PNEUMATIC MULTIPURPOSE GRINDER

Submitted in partial fulfillment of the requirement for the award of degree of

DIPLOMA
IN
MECHANICAL ENGINEERING
BY

Under the guidance of ………………………….

2005-2006

DEPARTMENT OF MECHANICAL ENGINEERING

 CERTIFICATE

Register number: _________________________

This is to certify that the project report titled “PNEUMATIC

MULTIPURPOSE MACHINE” submitted by the following students for the
award of the degree of bachelor of engineering is record of bonafide work carried
out by them.

Done by

Mr. /Ms._______________________________

In partial fulfillment of the requirement for the award of degree in

Diploma in Mechanical Engineering
During the Year- (2005-2006)

_________________ _______________
Head of Department Guide

Coimbatore –641651.
Date:

Submitted for the university examination held on ___________

_________________ ________________
Internal Examiner External Examiner
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ACKNOWLEDGEMENT
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 ACKNOWLEDGEMENT

At this pleasing moment of having successfully completed our

project, we wish to convey our sincere thanks and gratitude to the
management of our college and our beloved chairman
…………………………………………………, who provided all the
facilities to us.
We would like to express our sincere thanks to our principal
………………………………………, for forwarding us to do our
project and offering adequate duration in completing our project.
We are also grateful to the Head of Department Prof.
…………………………………….., for her constructive suggestions
& encouragement during our project.
With deep sense of gratitude, we extend our earnest & sincere
thanks to our guide
…………………………………………………….., Department of
Mechanical for her kind guidance & encouragement during this
project.
We also express our indebt thanks to our TEACHING and
NON TEACHING staffs of MECHANICAL ENGINEERING
DEPARTMENT,……………………….(COLLEGE NAME).
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PNEUMATIC MULTIPURPOSE
GRINDER
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CONTENTS
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 CONTENTS

CHAPTER PARTICULARS PAGE No.

ACKNOWLEDGEMENT

1. SYNOPSIS

2. INTRODUCTION

3. LITERATURE SURVEY

4. COMPONENTS AND DESCRIPTION

5. DESIGN AND DRAWINGS

6. PRINCIPLE OF WORKING

7. FABRICATION

8. LIST OF MATERIALS

9. COST ESTIMATION

10. PROCESS SHEET

11. APPLICATION

12. ADVANTAGES

13. CONCLUSION

BIBLIOGRAPHY
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Chapter-1
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SYNOPSIS
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 CHAPTER-1
SYNOPSIS

The aim of our project is to design and fabricate a pneumatically operated

multipurpose grinder. With this device a number of operations can be performed. They

are as follows:

1. Drilling

2. Reaming

3. Boring

4. Grinding

5. Screw driving

This device is operated by compressed air. It consists of the following main parts.

1. Barrel

2. Shaft

3. Control unit

4. Shaft

5. Couplings, etc.
 A high pressure compressed air is forced on a fan and the fan is made to rotate.

This rotation is transmitted to the machining head by a shaft and the required operation is

carried out.

Further if a hole is to be drilled in a part in an automobile, the particular part is to

be dismantled from the vehicle. By using this pneumatically operated device holes can

be drilled in the required part with one dismantling it from the vehicle.

So this pneumatically operated multi purpose device is used for various operations

with a less amount of investment.

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Chapter-2
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INTRODUCTION
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 CHAPTER-2

INTRODUCTION

The project work subject is one, in which actually we are leaning the theoretical

concepts in practical way. Also the practical experience is one of the aims of this subject.

For a developing industry these operating performed and the parts or components

produced should have its minimum possible production cost, then only the industry runs

profitably. There are a number of units having used in industries for various purposes.

For our thought the various project name are given below.

1. Pedaling sheet meal cutter.

2. Pneumatic multi purpose device.

3. Versa mill.

4. Paint mixer

5. Mechanical Jack.
 From the above we selected ‘PNEUMATIC MULTI PURPOSE GRINDER’. In

small scale Industries and automobile maintenance shops, there are frequent needs of

tightening and loosening of screws, Drilling, Boring, Grinding, etc. Huge and complicate

designed parts can not be machined in ordinary machines. Further for every operation

separate machine is required. This increases the initial cost required, large area

requirements and a large number of machines are required.

