A Project Report On Pneumatic Shearing M PDF

A
PROJECT REPORT ON
PNEUMATIC SHEARING MACHINE
Submitted By
DARSHIT GOSALIA
AMEY BAIT
RAVINDRA SIGH
ASHISH PATIL
Under the guidance of
PROF. ALVI
Submitted as a partial fulfillment of
Bachelor of Engineering
B.E. (Semester VIII), Mechanical Branch
[2013 - 2014]
from
Rizvi College of Engineering

New Rizvi Educational Complex, Off-Carter Road,
Bandra(w), Mumbai - 400050
Affiliated to
University of Mumbai
CERTIFICATE
This is certify that the project report entitled
PNEUMATIC SHEARING MACHINE
Submitted By
DARSHIT GOSALIA
AMEY BAIT
RAVINDRA SIGH
ASHISH PATIL
of Rizvi College of Engineering, Mechanical Branch has been approved in partial fulfillment of requirement for the degree of Bachelor of Engineering.
Prof. ALVI
Internal Guide
Prof. HUSSAIN J.
Head of Department
Dr. Varsha Shah

Principal
Prof.
Internal Examiner
Prof.
External Examiner
Date:
Acknowledgement
I am profoundly grateful to PROF. ALVI for his expert guidance and continuous encouragement
throughout to see that this project rights its target since its commencement to its completion.
I would like to express deepest appreciation towards Dr. Varsha Shah, Principal RCOE, Mumbai and
PROF. HUSSAIN J., HoD Mechanical Branch whose invaluable guidance supported me in completing
this project.
At last I must express my sincere heartfelt gratitude to all the staff members of Mechanical Branch
who helped me directly or indirectly during this course of work.
DARSHIT GOSALIA
AMEY BAIT
RAVINDRA SIGH
ASHISH PATIL
ABSTRACT
This machine is for sheet metal indusrty and can be made into multiple machine and should be used as
circle cutting cum straight cutting machine .The machine is simple to maintain easy to operate. hence
hence we tried out hands on Pneumatic Shearing Machine
In shearing operation as the punch descends upon the metal, the pressure exerted by the punch first
cause the plastic deformation of the metal. Since the clearance between the punch and the die is very
small, the plastic deformation takes place in a localized area and the metal adjacent to the cutting edges
of the punch and die edges becomes highly stressed, which causes the fracture to start on both sides of
the sheet as the deformation progresses.
Contents
Introduction
1.1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Literature Survey
10
2.1 ASME Paper No. 57-A-15 (1957) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1.2 Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Proposed Work
12
3.0.3 MACHINE CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Project Design
16
4.1 Requirement Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Implementation & Technologies Used

21
5.1 METHOD STUDY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Test Cases, Project Time Line & Task Distribution

6.1 Test Cases . . . . . . . . . . . . . . . . . . . .
6.1.1 OBJECTIVES . . . . . . . . . . . . .
6.2 Task Distribution . . . . . . . . . . . . . . . .
6.3 Project Time Line . . . . . . . . . . . . . . . .
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1
3
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Conclusion and Future Scope

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7.1 Future Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.2 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
References
44
APPENDICES
44
A Project Hosting
45
List of Figures
1.1
1.2
1.3
1.4
1.5
1.6
Pneumatic Cylinder . . . . . .
5/2 footcontrol valve . . . . .
5/2 direction footcontrol valve
Neutral Position . . . . . . . .
Working Position . . . . . . .
Machine fig. . . . . . . . . . .
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3.1
Heat treatment chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1
4.2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1
5.2
Machine Cost chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Labour Cost chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
More effective methods and reducing costs.

