VISVESVARAYA TECHNOLOGICAL UNIVEVERSITY

Jnana Sangama, Belgavi-590018, Karnataka, India

A Main Project Report on

“DESIGN AND FABRICATION OF SEMI AUTOMATIC

PNEUMATIC SHEET METAL CUTTING MACHINE”
Submitted in the partial fulfillment of the requirements for the award of
BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING

Submitted By

P.Sameer Basha 3PG19ME022

Kavitha.B 3PG20ME477
Vinay kumar. YP 3PG19ME020
Mohammed Waseem Akram. K 3PG20ME440

Under the guidance of

MURTHY.S.L
Asst.Professor
Dept of Mechanical Engineering
PDIT Hospet

BELLARI V. V SANGHAN’S
PROUDADEVARAYA INSTITUTE OF TECHNOLOGY
DEPARTAMENT OF MECHANICAL ENGINEERING
T.B. DAM ,HOSPETE-583225
 BELLARI V. V SANGHAN’S

PROUDADEVARAYA INSTITUTE OF TECHNOLOGY

DEPARTAMENT OF MECHANICAL ENGINEERING
T.B. DAM ,HOSPETE-583225

CERTIFICATE
“DESIGN AND FABRICATION OF SEMI AUTOMATIC
This is to certify that the project work entitled
PNEUMATIC SHEET METAL CUTTING MACHINE.” is a bonafied work carried out by P.SAMEER
BASHA, KAVITHA.B, VINAY KUMAR .Y.P ,MOHAMMED WASIM AKRAM.T in partial fulfillment for the
award of “BACHELOR OF ENGINEERING” in “MECHANICAL ENGINEERING” by the Vishvesvaraya
Technological University, belgaum During the academic year 2021-22. It is certified that all corrections / suggestions
indicated for internal assessment have been incorporated in the report deposited in the department library
The project phase -01 report has been approved as it satisfies the academic requirements in respect with the project work
prescribed for the said degree

____________________ ________________
Signature of Guide Signature of HOD
Murthi S.L M.tech Dr. Chandragowda M Mtech.,Ph.D
Asst.Professor professor & HOD
Dept of Mechanical Engineering Dept. of Mechanical Engineering
PDIT Hospet PDIT Hospet

_________________________
Signature of principal
Dr. Shashidhar S M M.tech.,Ph.D

External viva
Name of the examiner signature with date
1)
2) ______________________
 CONTENTS

CHAPTER NO. PARTICULAR PAGE NO.

1 AKNOWLEDGEMENT 1

2 ABSTRACT 2

3 INTRODUCTION 3

4 LITRATURE REVIEW 4-5

5 METHODOLOGY 6

6 COMPONENTS AND 7-12

DESCRIPTION

7 WORKING PRINCIPLE 13

8 2D DRAGRAMS 14-25

9 ADVANTAGES 26-27
DISADVANTAGES
AND APPLICATIONS
10 FUTURE SCOPE 28

11 CONCLUSION 29

12 REFERENCES 30
 ---------------------------------------------------------------------------------

DESIGN AND FABRICATION OF SEMI AUTOMATIC PNEUMATIC SHEET

METAL CUTTING MACHINE

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”SEMI AUTOMATIC PNEUMATIC SHEET METAL CUTTING MACHINE”

CHAPTER:1

AKNOWLEDGEMENT

The successful presentation of the DESIGN AND FABRICATION OF SEMI AUTOMATIC

PNEUMATIC SHEET METAL CUTTING MACHINE would be incomplete without the
mention of the people who made it possible and whose constant guidance crowned our effort with
success.

We would like to extend our gratitude to the VISHVESVARAYA TECHNOLOGICAL

UNIVERSITY Belagavi, for providing all the facilities to present the Automatic soil irrigation
system using aurdino uno Mini Project.

We would like to extend our gratitude to Dr S.M. SHASHIDHAR, Principal of PDIT,

HOSAPETE, for facilitating us to present the Mini Project.

We thank Dr.Chandragowda M, Head of the Department of Mechanical Engineering, PDIT.

We would like to thank our Project Guide MURTHY.S.L and Project Coordinator,
Dr.Chandragowda M for their constant guidance and inputs.

We would like to thank all the Teaching Staff and Non-Teaching Staff of the college for their
co-operation.

Finally, we extend our heart-felt gratitude to our family for their encouragement and support
without which We wouldn’t have come so far. Moreover, we thank all our friends for their
valuable support and cooperation.