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Chapter-3
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LITERATURE SURVEY
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 CHAPTER –3

LITERATURE SURVEY

PNEUMATICS

The word ‘pneuma’ comes from Greek and means breather wind. The word

pneumatics is the study of air movement and its phenomena is derived from the word

pneuma. Today pneumatics is mainly understood to means the application of air as a

working medium in industry especially the driving and controlling of machines and

equipment.

Pneumatics has for some considerable time between used for carrying out the

simplest mechanical tasks in more recent times has played a more important role in the

development of pneumatic technology for automation.

Pneumatic systems operate on a supply of compressed air which must be made

available in sufficient quantity and at a pressure to suit the capacity of the system. When

the pneumatic system is being adopted for the first time, however it wills indeed the

necessary to deal with the question of compressed air supply.

 The key part of any facility for supply of compressed air is by means using

reciprocating compressor. A compressor is a machine that takes in air, gas at a certain

pressure and delivered the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and delivered and the

volume expressed is that of the air at intake conditions namely at atmosphere pressure

and normal ambient temperature.

The compressibility of the air was first investigated by Robert Boyle in 1962 and

that found that the product of pressure and volume of a particular quantity of gas.

The usual written as

PV = C (or) PıVı = P2V2

In this equation the pressure is the absolute pressured which for free is about 14.7

Psi and is of courage capable of maintaining a column of mercury, nearly 30 inches high

in an ordinary barometer. Any gas can be used in pneumatic system but air is the mostly

used system now a days.

SELECTION OF PNEUMATICS

Mechanization is broadly defined as the replacement of manual effort by

mechanical power. Pneumatic 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 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 advantage of an all pneumatic system are usually economic and

simplicity the latter reducing maintenance to a low level. It can also have out standing

advantages in terms of safety.

PRODUCTION OF COMPRESSED AIR

Pneumatic systems operate on a supply of compressed air, which must be made

available, in sufficient quantity and at a pressure to suit the capacity of the system. When

pneumatic system is being adopted for the first time, however it wills indeed the

necessary to deal with the question of compressed air supply.

 The key part of any facility for supply of compressed air is by means using

reciprocating compressor. A compressor is a machine that takes in air, gas at a certain

pressure and delivered the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and delivered and the

volume expressed is that of the air at intake conditions namely at atmosphere pressure

and normal ambient temperature.

Clean condition of the suction air is one of the factors, which decides the life of a

compressor. Warm and moist suction air will result in increased precipitation of condense

from the compressed air. Compressor may be classified in two general types.

1. Positive displacement compressor.

2. Turbo compressor

Positive displacement compressors are most frequently employed for compressed

air plant and have proved highly successful and supply air for pneumatic control

application.
 The types of positive compressor

1. Reciprocating type compressor

2. Rotary type compressor

Turbo compressors are employed where large capacity of air required at low

discharge pressures. They cannot attain pressure necessary for pneumatic control

application unless built in multistage designs and are seldom encountered in pneumatic

service.

RECIPROCATING COMPRESSORS

Built for either stationary (or) portable service the reciprocating compressor is by

far the most common type. Reciprocating compressors lap be had is sizes from the

smallest capacities to deliver more than 500 m³/min. In single stage compressor, the air

pressure may be of 6 bar machines discharge of pressure is up to 15 bars. Discharge

pressure in the range of 250 bars can be obtained with high pressure reciprocating

compressors that of three & four stages.

 Single stage and 1200 stage models are particularly suitable for pneumatic

applications , with preference going to the two stage design as soon as the discharge

pressure exceeds 6 bar , because it in capable of matching the performance of single stage

machine at lower costs per driving powers in the range .

ULTIMATE AIM

The pneumatic multipurpose grinder can be widely used in low cost automation in

manufacturing industries. Working speed is high. The manpower requirement is reduced

also reducing the machining time.

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Chapter-4
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COMPONENTS AND DESCRIPTION

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 CHAPTER-4
COMPONENTS AND DESCRIPTION

The pneumatic multi purpose grinder consists of the following main parts.

1. BARREL:

It is made out of mild steel. It is a hollow cylinder. It has a length of 150 mm and

Inner diameter of 76 mm. It has two outlet holes on its top and two inlet holes drilled at

an angle for placing nozzles. It has threads at each end.