Piston . . . . . . . . . . . . . . . . . . . .
SHEET NO 1 . . . . . . . . . . . . . . . .
SHEET NO 2 . . . . . . . . . . . . . . . .
SHEET NO 3 . . . . . . . . . . . . . . . .
SHEET NO 4 . . . . . . . . . . . . . . . .
SHEET NO 5 . . . . . . . . . . . . . . . .
SHEET NO 6 . . . . . . . . . . . . . . . .
SHEET NO 7 . . . . . . . . . . . . . . . .
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3
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5
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33
34
35
35
36
37
38
39
40
41
42
Chapter 1
Introduction
Chapter 1
Introduction
Pneumatics, from the Greek (pneumatikos, coming from the wind) is the use of pressurized gases to do
work in science and technology.
Pneumatics was first documented by Hero of Alexandria in 60 A.D., but the concept had existed
before then. Pneumatic products represent a multi-billion dollar industry today. Pneumatic devices are
used in many industrial applications. Generally appropriate for applications involving less force than
hydraulic applications, and typically less expensive than electric applications, most pneumatic devices
are designed to use clean dry air as an energy source. The actuator then converts that compressed air into
mechanical motion. The type of motion produced depends on the design of the actuator. Pneumatics is
employed in a variety of settings. In dentistry applications, pneumatic drills are lighter, faster and simpler
than an electric drill of the same power rating (because the prime mover, the compressor, is separate from
the drill and pumped air is capable of rotating the drill bit at extremely high rpm). Pneumatic transfer
systems are employed in many industries to move powders and pellets. Pneumatic tubes can carry
objects over distances. Pneumatic devices are also used where electric motors cannot be used for safety
reasons, such as mining applications where rock drills are powered by air motors to preclude the need
for electric motors deep in the mine where explosive gases may be present.
Pneumatic cylinders are generally less expensive than hydraulic or electric cylinders of similar size
and capacity.
Types of shearing Machine:
Shearing machines are classified according to the following:1) Pneumatically operated
2) Hydraulically operated
3) Rack and pinion operated
4) Spring operated
Brief description of all the types are as follows.
1) Pneumatically operated:Here the advancement of the header is carried out in the upward and the 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
Rizvi College of Engineering, Bandra, Mumbai.
Chapter 1
Introduction
2) Hydraulically operated:Here the lowering and raising of the header is carried over using the hydraulic piston and cylinder
arrangement. To actuate the piston and cylinder, the oil is allowed to enter the cylinder from front or the
back side of the piston. But the oil is comparatively costlier and its leakage may cause so many problems.
3) Rack and pinion operated:Here the lowering and the raising of the header is 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 lever arrangement. Since the machine is robust and requires large pressure,
Hence it is not suitable.
4) Spring operated:The working of spring operated machine is similar to the rack and pinion operated machine but differs
from it in construction. Here the lowering and the raising of the heating handle is carried out manually
and it requires too much pressure for its operation and also there is possibility of having damage to the
work piece if not handled carefully.
Chapter 1
1.1
Introduction
Construction
Pneumatic cylinder
Pneumatic cylinders or air cylinders are mechanical devices used to impart a force from a fluid, typically
compressed air.
Figure 1.1: Pneumatic Cylinder
A typical pneumatic cylinder consists of a piston, piston rod, and a body or tube. Compressed air
enters at one end of the tube, imparting force on the piston, which is then displaced (moves) in order to
balance the force exerted on the piston. Air cylinders, or actuators as they are also called, are available in
a variety of sizes, shapes, and have varying strokes. Typical cylinder sizes range from a small 2.5mm air
cylinder, which might be used for picking up a small transitor or other electronic component, to 400mm
diameter air cylinders which would impart enough force to lift a car.
COMPONENTS OF PNEUMATIC SHEARING MACHINE :-Different components of pneumatically shearing machine are:1) Shearing blade 2) Pneumatic cylinder 3) 5/2 Direction control foot operated valve 4) Air circulating
devices 5) Frame
Double acting cylinder :-Here we have used double acting cylinder. It is the pneumatic actuator, which
Chapter 1
Introduction
is actuated using compressed air. The Force exerted by the compressed air moves the piston in two
directions in a double acting cylinder. In principle, the stroke length is unlimited, although buckling and
bending must be considered before we select a particular size of piston diameter, rod length and stroke
length.
The double acting cylinder consists of
1) Cylinder tube,
2) Piston unit,
3) Double cup packing on piston, rod packing of O rings,
4) Bronze rod guide,
5) Piston rod,
6) End covers (flanges)
7) Port connection,
8) Cushion assembly.
The cylinder is manufactured from aluminium solid bar with central bore on lathe machine. It is then
made smooth internally using method of honing and lapping. It contains piston and piston rod, which
reciprocates to and fro with the application of high pressure air. The piston is fitted with the piston
ring which is made of Teflon rubber to make perfect compression of the air. 5/2 Direction control foot
operated valve:
Its basic symbol is as shown
Figure 1.2: 5/2 footcontrol valve
Chapter 1
Introduction
Figure 1.3: 5/2 direction footcontrol valve
Chapter 1
Introduction
To control the to and fro motion of a pneumatic cylinder, the air energy has to be regulated, controlled, and reversed with a predetermined sequence in a pneumatic system. Similarly one has to control
the quantity of pressure and flow rate to generate desired level of force and speed of actuation.
To achieve these functions, valves are used to(i) start and stop pneumatic energy,
(ii)control the direction of flow of compressed air,
(iii)control the flow rate of the compressed air
(iv) control the pressure rating of the compressed air.
A direction control valve has two or three working positions generally. They are:
1) Neutral or zero position 2) Working position
The positions are mostly numbered as 0,1,2. Direction control valves are designated to indicate both
the number of ways as well as the number of working positions such as 4/2, 3/2,5/2 means 5 ways /
2positions.
Here the spool slides inside the main bore and according that the spool position is made ON or OFF due
to the fact that the spool gets connected to the open side or the closed side of the air opening.
Air circulating devices:
The compressed air is stored in an air receiver from which air is drawn out in to the consumer point by
means of pipe line.
While laying out the pipe line for the system, one should take sufficient care and pay attention to see that
the pressure drop from the generating point to the point of consumption remains as low as possible. For
economical reason, it is always better if the total drop of pressure is kept limited to a maximum value of
0.1 bar or even less.
The following factors are taken into account while selecting pneumatic pipeline and other air- line
installations:1) Pressure of compressed air in the lines. 2) Total flow rate per unit time through the line. 3) Permissible pressure drop in the line. 4) Types of tube material and types of line fitting. 5) Length and diameter
of tube or other pipelines. 6) Working environment.
Considered the above factors we have selected the flexible hose tubes of 1/8diameter.
Frame Base :- It forms the robust support to stand the machine vertically. It holds the weight of the
vertical post and supports the direction control valve. It is made of mild steel channels of rectangular
base with the vertical post and the horizontal channel at the t.
Shearing blade : Shearing, also known as die cutting, is a process which cuts stock without the formation of chips or the use of burning or melting. Strictly speaking, if the cutting blades are straight the
process is called shearing; if the cutting blades are curved then they are shearing-type operations. The
most commonly sheared materials are in the form of sheet metal or plates,
Chapter 1
Introduction
Figure 1.4: Neutral Position
Chapter 1
Introduction
Figure 1.5: Working Position
Chapter 1
Introduction
Figure 1.6: Machine fig.
Chapter 2
Literature Survey
Chapter 2
Literature Survey
2.1
2.1.1
ASME Paper No. 57-A-15 (1957)

