that the riveting joint is one of the
important joint methods to permanently fasten two thin-walled
sheet-metal parts.
It is most basic to efficiently analyse and estimate the deformation of the riveting
joint for the performance, fatigue durability and damage of the riveting structure
in the aircraft. This paper researches the riveting process mathematics modelling
and simulating to more accurately analyse deformation of thin-walled sheet-metal
parts. First, the mathematics and mechanics models for the elastic deformation,
plastic deformation and spring back of the rivet are built by mechanics theory.
Second, on the basis of ABAQUS system, a finite element system, an instance
made up of the rivet and two thin-walled sheet-metal parts of aluminium alloy is
used to analyse and simulate the stress and deformation. What’s more, a
comparison is made between the results obtained by the mathematics and
mechanics models and those by finite element method (FEM). The models are
proved true by the calculating and simulation results of the instance.
J. Mucha &Witkowsky [2] have discussed that the main principle used by the
designers of riveting joints is a shear condition of rivet material. In case of
shear test of conventional riveting joints, their strength is determined by
the mechanical properties of the fastener material. Hence, it is expedient to have
more insight on the fracture mechanism of various joints during tensile tests.
This paper discusses the strength of riveting joints of various sheet materials:
DC01 steel, AW-5754
aluminium alloy, and their hybrid arrangements. We also analyse of the fracture
mechanism of riveting joints in unilateral tensile tests of T-shaped specimens
made of various sheet materials. The experimental results on the joint critical
static load are compared with those obtained in the lap joint shear tests for the
same rivet types.
S. H. Satbhai Et al[3] have discussed that the successful implementation of any
manufacturing sector is largely dependingupon the quality & its productivity. In
traditional machining process for performing the different operation a separate
machine required whichbecomes a time consuming also the inaccuracy in
productivity due to involvement of human error which affects to productivity
cannot be get improved at faster rate .the main purpose of this paper to develop
special purpose machine for drilling and riveting machine which leads to
improve the quality and productivity by minimizing the time period. In this
process two or more operation can be performed simultaneously due to this
cost of a material reduces.
Aditya Polapragada Et al [4] have discussed that the pneumatic system has
gained a large amount of importance in last few decades. This importance
is due to its accuracy and cost. This convenience in operating the pneumatic
system has made us to design and fabricate this unit as our project. This unit,
as we hope that it can be operated easily with semi- skilled operators. The
pneumatic press has an advantage of working in low pressure, that is even a
pressure of 6 bar is enough for operating the unit. The pressurized air
passing through the tubes to the cylinder,forces
the piston out whose power through the linkage is transmitted to the punch.The
work piece thus got is for required dimensions and the piece can be collected
through the land clearance provided in the die. The die used in this is fixed
such that the die of required shape can be used according to the requirement.
CHAPTER-3
PROBLEM IDENTIFICATION
The Existing Machine was the Spin Riveting machine which had the following
problems:
There are total 8 types of wastes during manufacturing process such as:
T-Transport
I – Inventory
M- Motion
W- Waiting
O- Over production
O- Over processing
D- Defects
S- Skill manpower
Therefore, to reduce the 4 wastes such as Motion, over processing, Defects, Skill
manpower we have chosen to design Press riveting machine.
Methodology:
We provid fixture sliding track in which the fixture blocks move automatically and
after riveting the ejection of the component is automatic. The outcomes of
this machine are that cycle time is reduced from 6 sec to 4 sec and the output is
increased from 600 to 900 products per hour.
By designing this machine, we are able to provide better joint strength and it
improves quality and productivity by minimizing the cycle time and strength of rivet
will be high and to increase productivity and customer satisfaction due to timely
delivery of product and this will be a semi-automatic machine.
Fig.5.Existing Spin Riveting Machine
APPLICATION OF RIVETING
Hence a careful design approach has to be adopted. The total design work has been
split into two parts:
System design
Mechanical design
System design mainly concerns the various physical constraints and ergonomics,
space requirements, arrangement of various components on main frame at system,
man + machine interactions. No. Of controls, position of controls, working
environment of machine, chances of failure, safety measures to be provided, ease of
maintenance, total weight of the machine, etc.
In mechanical design the components are listed down and stored on the basis of their
procurement, design in two categories namely,
Designed parts
Parts to be purchased
For designed parts detached design is done & distinctions thus obtained are compared
to next highest dimensions which are readily available in the market. This amplifies
the assembly as well as postproduction work. The various tolerances on works are
specified. The parts which are to be purchased directly are selected from various
catalogues.
DESIGN CONSIDERATIONS
CONSTRUCTION
Pneumatic mounting
Electrical panel
Output chute
Specifications
• Brand: Siemens
• PLC Power: 24V DC
• Current: 0.3A
• Mounting Type: Panel, Din Rail
• Digital Input: 24
• Digital Output: 20
• Analog Input: 8
• Analog Output: 8
• Software: Logo Soft
• Actual Digital Input: 14
• Actual Digital Output: 5
• The purpose of flow control in a hydraulic system is to regulate speed. All the
devices discussed here control the speed of an actuator by regulating the flow rate.