2. SHAFT:

It is made up of mild steel. It is a straight rod having a step. It is supported by two

bearings in the cylinder. The diameter of rod is 15 mm for a length of 150 mm and

13.5mm diameter for 22 mm length. The fan is fitted on the shaft through flanges. The

fan is fixed to flanges and the flanges are fixed to the shaft through drilled holes.

3. COUPLINGS:

The couplings are made out of mild steel. The couplings cover the sides of

barrel. The couplings have internal threads. With the help of these threads the couplings

are fitted to barrel. It has a smaller diameter hole to place the bearings.
 4. FLANGES:

The flanges are made out of mild steel. It is a cylindrical tube having a flange at

its one of the ends. It also has a centre drill of 16mm. There are holes drilled in flanges

correspondingly. Such that the holes drilled in two flanges coincide each other. The fan

is placed between the two flanges and screwed.

5. FAN:

The fan 18 made out of aluminium. It is placed between the flanges, which are

fitted to the shaft through nuts and bolts. Air is forced on the fan and it is rotated and the

rotation is transmitted to the shaft. The fan is twisted such that it could be driven in

either direction.

6. CONTROL UNIT:

The control unit consists of the following parts:-

Gate valve, pressure gauge, Hose collar, Reducer T-Tubes and one way corks.
 The air from the compressor passes through the control unit where its

pressure is controlled by the gate valve. The pressure is read by a pressure gauge. Then,

the air is passed through any one of the two one way corks. The parts are connected by

tubes and are clamped by clamps. Thread seals are applied between thread connections

to avoid leakage of air through threads. The above parts are enclosed in a wooden box.

The air from control unit passes through nozzle. The nozzle is planed in

such a position. So that the direction of air rotates the fan. The air can be sent to any one

of the two nozzles by operating the one way corks.

7. COMPRESSOR:

The compressor gives the source of energy that is compressed air. The compressor

is a storage tank of air. The air is drawn. Compressed and stored into a tank by two

reciprocating pistons inside two cylinders. There is a pressure gauge fitted to the

compressor to read the pressure inside the tank. There is a safety valve which puts off the

motor driving the pistons. When the pressure exceeds a limit. The air is taken out by a

gate valve fixed to the out let of the tank. The capacity of compressor is 10 kg km². The

compressed air is utilized in this unit to run the fan to get a torgue for machining.
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Chapter-5
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DESIGN AND DRAWING

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 CHAPTER –5

DESIGN AND DRAWINGS

5.1 Pneumatic components and its specification

The pneumatic auto feed drilling machine consists of the following components to

full fill the requirements of complete operation of the machine.

1. Flow control Valve

3. Connectors

4. Hoses

1. 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
2. Connectors

Technical data

Max working pressure : 10 x 10 ⁵ N/m²

Temperature : 0-100 º C

Fluid media : Air

Material : Brass

3. 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

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Chapter-6
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WORKING PRINCIPLE
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 CHAPTER-6

WORKING PRINCIPLE

The pneumatic multi purpose device is an air operated device used for many small

operations. It is a portable one. Compressed air is the source of energy for this device.

The compressed air is allowed through the nozzle in such a way to rotate to fan. The

rotation obtained is utilized for machining. The nozzles are welded to the barrel at an

angle to facilitate free rotation. The fan can be rotated in either direction by operating the

one way corks. The rpm and torque of the shaft depends upon the pressure of the air

admitted so by varying the pressure the rpm and torque can be varied.

The parts are interred connected by thick tubes. Clamps are used at the connecting

parts to prevent leakage. In threaded parts thread seals are used to prevent leakage.

Here the compressed air from the compressor firstly enters the control unit. In the

control unit the pressure of the air is controlled and sent to the barrel to rotate the fan in

any one direction.

 The air from the compressor enters the gate valve. The gate valve controls the

pressure and volume of air. Then the pressure is read by a pressure gauge. Then the air

is admitted to the barrel through any one of the two one way corks to rotate fan. In the

barrel, a shaft is placed and if carries the fan. The shaft is supported in either and by

bearings. The bearings are placed in the couplings, which covers the ends of barrel.

The following dates are collected from our tests.

1. Maximum pressure that can be used - 7 to 8 kg/cm²

2. Maximum dia drill that can be used - 6 mm

3. Maximum size of grinding wheel that can be used - mm width

4. Total weight of handling unit - 2 kg.

5. Maximum rpm obtained at maximum pressure - 7000 to 7500 rpm

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Chapter-7
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FABRICATION
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 CHAPTER-7

FABRICATION

The fabrication of main parts is given below.