Summary
The formation of any business begins with someone producing the initial idea for the project. The
continued success of an established business depends upon the number and quality of the ideas fed into
it. Without a continual flow of new ideas, a business cannot function profitably or expand successfully
and must, therefore eventually fade into total obscurity.
Ideas for a new business project, a new product, a means of reducing manufacturing costs, or for
solving industrial labour problems, begin in the human mind. Most people conceive their ideas unconsciously, and because they are unaware of the mental mechanics that caused the idea to be produced,
they cannot repeat the ideation process to produce further profitable ideas at will.
Fortunately, there are available established creative techniques which, when used correctly, do enable
a person to produce a large number of first-class ideas at will. One such creative technique, and probably
the most widely used in American industry, is brainstorming.
In shearing operation as the punch descends upon the metal, the pressure exerted by the punch first
cause the plastic deformation of the metal. Since the clearance between the punch and the die is very
small, the plastic deformation takes place in a localized area and the metal adjacent to the cutting edges
of the punch and die edges becomes highly stressed, which causes the fracture to start on both sides of
the sheet as the deformation progresses and the sheet is sheared.
2.1.2
Advantages
1-Like hydraulics, pneumatics is a type of fluid power application where instead of an incompressible
liquid, pneumatics employ gas in their system.
2-Hydraulics present certain advantages over pneumatics, but in a given application, pneumatic powered equipment is more suitable, particularly in industries where the factory units are plumbed for compressed air.
3-The air used in pneumatic devices is dried and free from moisture so that it does not create any
problem to the internal parts of the system.
4- Moreover, to avoid corrosive actions, oil or lubricants are added so that friction effects can be
reduced. Compressed air is used in most of the machines and in some cases compressed carbon dioxide
10
Chapter 2
Literature Survey
5-As most of the pneumatic devices are air based, they have a less complicated design and can be
made of inexpensive material
6-Mass production techniques can be adopted to produce pneumatic systems, which not only save
money but save time too
7-Initial cost is less; hydraulics equipment cost as much as twice the price of pneumatic equipment.
8-For opening and closing valves, pneumatic systems work well because they can sustain overload
pressure conditions.
9-Pneumatic actuators also have long life and perform well with negligible maintenance requirement
throughout their life cycle.
10-Very suitable for power transmission when distance of transmission is more.
11-In a nutshell, in order to execute low scale engineering and mechanical tasks, pneumatic devices
would be the best suited and a viable alternative over hydraulic systems.
12-Also, hydraulic systems are dirtier than pneumatic systems
11
Chapter 3
Proposed Work
Chapter 3
Proposed Work
To prepare any machine part, the type of material should be properly selected, considering design, safety
and following points:- The selection of material for engineering application is given by the following
factors:1) Availability of materials.
2) Suitability of the material for the required components.
3) Suitability of the material for the desired working conditions.
4) Cost of the materials.
In addition to the above factors the other properties to be considered while selecting the material are
as follows:1) Availability of materials.
2) Suitability of the material for the required components.
3) Suitability of the material for the desired working conditions.
4) Cost of the materials.
In addition to the above factors the other properties to be considered while selecting the material are
as follows:- Physical properties:These properties are colour, shape, density, thermal conductivity, electrical conductivity, melting
point etc. Mechanical properties:The properties are associated with the ability of the material to resist the mechanical forces and load.
The various properties are:i) Strength : It is the property of material due to which it can resist the external forces without breaking or yielding.
ii) Stiffness : It is the ability of material to withstand the deformation under stress.
iii) Ductility:- It is the property of material due to which it can be drawn into wires under
a tensile load. iv) Malleability: It is the property of material which enables it to be rolled into sheets.
12
Chapter 3
Proposed Work
vi) Brittleness: It is the property of material due to which it breaks into pieces with little deformation.
vii) Hardness : It is the property of material to resist wear, deformation and the ability to cut another
material.
viii)Resilience : It is the ability of the material to store energy and resist the shock and impact loads.
ix) Creep : It is the slow and permanent deformation induced in a part subjected to a constant stress
at high temperature. We have selected the material considering the above factors and also as per the
availability of the material. The materials which cover most of the above properties are:1) MILD STEEL :
Why steel, in particular?
Simply because, in my humble opinion, it is the greatest material mankind has for construction. It is
cheap, strong, readily available, easily cut, joined, and formed. Wood can be light and stiff, but not very
strong. The best aluminium is strong and light, but very difficult to join. Titanium is superb in terms
of strength to weight ratio and stiffness but its incredibly expensive, difficult to obtain, and even more
difficult and expensive to machine properly. Theres no way youre ever going to perform a battery-weld
field-fix on a part made from 7075-T6 aluminium or titanium! In the end we come back to steel from
mild carbon to some of the more exotic alloy steels pound for pound it is the most righteous material
available for our needs.
Where does steel come from? Steel is not a naturally occurring substance - it is entirely man made.
Steel is chiefly a combination of two naturally occurring elements: iron and carbon (along with small
amounts of other elements - depending on the steel in question). The process by which man makes steel,
would, again, fill several volumes. Here is my amateur synopsis:
Iron is mined from the ground in the form if a reddish-brown rock called iron-ore. This ore is then
smashed up, strained, filtered, chemically treated etc, until ultimately it is melted in huge blast furnaces
into something called pig iron. The process uses coke (a type of coal), which in turn imparts large
amounts of carbon to the pig iron. As a result, pig iron itself is full of impurities, brittle, and unmachinable - practically useless. Except - it is the raw material from which all other irons and steels are made.
Pig iron is so produced in either huge vats of molten material, or it is cast into ingots (in fact, pig iron
got its name because the ingots or chunks produced were thought to have resembled piglets).
Pig iron is then refined into either metallic iron or steel using specialized furnaces and processes. The
distinction between the two is that metallic iron has between 2-6
A final word about carbon. carbon is critically important to our whole discussion because it is the
presence of carbon that turns the element of iron that is naturally soft and weak, into the strong, rigid
materials we know as iron and steel. Precisely how this is so is beyond the scope of this article, suffice
to say:
The strength, hardness and toughness that make the ferrous based metals useful to us are profoundly
influenced by the remarkable sensitivity of the physical and chemical properties of iron crystals to relatively small percentages of carbon dissolved within their matrixes (actually, the sensitivity is to the
movement of dislocations within the crystal space lattice). This sensitivity to dissolved carbon is in fact,
the very basis of ferrous metallurgy.
13
Chapter 3
3.0.3
Proposed Work
MACHINE CONSTRUCTION
The machine is basically made up of mild steel.