Project associates
I
ACKNOWLEDGEMENT
The successful presentation of the DBMS MINI PROJECT would be incomplete without the
mention of the people who made it possible and whose constant guidance crowned my effort
with success.
IwouldliketoextendmygratitudetotheMANAGEMENT, KAMMAVARI
SANGHAM, Bengaluru, for providing all the facilities to present the Web Technology Mini
Project.
I would like to extend mygratitudetoDr. K.RAMA NARASIMHA,Principal /
Director,K.S. School of Engineering and Management,Bengaluru,forfacilitating me to
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present the Web Technology Mini Project.

I thankDr. Vandana Jha., Associate Professor and Head, Department of Computer
Science and Engineering, K. S. School of Engineering and Management, Bengaluru, for her
encouragement.
I would like to thank our Project Guide,Dr. PRADEEP.K. R, Assistant Professor,
DepartmentofComputerScienceandEngineering,K.S.SchoolofEngineeringand
Management, Bengaluru, for their constant guidance and inputs.
I would like to thank all the Teaching Staff and Non-Teaching Staff of the college for
their co-operation.
Finally,Iextend my heart-felt gratitude tomyfamilyfor their encouragement and
support without which I wouldn’t have come so far. Moreover, I thank all my friends for their
invaluable support and cooperation.
P. SAMEER BASHA
KAVITHA. B
VINAY KUMAR Y. P
I
ACKNOWLEDGEMENT
The successful presentation of the DBMS MINI PROJECT would be incomplete without the
mention of the people who made it possible and whose constant guidance crowned my effort
with success.
IwouldliketoextendmygratitudetotheMANAGEMENT, KAMMAVARI
SANGHAM, Bengaluru, for providing all the facilities to present the Web Technology Mini
Project.
I would like to extend mygratitudetoDr. K.RAMA NARASIMHA,Principal /
Director,K.S. School of Engineering and Management,Bengaluru,forfacilitating me to
present the Web Technology Mini Project.
I thankDr. Vandana Jha., Associate Professor and Head, Department of Computer
Science and Engineering, K. S. School of Engineering and Management, Bengaluru, for her
encouragement.
I would like to thank our Project Guide,Dr. PRADEEP.K. R, Assistant Professor,
DepartmentofComputerScienceandEngineering,K.S.SchoolofEngineeringand
Management, Bengaluru, for their constant guidance and inputs.
I would like to thank all the Teaching Staff and Non-Teaching Staff of the college for
their co-operation.
Finally,Iextend my heart-felt gratitude tomyfamilyfor their encouragement and
support without which I wouldn’t have come so far. Moreover, I thank all my friends for their
invaluable support and cooperation.

PROJECT ASSOC Tharun.J T

MD.WASEEM AKRAM. K

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CHAPTER:2

ABSTRACT

The sheet metal cutting process is a main part of the all industries. Normally the sheet metal

cutting machine is manually hand operated one for medium and small scale industries. Our

project is “ SEMI AUTOMATIC PNEUMATIC SHEET METAL CUTTING MACHINE”.

Automation in the modern world is inevitable. Any automatic machine aimed at the economical

use of man, machine, and material worth the most. In our project is hand lever valve is used The

sheet metal cutting machine works with the help of pneumatic double acting cylinder. The piston

is connected to the moving cutting tool. It is used to cut the small size of sheet metal. The

machine is portable in size, so easy transportable.

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CHAPETR:3

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.

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CHAPETR:4
LITERATURE REVIEW
In cutting operation as or blade descends upon the metal, the pressure exerted by the
blade first caused the plastic deformation of the metal, since the clearance between to blade is
very small. The plastic deformation takes place in localize area and the metal adjacent to the
cutting edges of the blade edges become highly stress, with courses the facture to start on both
side of the sheet as the deformation progresses and sheet is shear.

Types of cutting machine:

 Pneumatically operated
 Hydraulically operated
 Rack and pinion operated
 Spring operated

Brief description of all the type is as follows

Pneumatically operated:

Here is the advancement of the header which is carried out in the upward and 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.

Hydraulically operated:

Here the lowering and raising of the header which is carried over using the hydraulic
piston and cylinder arrangement. To actuate the piston and cylinder, the oil is allow to enter the
cylinder for front or back side of the piston. But the oil is comparatively cost layer and it is
leakage may cause so many problem.

Rack and pinion operated:

Here the lowering and raising of the header 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 leaver arrangement. Since the machine robust and required large pressure,
hence it is not suitable.