1. BARREL:

Barrel is the cover for the driving unit. It supports the nozzle. It has couplings at

its two ends. Inside the barrel, a shaft carrying a fan is placed. The air rotates the fan.

The barrel has a length of 150 mm. Inner air rotates the fan. The barrel has a length of

150 mm. Inner diameter-76mm and outer diameter of 82 mm. The barrel is turned out to

the required size in a lathe. Threads for holding couplings are also cut in lathe.

Turning is the operation of reducing the outer diameter and increasing the

inner diameter to the required size. It is the operation by which metal is removed from

the outer or inner surface of a part. The machine used for turning is the lathe. The

component is held in a chuck and rotated a tool is used to remove the meal from the

surface. Using a lathe threading can also be done. Threads are cut on the ends of the

barrel. Holes for outlet and inlet of air are drilled in a radial drilling machine.
2. COUPLINGS:

The couplings form the cover for barrel in its two ends. The couplings are

screwed on the barrel by the threads on the barrel. Each coupling is turned out from a

rod of 90mm diameter and a length of 55mm. The couplings are turned in a lathe and

threads are also cut in lathe. A straight drill of 35mm is drilled through the coupling

for bearing seat.

The coupling at the backside is screwed to the barrel and at the top

most point a handle which is bended at 90º is welded of its one end. The couplings

should be turned accurately to match the threads in barrel and couplings. In the front

side coupling a hole is drilled of the bottom side to fix a handle. The front handle is

for feeding.

3. SHAFT:

The shaft is a rod of two different diameters. The shaft is made up of mild

steel. The shaft has a diameter of 15 mm for a length of 180 mm and a diameter of

13.5 mm for a length of 22 mm. The shaft is turned to the required diameter in a

lathe. Flanges are fixed to the shaft by means of bolts and nuts through a drilled cross

hole. Corresponding holes are made on flanges also.

 The shaft is supported on either ends by means of bearings which are placed in

couplings. The shaft should be turned accurately, because if should not be very tight

or loose to hold the bearings. At the front end of the shaft a drill chuck is fitted.

4. FLANGES:

The flanges are hollow cylinders having flanges at its any one of the two

ends. The flanges are made out of mild steel. The flange is turned in a lathe. The

centre hole is drilled in a radial drilling machine. The flanges are placed in either

sides of the fan. Holes are drilled in the two flanges correspondingly and also in the

fan. Further cross holes are drilled to fix the flanges on the shaft. The fan is fixed

between the flanges using nuts and bolts through the holes in flanges and the fan. The

flange is fixed to the shaft by using nuts and bolts through the cross holes drilled.

5. FAN:

The fan is made up of aluminium. The outer diameter of the fan is 73mm,

so the fan can rotate freely inside the barrel. First the aluminium sheet is cut to the

required diameter. Dimensions for leaves are marked and the leaves are cut and the

edges are filed. Then the fan is fixed to the flanges.

 The fan with flanges on either side is held in a vise, and each leaves are

twisted to a particular angle, such that it could rotate in either direction, when the

direction of air is varied. The fan is fixed to flanges and flanges are fixed to the shaft.

Thus the rotation of fan is transmitted to the shaft through flanges to the shaft. The

thickness of the fan leaves are 2mm.

6. CONTROL UNIT:

The control unit controls the air pressure and volume entering the barrel.

The control unit consists of gate valve-10ft, pressure gauge-10ft, T-tube – 20ft.,

Reducer – 10ft., one way corks – 20ft and connectors 40ft. Clamps are used to clamp

the tubes to avoid dis-connection during mounting of pressure. Thread seals are used

to prevent leakage through threads.

The above parts are enclosed in a wooden box. The wooden box is pointed with

Decholon sheet. The compressed air before entering the barrel passes through the

control unit.
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Chapter-8
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LIST OF MATERIALS
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 CHAPTER-8

LIST OF MATERIALS

Sl. No.
Name of the Parts Quantity
01. Barrel 1
02. Coupling 2
03. Flange 2
04. Handle 1
05. Drill chuck 1
06. Gate valve 1
07. Hose Collar 1
08. Bearings 1
09. Reducer 1
10. T-Tube 2
11. Tube 4
12. Bolts and Nuts 6
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Chapter-9
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COST ESTIMATION
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 CHAPTER-9

COST ESTIMATION

1. MATERIAL COST:

Sl. No. Cost (Rs.)