Reasons:
1. Mild steel is readily available in market
2. It is economical to use
3. It is available in standard sizes
4. It has good mechanical properties i.e. it is easily machinable
5. It has moderate factor of safety, because factor of safety results in unnecessary wastage of material
and heavy selection. Low factor of safety results in unnecessary risk of failure
6. It has high tensile strength
7. Low co-efficient of thermal expansion
Properties of Mild Steel:
M.S. has a carbon content from 0.15
BRIGHT MATERIAL:
It is a machine drawned. The main basic difference between mild steel and bright metal is that mild
steel plates and bars are forged in the forging machine by means is not forged. But the materials are
drawn from the dies in the plastic state. Therefore the material has good surface finish than mild steel and
has no carbon deposits on its surface for extrusion and formation of engineering materials thus giving
them a good surface finish and though retaining their metallic properties
A poor, but perhaps useful metaphor may be the use of fibre-mat and resin in fibre glass work. The
bulk raw material of fiberglass is the fibre matting (as iron is to steel) - but by itself the matting is of no
practical use. Not until we add the resin to it to make fibre glass (as we add carbon to iron to make steel)
do we get a useful product. In both cases, neither raw material is much use alone, but combines them
nor do we really have something. Similarly, though carbon may only be present in small quantities, just
as the amount of hardener added to fibre glass resin has a profound effect on the material, so does the
small amount of carbon present in useful metallic iron and steel
. Composition : Carbon 0.20
Properties : Tensile strength 44.54 kgf/mm
Yield stress 28 kgf/mm
Hardness 170 BHN
Uses : General purpose steels for low stressed components.
14
Chapter 3
Proposed Work
Figure 3.1: Heat treatment chart
15
Chapter 4
Project Design
Chapter 4
Project Design
4.1
Requirement Analysis
GENERAL CONSIDERATION IN MACHINE DEVELOPMENT

FIRST STAGE DESIGN CONSIDERATION IN NEW MACHINE
The word design means different things to different people a wallpaper pattern a fashionable dress,
the appearance of a racing car and so on. We therefore start by defining what we mean by design in the
present context ie. What design is all about. This understanding will lead to an examination of
1 Why we need to design particularly in an engineering environment, and
2 How we might best go about designing
What is design ?
The Concise Oxford Dictionary explains design as a mental plan a scheme of attack, end in view,
adaptation of means to ends preliminary sketch for picture invention Evidently there is a lot more to
design than mere visual aspects, and design is not restricted to engineering. Key components of this
explanation are as follows
1 Means to ends implies that we design not for the abstract mental exercise, but with a definite goal
in view some action or some physical object will result from the design.
2 Mental suggests that design is a thinking process. When we design we deal primarily with ideas,
with abstractions rather than with numbers - and computers for example cannot do the job for us, though
they can help in certain tasks.
No matter what we design, it is vital that we develop and apply our imagination to
visualise realistically the future form of the artefact or action, how it will eventually come into being
and most importantly how it will thereafter interact with people and other artefacts or actions.
3 Plan, scheme infers that design is distinct from implementation. Designers especially in engineering seldom execute their plans, but rather communicate them to others either by word of mouth, or
visually
16
Chapter 4
Project Design
So, can we now define design completely? No ! and neither do we need to. A rigid definition implies a rigid process, and design is anything but that. We shall adopt the following interpretation as it
incorporates the above concepts and conveys a reasonably clear idea of what design is all about Design
is the application of creativity to planning the optimum solution of a given problem and the communication of that plan to others. Apart from the communication aspect therefore, we understand the essence of
design to be problem solving, though the type of problem encountered in design is not like a typical textbook mathematics problem for example in which the unique correct solution is guaranteed by following,
automaton-like, a series of learned solution steps. A design problem on the other hand is a real-life problem with many solutions, some of which meet the problem requirements better, some worse, and where
the process of discovering the solutions is not mechanistic. Some problems might appear not to need
design as a solution can be cobbled together without much thought. This is true enough if the solution
can be based on direct experience. However we shall soon come to realise that without experience such
a thoughtless solution usually comes to grief sooner or later the more involved the
problem and the more folk affected by the solution the more likely is the solution going to fall in a
heap. Any old solution will not do we must strive for the optimum solution.
We expect that the design process, if properly carried out, will show a high probability of disclosing
a solution which is optimum or close-to-optimum, if indeed a unique optimum exists.
The prime aim of this chapter is to develop a structured approach to design an approach which will
promote confidence in effectively solving real life problems. We shall focus on problems involving engineering hardware particularly for Design and Build Competitions however the approach is perfectly
general and applicable to problems arising from a marketing sortie or a labour wrangle for example. The
approach is thus very relevant to managers and the like not just to hardware designers.
Why do we design ?
Most people these days exist by providing thingsto others in the case of engineers these things are
technical muscle-power or knowhow, or physical artefacts that is solutions to buyers or hirers particular
problems. If these clients are not completely satisfied with the thing provided then they will dismiss the
provider, go somewhere else for their next thing and tell everyone about the providers unsatisfactory
things. If this happens often enough to a particular provider then that provider will cease to exist as a
market force nobody will want to know.
So clearly, if things are not designed with care and attention to clients needs then the provider will
have problems.
DESIGN PARAMETERS:STATEMENT FOR DESIGN:The Pneumatic Shearing machine is to be designed to operate at the maximum pressure of 10 bar and
the lever operating force required is 150N, with the operating temperature of 2000 C. Cylinder Sizing
Calculator
The air cylinder sizing calculator below performs the following steps:
17
Chapter 4
Project Design
1. Calculate the area of the cylinder piston