Flow rate also determines rate of energy transfer at any given pressure. The two are
related in that the actuator force multiplied by the distance through which it moves
(stroke) equals the work done on the load. The energy transferred must also equal
the work done. Actuator speed determines the rate of energy transfer (i.e.,
horsepower), and speed is thus a function of flow rate.
• Directional control, on the other hand, does not deal primarily with energy control,
but rather with directing the energy transfer system to the proper place in the system
at the proper time. Directional control valves can be thought of as fluid switches that
make the desired "contacts." That is, they direct the high-energy input stream to the
actuator inlet and provide a return path for the lower-energy oil.
The purpose of flow control in a hydraulic system is to regulate speed. All the devices
discussed here control the speed of an actuator by regulating the flow rate. Flow rate also
determines rate of energy transfer at any given pressure. The two are related in that the
actuator force multiplied by the distance through which it moves (stroke) equals the work
done on the load. The energy transferred must also equal the work done. Actuator speed
determines the rate of energy transfer (i.e., horsepower), and speed is thus a function of
flow rate.
Directional control, on the other hand, does not deal primarily with energy control, but
rather with directing the energy transfer system to the proper place in the system at the
proper time. Directional control valves can be thought of as fluid switches that make the
desired "contacts." That is, they direct the high-energy input stream to the actuator inlet and
provide a return path for the lower-energy oil.
It is of little consequence to control the energy transfer of the system through pressure and
flow controls if the flow stream does not arrive at the right place at the right time. Thus, a
secondary function of directional control devices might be defined as the timing of cycle
events. Because fluid flow often can be throttled in directional-control valves, some
measure of flow rate or pressure control can also be achieved with them.
R.H. Sapat College of Engineering, B.E.(Mechanical) 25 | P a g e
Pneumatic cylinder is a mechanical device which use the
power of compressed gas to produce force in a reciprocating
linear motion . As per PLC program it stays at bottom position
for 1.8 sec and at top position for 1 sec .
HORIZONTAL CYLINDER
• Compressed air – filtered - lubricated
• Cylinder bore (mm) = 80
• Stroke length (mm) = 28
• Working pressure = 0.5-10 bar
• Material of construction; aluminum, brass, steel
• Brand :Janatics
REED SWTICH
• Integrated led
When the piston passes under the pneumatic cylinder reed
switch, the switch’s reeds closes a circuit to generate a signal
that is passed to plc and within 200mili sec the feedback is
given
Calculation
Pressure=Force/Area
We provide 6 Bar pressure but by cosidering some lossses we take 5.5 bar for our
calculation.
F= Axial Force
Diameter=0.1 Meter
A = 0.1 x 0.1 x 𝜋
4
=7.85*10-3 M2
F=PxA
F = 5.5*105 x 7.85*10-3
∴ F = 4317.5 Newton
F=4317.5N
0.025 m
0.12 m
δmax FL
3
= 48EI
b d3
I= 12
b= 0.12 m, d= 0.025 m
3
0.12 x 0.025
I= 12
I= 1.5625 x 10-7 m4
A poka-yoke is any mechanism in any process that helps an equipment operator avoid
mistakes. Its purpose is to eliminate product defects by preventing, correcting, or
drawing attention to Human Errors which occurs.
In fixture design, poka-yoke is used. In this, the P, N, E contact terminals have their
separate designs. These contact terminals cannot be interchanged into one another.
So there is no chance of rejection of products.
Fig.11.1 OPERATION 1
Fig.11.2 OPERATION 2
Fig.11.3 OPERATION 3
Cost Estimation
Total: 60.7652 kg
• Cost of MS/kg = Rs 75
• Cost of Total Raw Material = Rs 75 × 60.76kg. = Rs 4557
• Cost of Fliter Regulator Lubricator ( Janatics company) = Rs 4500
• Cost of Pneumatic Actuator ( Janatics company) = Rs 20,000
• Cost of single small Pneumatic Actuator ( Janatics company) = Rs 1,200
• Cost of 5 small Pneumatic Actuator = Rs 6,000
• Cost of Electrical Pannel = Rs 22,500
• Read Switch Position Sensor(10 Units,2500Rs/item) = Rs 25000
• Direction Control Valve(5 Units,1500Rs/item) = Rs 7500
Conclusion
Our riveting machine will offer greater consistency, productivity, and lower cost
when compared to manual riveting.
There will be no damage to the component as the riveting is done automatically and
hence rejection is approximately equal to zero. By designing this machine,we provide
better joint strength and it improves quality and productivity by minimizing the cycle
time.
Also it can be easily operated by Semi-Skilled operator. Our pneumatic press has an
advantage of working in low pressure that is even a pressure of 6 bar is enough for
operating the unit.
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 mechanical Engineers
and having the ability to think and plan. But due to time constraints, we put following future
modifications.
Our machine is semi automatic which can be turned into full automatic by doing some
modifications.
Different types fixtures are also can be designed for this machine for different components
holding purpose.
Also we can apply real-time condition monitoring and protection for this machine to check
health of machine.
Implementation of this Project to all Press Operation industries.
Life cycle during outdoor operations.
References
[2] J. Mucha and W. Witkowsky: “Mechanical behaviour and failure of riveting joints
in tensile and shear tests”, Strength of materials , vol.47, no.5, 2015 pp-755-767
Andrew Parr.