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Spring operated:

The working of spring operated machine is similar to rack and pinion operated machine
but differs for it in construction. Here the lowering and the raising of the heating handle are
carried out manually and it required too much pressure for its operation also there possibility to
having damage to the work piece if not handled carefully.

To prepare any machine part, the type of material should be properly selected, considering
design, safety. Selection of material for engineering application is given by following factor

1. Availability of material.
2. Suitability of the material for the required component.
3. Cost of the material.

The machine is basically made of mild steel the reason for the selection are mild steel is readily
available in market. It is economical to use and it is available in standard size. It has good
mechanical properties. It has moderate factor of safety, because factor of safety result in
unnecessary wasted of material and heavy selection. Low factor of safety result in unnecessary
risk of failure, it has high tensile strength, low coefficient thermal expansion. The material of the
sheet to be cut are takes as aluminum and plastic as they replacing many metal in the present
scenarios because of their distinguished properties of features.

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CHAPETR:5
METHODOLOGY

Material SelectionFrame:-
The frame is made up of mild steel material. Because, mild steel is readily available in market
and is economical to use. It has good mechanical properties such as high ductility and high
toughness. Mild steel has carbon content ranging from 0.15% to 0.25%. The ultimate strength
and compressive of this steel increases with increase in the carbon content.

Shearing Blade:-
The shearing blade is made up of high speed steel material. The blade has to withstand the high
cutting forces and this can be achieved by using high speed steel as a blade materi- al. High
speed steel offers reliable toughness and it retains good wear resistance. A typical composition
is: 18% of tung- sten, 4% of chromium, 1% of vanadium, 0.7% of carbon and the rest is iron.

Design

CATIA V5R20 software is used for designing and model- ling. The blade design considerations
are:

 Clearance is typically 2% to 10% of the material thick- ness.

 The upper blade is angled so that as the cutting pro- gresses from one end to other end, thus

reducing the re- quired force ( 50 shear angle reduces force by 20% ).
 Scissor type cutting blade is used.
 Square edged blade is preferred rather than knife edge. The frame design considerations
are:
 Based on the length of the cutting blade used, the width of the frame is selected.
 The length of the frame is designed to make the ma- chine compact and also to
accommodate the length of the sheet metal to be cut.

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CHAPETR:6

COMPONENTS AND DESCRIPTION

The major components of these systems are,

 Compressor,

 Pneumatic Cylinder,

 Direction control valve,

 Hose and fitting,

 Seals,

 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 varicty
of other devices in industry. Compressed air is sucked for producing ballast of air in blast
furnaces and Bessemer converter.

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
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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

DIRECTION CONTROL VALVE

Directional control valves are one of the most fundamental parts in hydraulic

machinery as well and pneumatic machinery. They allow fluid flow into different

paths from one or more sources. They usually consist of a spool inside a cylinder

which is mechanically or electrically controlled. The movement of the spool

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”SEMI AUTOMATIC PNEUMATIC SHEET METAL CUTTING MACHINE”

restricts or permits the flow, thus it controls the fluid flow.

Directional control valves can be classified according to-

 Number of ports

 Number of positions

 Actuating methods

 Type of spool.

Example: A 5/2 directional control valve would have five ports and two

spool position.

Number of Ports

According to total number of entries or exits connected to the valve through

which fluid can enter the valve or leave the valve. There are types such as two way,

three way, and four way valves.

Number of Positions

Including the normal and working positions which a valve spool can take

there are types like two position, three position and proportional valves.

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Actuating Methods

Manual, spring, electrical, electronic, pneumatic and hydraulic.

Manually Operated

Manually operated valves work with simple levers or paddles where the

operator applies force to operate the valve. Spring force is sometimes used to

recover the position of valve. Some manual valves utilize either a lever or an

external pneumatic or hydraulic signal to return the spool.

Mechanically Operated

Mechanically operated valves apply forces by using cams, wheels, rollers,

etc; hence these valves are subjected to wear.

Hydraulically Operated

A hydraulically operated DCV works at much higher pressures than its

pneumatic equivalent. They must therefore be far more robust in nature so are

precision machined from higher quality and strength materials.