o Area = Pi x r2
2. Multiply the piston area by the air pressure to be used
o Area x Pressure = Force Output
Note: The force output on the rod end of a cylinder will be slightly less due to the displacement of
the rod. The real force output of a cylinder will be less than the theoretical output because of internal
friction and external side loading. It is best to use a cylinder that will generate from 25
Material : Al. fs= 210kg/cm2
Bolt material : M.S. ft = 280 kg/cm2
Design a cylinder of internal diameter for Di=8 cm, Internal air pressure
P= 25 kg/cm Max. ft=210kg/cm and max. ftb= 280 kg/cm.
Figure 4.1:
For safety purpose we will design the cylinder using factor of safety as 4
Therefore t = 4x 0.2 = 0.8 cm
To find the outer diameter of the cylinder,
Outer diameter Do = Di + 2 ( t ) = 100mm
Width of packing = 0.5 cm
In side diameter of cylinder, D = D + ( 2 x width of packing)
= 8 + (2 x 0.5)
= 8 + 1 = 9 cm
Force trying to separate the flanges,
F = 3.14 D1 x P/4
= ( 3.14/4 ) ( 9 ) ( 9 ) x 25
= 1589.6 kg
Force trying to be resisted by four bolts, i.e. Force on each bolt F = F1
Let dc = core diameter
F = / 4 dc ft 1/2 dc = ( 4 x 397.65/ 3.14 x 280 )
= 1.344 cm
= 0.013 mm
18
Chapter 4
Project Design
Nominal diameter of the bolts are arranged at the corners of a square of such size that the corners of
the nut clears the outside of the cylinder.
Therefore the minimum Length of diagonal of square,
Figure 4.2:
L=D+2t+2d
= 8 + 2 x ( 0.8 ) + 2 x 2
= 13.6 cm
The sides of the square = L1 = L / 2 = 9.28 cm
The sides of the flange must be of sufficient length to accommodate the nuts and bolts Heads without
overhung
Therefore Length L2 = L1 + 2 d
= 9.28 + ( 4 )
L2 = 13.28 cm
In order to find the thickness of the flange, consider the bending moment. It will take place due to
the force in two bolts. Bending moment due to the force in two bolts,
M1 = 2 F x L1/2
= 2 x 397.65 x 9.28 / 2
= 3690 kg - cm
The air pressure acting on half flange,
2 x F = 2 x 397.65 = 795.3 kg
The flanges are screwed with the cylinder having metric threads of 4.4 threads / cm (Pitch = ( 0.0228 )
Hence the Nominal or Major diameter of thread,
=D+2xt
= 8 + 2 ( 0.8 ) = 9.6 mm
Nominal radius of thread = Major diameter = 9.6 = 4.8 mm
Now the depth of the thread, = 0.64 x pitch
19
Chapter 4
Project Design
= .64 x .228 = 0.145 cm

= 1.4mm
Core or minor radius of the thread, = Nominal radius depth
= 5.6-0.145 = 5.45 cm.
Mean radius of arc over which load due to air pressure may be taken to be concentrated
= ( Nominal radius + minor radius)
= ( 5.6 + 2.8) = 4.2 cm.
The centroid of this arc,
= 0.6366 x Mean radius
= 0.6366 x 4.2 = 2.67 cm
Bending moment due to air pressure,
M2 = 2 x F X The centroid of t
= 22 x 122.65 x 2.67
= 655.86 kg- cm.
Since M1 and M2 are in the opposite direction
Therefore the resultant bending moment will be,
M = M2 M1 = 655.86 637.78 = 18.08 kg cm.
Material :- M.S.
The horizontal channel is subjected to bending stress Stress given by = M/I = fb / y In the above
equation first we will find the moment of inertia about x axis and y axis and take the minimum moment
of inertia considering the channel of ISLC 75 x 40 size.
Design of welded joint:Checking the strength of the welded joints for safety the transverse fillet weld welds the horizontal
channel and angles, plates. The maximum load, which the plate can carry for transverse fillet weld, is P
= 0.707 x S x L x ft
20
Chapter 5
Chapter 5