Name of the Parts Quantity
01. Barrel 1
02. Coupling 2
03. Flange 2
04. Handle 1
05. Drill chuck 1
06. Gate valve 1
07. Hose Collar 1
08. Bearings 1
09. Reducer 1
10. T-Tube 2
11. Tube 4
12. Bolts and Nuts 6
TOTAL

1. LABOUR COST

LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS CUTTING:

Cost =
3. OVERHEAD CHARGES

The overhead charges are arrived by “Manufacturing cost”

Manufacturing Cost = Material Cost + Labour cost

=
=

Overhead Charges = 20% of the manufacturing cost

=

TOTAL COST

Total cost = Material Cost + Labour cost + Overhead Charges

=
=

Total cost for this project =

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Chapter-10
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PROCESS SHEET
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 CHAPTER-10

PROCESS SHEET

Sl. No. Name of Parts Operation Machine or Equipment

1. Barrel Turning Lathe

Threading Lathe

Drilling Drilling Machine

Welding Arc welding machine

2. Coupling Turning Lathe

Drilling Drilling Machine

Boring Lathe

Threading Lathe

3. Shaft Turning Lathe

Drilling Drilling Machine

4. Fan Blanking Sheet Metal cutter and File

Cutting Leaves Hack saw and File

Twisting Tongs

5. Handle Turning Lathe

Bending And Welding Arc Welding Machine

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Chapter-11
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APPLICATIONS
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 CHAPTER-11

APPLICATIONS

This multipurpose grinder has a numerous applications in various fields. In

industries, this is used in assembly section. The required pressure is set and the operation

is carried out. In automobile shops various operations are required frequently. Drilling,

boring, reaming, grinding etc. It is also used as a screw driver for tightening and

loosening nuts and bolts. It is used.

1. In automobile workshops

2. In small scale industries

3. In such places where frequent changes in operations are required

4. In welding shops for grinding.

5. For performing operations in huge parts which can not be done in ordinary

machines, since it is portable.

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Chapter-12
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ADVANTAGES
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 CHAPTER-12

ADVANTAGES

The pneumatically operated multi purpose grinder has many advantages. They are

as follows:

Low cost, so it can be used in small scale industries.

Higher rate and quicker operations

A number of operations like (drilling), screw driving, reaming etc.,

can be done.

The nuts and bolts can be tightened to a particular pressure by

operating the gate valve placed in the control unit and the pressure

gauge.

Both loosening and tightening is possible. Since there is air flow in

both directions.

The weight of the unit is less and can be easily handled.

Efficient operation. Since if does not require any electricity for

running.
The weight of the machine is concentrated towards the machining

head to facilitate easy manipulation of the machining.

The design is simple and there is no maintenance required. The

control valve for allowing or restricting air may be placed on handle

to make easier to control the speed of the machine.

The maximum rpm of the unit of the unit is 7000 rpm. The speed

provides a torque which is suitable for machining. The maximum

pressure that can be used is 7 kg km². The rpm and torque can be

varied by varying the pressure of the air inlet.

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Chapter-13
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CONCLUSION
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 CHAPTER-12
CONCLUSION

This project can be readily commercialized in the market due to its efficient

operation and competitive cost. Since a number of operation can be performed in a single

and simple unit. It is efficient and economical. Considering its uses and cost of this

project, it becomes relatively cheap when compared to other units.

Improvement of the project:

The project work done by us can be used in various fields. However the weight of

the handling unit can be reduced by using aluminium or fibre instead of mild steel.

Further the controlling of the unit is slightly difficult for a single man. If the air

flow control valve is fitted to the handle it will be easier.

The outlet air from the top can be forced at the machining point to remove the

chips while machining.

The above modifications can be made. Due to very short period, we could not

carry out further. However this project is a successful one because we have tested it for
the fullest satisfaction. Thus we submitted this project to out Government polytechnic

work shop for future use.

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BIBLIOGRAPHY
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BIBLIOGRAPHY

1. Design data book - P.S.G. Tech.

2. Pneumatic hand book - R.H.Warrning

3. Machine tool design hand book - Central machine tool Institute,

Bangalore.

4. Strength of materials - R.S.Kurmi

5. Manufacturing Technology - M.Haslehurst.