Solenoid Operated

They are widely used in the hydraulics industry. These valves make use of

electromechanical solenoids for sliding of the spool. Because simple application ofelectrical
power provides control, these valves are used extensively. However,

electrical solenoids cannot generate large forces unless supplied with large

amounts of electrical power. Heat generation poses a threat to extended use of

these valves when energized over time. Many have a limited duty cycle. This

makes their direct acting use commonly limited to low actuating

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FLOW CONTROL VALVE

A flow control valve regulates the flow or pressure of a fluid. Control valves

normally respond to signals generated by independent devices such as flow

meters or temperature gauges. Control valves are normally fitted with actuators

and positioners. Pneumatically-actuated globe valves and Diaphragm valves are

widely used for control purposes in many industries, although quarter-turn types

such as (modified) ball, gate and butterfly valves are also used.

Control valves can also work with hydraulic actuators (also known as

hydraulic pilots). These types of valves are also known as Automatic Control

Valves. The hydraulic actuators will respond to changes of pressure or flow and

will open/close the valve. Automatic Control Valves do not require an external

power source, meaning that the fluid pressure is enough to open and close the

valve. Automatic control valves include: pressure reducing valves, flow controlvalves, back-
pressure sustaining valves, altitude valves, and relief valves. An

altitude valve controls the level of a tank.

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.

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”SEMI AUTOMATIC PNEUMATIC SHEET METAL CUTTING MACHINE”

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.

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CHAPETR:7

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 flow control valve.

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

direction control valve is operated manually with the help of the hand lever attached to it. The

5/2 direction control 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 hand lever by operated manually.

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CHAPETR:8

2D DRAWING

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PNEUMATIC SHEET METAL CUTTING MACHINE

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CHAPETR:9

ADVANTAGES AND DISADVANTAGES

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

DISADVANTAGES

While working, the compressed air produces noise therefore a silencer may be used.

High torque cannot be obtained

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

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”SEMI AUTOMATIC PNEUMATIC SHEET METAL CUTTING MACHINE”

APPLICATIONS

This machine is very useful for small scale industries

This machine is used to cut the roller sheet metal

All Industrial Application

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CHAPETR:10
FUTURE SCOPE
Since old age man always time to gain more and more luxurious. Man is always trending to
develop more and more modified technique with the increasing the ascetic look and economic
consideration, hence there is always lot of scope but being the diploma engineers and having the
ability to think and plan but due to the some time constraints, and also due to lack of font , we
only have thought and put in the report the following future modification.

 It can be made hydraulically power operated by installing the gear oil pump at the place
of air compressor and pneumatic air arrangement

 It can be made as rack and pinion operated or spring an leaver operated, by replacing
pneumatic circuit by rack and pinion arrangement by the square threaded screw and nut
arrangement

 The place where there is scarcity of the electric the electric motor operate

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CHAPETR:11

CONCLUSION

A strong multidiscipline team with a good engineering base is necessary for the

Development and refinement of advanced computer programming, editing techniques, diagnostic

Software, algorithms for the dynamic exchange of informational different levels of hierarchy.

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, purchasing,

assembling and machining while doing this project work.

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

“FABRICATION OF SEMI AUTOMATIC PNEUMATIC SHEET METAL CUTTING 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. Thus we have developed a “PNEUMATIC SHEET METAL

CUTTING MACHINE”. By using more techniques, they can be modified and developed according

to the applications.

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CHAPETR:12

REFERENCES
[1] Aniruddha Kulkarni, Mangesh Pawar, “Sheet Metal Bending Machine”, International
Journal of Engineering Re- search and Technology, Vol. 2, March 2015.
[2] Adithya Polapragada A.S, K.Srivarsha, “Pneumatic Auto Feed Punching, Cutting and
Riveting machine”, International Journal of Engineering Research and Technology,
Vol.1, Sep- tember 2012.
[3] Dinesh Lamse, Akash Navghane, Rahul Chavhan, Ajay Ma- hawadiwar, “ Design and
Fabrication of Pneumatic Sheet Metal Cutting and Sheet Metal Bending Machine”,
Interna- tional Research Journal of Engineering and Technology, Vol. 4, March 2017.
[4] Paul.Degarmo .E, “Shearing in metal cutting”, Materials and Processes in
Manufacturing, Eight edition, 2003, p. 518-528.
[5] Karthikumar K , K.V.S.S. Saikiran, Jakkoju Satish, “Pneu- matic Sheet Metal Cutting
Machine”, International Journal and Magazine of Engineering and Technology,
Management, Research”, Vol. 3, March 2016.
[6] Madhu Kumar V, Arun Kumar N, Harsha B S, Naveen Kumar K N, “Design and
Fabrication of Pneumatic Sheet Metal Cutting and Bending Machine”, International
Journal

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