5.1
METHOD STUDY
MACHINING TIME ESTIMATION

This machining cost estimation gives us time require to machine a particular component on machine.
This gives us an estimation of how much time will be required to hire the machine for that particular
component. This is done for all components except standard parts.
PROCEDURE FOR CALCULATING MACHINING TIME
1) After the machining time has been calculated including allowance for each component because a
component can have more than one operation to be carried out. Hence, rates of machine are different.
2) The machining time is calculated using standard working rates.
3) The time required to manufacture a given component on a machine is multiplied by machine rate
to give machine cost.
4) The estimation of machining cost for total number of components gives us machining cost estimation.
5) Machining time of components are estimated in order to know total manufacturing cost of component.
Total time includes basic time and various factors which are taken into consideration and they are :1) Up time and down time = 100% of basic
Transportation time = 10 min
Centrime time = 20 min
Inspection time = 20 min
other allowances taken into consideration are:1) Personal allowance = 5% of basic time
2) fatique allowance = 7% of basic time
3) Contingency allowance = 5% of basic time
21
Chapter 5
TIME ANALYSIS
A) Turning Operation
The machining time in a lather work can be calculated for particular operation. If speed of job, food
and length of job is known as J.C. Time taken for complete cut
= 1 min
= s x n Where,
.s = feed per revolution
.n = No. of revolution / min of job
.l = Length of job to be m/ced
B) Shaping operation
If length of cutting stokes, breadth of job feed and cutting speed are known time required to complete
job may be calculated as
T = L X B (1 + m)/1000 R V x S.
Where,
T = Total time taken to complete cut.
L = length of stoke in mm
R = The ratio of return time to cutting time
V = The cutting speed expressed in m/min
S = Feed expressed in mm/per double stroke
C) Milling operation
Time required to mill any component surface can be given as,
T = A/sz x z x n
Where,
T = Time required to complete cut in min
L = Length of table travel to complete cut in mm
SZ = Feed per tooth in mm
Z = No.of teeth of cutter
.n = No.of revolutions of cutter per minute
D) Drilling operation
Machining time in drilling operation can be determined by formula. T = 1/sr x n mm. Where,
T = Machining time in min.
.l = Length of travel of drill per min.
.n = No.of revolutions of drill in mm.
TIME REQUIRED FOR MACHINING TIME COMPONENTS
1) Frame
Angle measuring = 30 min
Angle cutting = 45 min
Welding = 120 min
Total time = 195 min
22
Chapter 5
2) Linkage
Measurement = 15 min
Cutting = 15 min + 10 min = 25 min
Drilling = 20 min
Welding = 10 min
3) Pneumatic cylinder
Facing = 20 min
Turning = 25 min
Drilling = 10 min + 20 min = 30 min
Boring = 20 min
Total time = 95 min
4) Container
Facing = 20 min + 20 min = 40 min
Turning = 20 min + 30 min + 10 min = 60 min
Drilling = 20 min + 20 min = 40 min
Boring = 25 min
5) vertical push rod (Shaft)
Facing = 20 min + 20 min = 40 min
Turning = 60 min + 60 min = 120 min
6) Casing
Cutting = 120 min
Bending = 40 min
Drilling = 30 min
Riveting = 25 min
7) Slots
Cutting = 15 min
Milling = 180 min
Boring = 15 min
8) Rest plates
Cutting = 15 min
Bending = 10 min
welding = 25 min
Total time = 50 min
23
Chapter 5
COST ESTIMATION
1.1 INTRODUCTION:- Cost estimation may be defined as the process of forecasting the expenses
that must be incurred to manufacture a product. These expenses take into a consideration all expenditure
involved in a design and manufacturing with all related services facilities such as pattern making, tool,
making as well as a portion of the general administrative and selling costs.
1.2 PURPOSE OF COST ESTIMATING:
1. To determine the selling price of a product for a quotation or contract so
as to ensure a reasonable profit to the company.
2. Check the quotation supplied by vendors.
3. Determine the most economical process or material to manufacture the
product.
4. To determine standards of production performance that may be used to
control the cost
.
TYPES OF COST ESTIMATION:1. Material cost
2. Machining cost
MATERIAL COST ESTIMATION:
Material cost estimation gives the total amount required to collect the raw
material which has to be processed or fabricated to desired size and functioning
of the components.
These materials are divided into two categories
.
1. Material for fabrication:
In this the material in obtained in raw condition and is manufactured or
processed to finished size for proper functioning of the component.
1. Standard purchased parts:
This includes the parts which was readily available in the market like allen
screws etc. A list in forchard by the estimation stating the quality, size and
standard parts, the weigh of raw material and cost per kg. For the fabricated
parts.
MACHINING COST ESTIMATION:
This cost estimation is an attempt to forecast the total expenses that may include
to manufacture apart from material cost. Cost estimation of manufactured parts
can be considered as judgment on and after careful consideration which
includes lab our, material and factory services required to produce the required
24
Chapter 5
Figure 5.1: Machine Cost chart
1.3 CALCULATION OF MATERIAL COST:

The general procedure for calculation of material cost estimation is
1. After designing a project a bill of material is prepared which is divided
into two categories.
a. Fabricated components
b. Standard purchased components
2. The rates of all standard items are taken and added up.
3. Cost of raw material purchased taken and added up.
LABOUR COST:
It is the cost of remuneration (wages, salaries, commission, bonus etc.) of the
employees of a concern or enterprise.
25
Chapter 5
Figure 5.2: Labour Cost chart
Hence the total labour cost incurred = 1395/- Rs.

Hence the total manufacturing cost = A( i + ii ) + B + C
= (2155 + 8990) + 1940 +1395
= 14080/This cost can be reduced by 25% , if this machine is manufactured on
mass quantity
26
Chapter 5
Labour cost is classifies as:

1. Direct labour cost
2. Indirect labour cost
Direct labour cost:
The direct labour cost is the cost of labour that can be indentified directly with
the manufacture of the product and allocated to cost centers or cost units.
The direct labour is one who counters the direct material into saleable product,
the wages etc. of such employees constitute direct labour cost. Direct labour
cost may be apportioned to the unit cost of job or either on the basis of time
spend by a worker on the job or as a price for some physical measurement of
product.
Indirect labour cost:
It is that labour cost which can not be allocated but which can be apportioned to
or absorbed by cost centers or cost units. This is the cost of labour that doesnt
alters the construction, confirmation, composition or condition of direct material
but is necessary for the progressive movement and handling of product to the
point of dispatch e.g. maintenance, men, helpers, machine setters, supervisors
and foremen etc.
The total labour cost is calculated on the basis of wages paid to the labour for 8
hours per day.
Cost estimation is done as under
Cost of project = (A) material cost + (B) Machining cost + (C) lab our cost
(A) Material cost is calculated as under :i) Raw material cost
ii) Finished product cost
i) Raw material cost:It includes the material in the form of the Material supplied by the Steel authority of India limited as the
round bars Channels, angles, square rods , plates along with the strip material form. We have to search
for the suitable available material as per the requirement of designed safe values.
27
Chapter 5
Rate= 40/- per kg.

Hence the cost of the raw material is as follows:Total of above = 2155/- Rs.
ii) Finished product cost:Following the components which we have directly purchased from the Market, being easily available
and cheaply availably available as compared to their manufacturing cost
1) Pneumatic cylinder = 3800/2) FRL Unit = 2500/3) O ring for the piston = 30/4) Flexible air hose pipe = 250/5) Brass nipple = 120/6) electric wire 18 gauge = 90/7) socket pin point 5 amp= 100/8) colour red,yellow,black= 200/9) nut bolt and washers (24)= 150/10) 4 nos springs10 and 20 = 200/11) bright pins 8mm = 050/12) 5 / 2 direction control valve= 1500/Total cost of the finished components = 8990/- Rs.
28
Chapter 5
DIE OPERATIONS
Cutting operations are classified either by the purpose or the shape of cutting actions as follows :(A) Operations for producing blanks :
1) Blanking :- Stamping having an irregular contour must be blanked from the strip. Piercing, embossing and various other operations may be performed on the strip prior to the blanking station.
2) Cut off :- Cut off operation are those, in which strip of suitable width is cut of required length.
Preliminary operation before cutting off include piercing, notching, embossing. Although they are simple, many parts may be produced by cut off dies.
3) Shearing :- In this, work piece is cut off. The cutting action must be along a straight line
4) Parting :It is an operation in which two single line are made to cut blank from the strip. During parting some
amount of scrap is produced
(B) Operations for cutting holes :1) Piercing :
Piercing dies pierce a hole in previously blanked, formed or drawn parts. It is often impractical to pierce
holes while forming or before forming because they would become distorted in the forming operation.
In such case, they are pierced in a piercing die after forming.
2) Punching : It is a cutting operation by which various shaped holes are made in the sheet metal.
3) Perforating : This is the process operation by which multiple holes are punched
(C) Operations for Progressive Working :
1) Notching :- This is the cutting operation by which metal pieces are cut form the edges of the sheet.
2) Lancing :- This is the cutting operation in which the hole is partially cut and then one side is bent
down to form a start tab or louver. There will be no scrap.
(D) Operations for size control :
1) Trimming :- When cups and shells are drawn from the flat metal sheet the edge is left wavy and
irregular, due to uneven flow of the metal. This irregular edge is trimmed in trimming die. Shown is a
plunged shell as well as the trimmed ring removed from around the edge
.
2) Shaving :- Shaving consist in removing a chip from around the previously blanked stamping.
Straight smooth edge is provided and therefore shaving is frequently performed on instrument parts,
watch and clock parts. Shaving is accomplished in shaving dies especially designed for the purpose.
29
Chapter 5
3) Slitting :- It refers to the operation of making incomplete hole in a work piece.

(E) Forming operations :
1) Bending :- Bending dies apply simple bends to stampings. The simple bend is straight. One or
more bends may be involved and bending dies are a large and important class of press tool.
2) Drawing :- Drawing dies transform flat sheet of metal into cups, shells or other drawnshapes by
subjecting the material to severe plastic deformation.
3) Squeezing :- Under this operation the metal is caused to flow to all operation to die cavity under
the action of compressive forces.
4) Embossing :- Embossing group of operations is used to deform sheet metal away from the blank
or part edge or in the central region.
(F) Miscellaneous operations :
1) Extruding :- Extruding dies caused metal to be extruded or squeezed out, much like toothpaste
is extruded from its tube when pressure is applied. This shows a collapsible tube formed and extruded
from a solid slug of metal
.
2) Horning :- Horn dies are provided with an arbor or horn over which the parts are placed for secondary operation such as seaming. Horn dies may also be used for piercing holes in the side of shells.
3) Bulging :- Bulging dies expand the bottom of the previously drawn plates. The bulged bottom of the
some types of pots are performed in bulging dies.
4) Curling :- Curling dies curl the edge of the drawn shells to provide strength and rigidity. The curl
may be applied over a wire ring for increasing strength. You may have seen the tops of sheet metal
pails curled in this manner. Flat parts may also be curled. A good example is a hinge in which both the
members are curled to provide hole for a hinge pin.
5) Cold forming :- In cold forming operation, metal is subjected to high pressure and caused to flow
in a determined form. In cold forming, the metal is caused to flow into the shape of the die cavity.
6) Progressive operation : Progressive operation are those in which progressive dies performs work
at number of stations simultaneously. A complete part is cut off , at the final station, with each stroke of
the press.
30
Chapter 6
Chapter 6
Test Cases, Project Time Line & Task

Distribution
6.1
6.1.1
Test Cases
OBJECTIVES
(1) The improvements of processes and procedures.

(2) The improvements of factory, shop and work place. Layout and design of
plat and equipment.
(3) Economy in human effort.
(4) Improvements in the use of materials, machines and manpower.
(5) The development of better physical working environment.
RECORDING TECHNIQUES:
The next step in basic procedure after selecting the work to be studies is to
record all the facts relating to existing methods.
PURPOSE OF RECORDING:
(1) To enable the process to be clearly understood.
(2) To present the existing facts for analogs.
FLOW PROCESS CHARTS:
Flow process chart is defined as a graphic representation of all storages, occurring during a process or
procedure which includes information considered necessary for analysis such as time required quantity
and distance moved etc.
TYPES OF FLOW PROCESS CHART:
(a) man type : It records what the worker does. (b) material type: It records what happens to the materials. (a) Equipment type: It records how the equipment is used. Flow process chart gives a complete
picture at what is being done and helps the man to understand the facts and their relationship to one
another.
31
Chapter 6
OBJECTIVE OF FLOW PROCESS CHART:

(1) To visualize the complete sequence of events occurring in process.
(2) To study the events in a systematic way for the complete analysis of the manufacture of the component part for the following purposes.
(a) To improve the layout
(b) To improve material handling
(c) To reduce delays.
(d) To diminutive, combine or re-arrange the events in a systematic way.
(3) To submit the proposals to managements in a form which can be easily understood.
(4) To guide supervisors and operators regarding detailed operating instructions.
According to the nature of job being studies and purpose for the record is required.
(A) CHARTS : Outline process chart
Flow process chart : man type
Flow process chart : material type
Flow process chart : equipment type
(B) CHARTS : using time scale
i) multiple activity chart
ii) simo chart
iii) P.M.T.S. chart
( C) DIAGRAMS INDICATING MOVEMENTS and MODELS:
i) Flow diagrams
ii) String diagrams
iii) Cycle graph
iv) Chromo cycle graph
v) Travel chart
(3) To compare between two or more alternative methods.
(4) To select operations for a detailed study.
32
Chapter 6
6.2
Task Distribution
METHOD STUDY:
Method of the study is the systematic recording and critical Examination of
existing and proposed ways of doing work, as a means of developing and applying
Figure 6.1: More effective methods and reducing costs.
33
Chapter 6
6.3
Project Time Line
MANUFACTURING PROCESS:- The process of conversion of raw material in to finished products

using the three resources as Man, machine and finished sub-components. Manufacturing is the term by
which we transform resource inputs to create Useful goods and services as outputs. Manufacturing
can also be said as an intentional act of producing something useful . The transformation process is
shown belowinput
conventional process
out put
34
Chapter 6
Hence referring to the those values we will plan The various processes using the following machines:i) Universal lathe
ii) Milling machine
iii) Grinding machine
iv) Power saw
v) Drill machine
vi) Electric arc welding machine
Figure 6.4: Piston
35
Chapter 6
OPERATION SHEET NO 01
PART NAME Main Vertical cylinder Plunger
RAW MATERIAL BRIGHT STEEL rod of 26mm
TABLE 4 MAIN PLUNGER MANUFACTURING
Figure 6.5: SHEET NO 1
36
Chapter 6
OPERATION SHEET NO:02

COMPONENT: Horizontal channel
MATERIAL:- M.S. Channel and angle
MATERIAL SPECIFICATION:-I.S.L.C. 40X.75 and 25x25x5 angle
37
Chapter 6
OPERATION SHEET NO:03

COMPONENT: cylinder
MATERIAL:- Aluminium
MATERIAL SPECIFICATION:-70 x 200mmlength
38
Chapter 6
COMPONENT NO 04
PART NAME FRAME
SIZE AS PER DRAWIING
39
Chapter 6
Part NO 05 QUANTITY 01
NAME DIE HOLDING FIXTURE
40
Chapter 6
PART NO 06 QUANTITY - 01
NAME FRAME OF PNEUMATIC SHEARING MACHINE
41
Chapter 6
PART NO 07 QUANTITY - 02
PART NAME PLUNGER SHAFT
42
Chapter 7
Chapter 7

7.1
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 degree Engineers and having the ability to
think and plan. But due to some time constraints, and also due to lack of funds, we only have thought
and put in the report the following future modifications:1) It can be made to run has bottle cap sealing machine. The stationary platform can be made auto
swiveling type by installing the timer and heat sensor arrangement on the platform. It can be done such
that when the bottle mouth is sealed up to the desired temperature the electrical heater circuit gets cut
off . At the same time the motor installed on the reduction gear box starts operating the bevel gearing
and the platform starts rotating thus it can be made auto rotating type.
2) It can be made hydraulic operated type by replacing the hand lever by hydraulic cylinder and along
with the ratchet and Paul arrangement..
3) It can be made hydraulically power operated by installing the gear oil pump at the place of air
compressor and pneumatic cylinder arrangement.
4) It can be made rack and pinion operated or spring and lever operated, by replacing the pneumatic
circuit by rack and the pinion arrangement by the square threaded screw and nut arrangement.
5) The place where there is scare city of the electricity the electric motor operate compressor is replaced by an I.C.Engine installed compressor.
Thus in future there are so many modifications, which we can make to survive the huge global world
of competition.
7.2
Conclusion
Now we know that Pneumatic Shearing machine is very cheap as compared to hydraulic shearing machine.The range of the cutting thickness can be increased by arranging a high pressure compressor and
this machine is advantageous to small sheet metal cutting industries as they do not have rely on the
expensive hydraulic shearing machine
43
References
References
[1] J. P. Den Hartog, Advanced Strength of Materials (McGraw-Hill, New York, 1952), TA 405 D4,
1952. ; Author Name, Conference Name, year etc
[2] E. W. Comings, High Pressure Technology (McGraw-Hill, New York, 1956). ; Author Name, Conference Name, year etc
[3] Adaptive Steady State Genetic Algorithm for scheduling university exams,AlSharafat W.S.; AlSharafat M.S., Networking and Information Technology (ICNIT), 2010 International Conference
on , vol., no., pp.70-74, 11-12 June 2010 doi: 10.1109/ICNIT.2010.5508555
[4] http://google.com
http://www.engineersedge.com/
http://www.efunda.com/
http://www.steeltubeinstitute.org/
http://www.emjmetals.com/
http://www.usstubular.com/
1 Machine design R.S. Khurmi
2 Work shop technology R.K.Jain.
3 Machine tool design handbook.
4 P.S.G. Design Data Book
5 www.altavista.com
44
Project Hosting
Appendix A
Project Hosting
The project is hosted at Google Code. The complete source code along with the manual to operate the
project and supplementary files are uploaded.
Project Link : https://code.google.com/p/proquiz
QR CODE:
45

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A

Rizvi College of Engineering

Dr. Varsha Shah

Implementation & Technologies Used

Test Cases, Project Time Line & Task Distribution

Conclusion and Future Scope

Heat treatment chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Machine Cost chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

More effective methods and reducing costs.

Rizvi College of Engineering, Bandra, Mumbai.

Rizvi College of Engineering, Bandra, Mumbai.

Figure 1.1: Pneumatic Cylinder

Figure 1.2: 5/2 footcontrol valve

Rizvi College of Engineering, Bandra, Mumbai.

Figure 1.3: 5/2 direction footcontrol valve

Rizvi College of Engineering, Bandra, Mumbai.

Rizvi College of Engineering, Bandra, Mumbai.

Figure 1.4: Neutral Position

Rizvi College of Engineering, Bandra, Mumbai.

Figure 1.5: Working Position

Rizvi College of Engineering, Bandra, Mumbai.

Figure 1.6: Machine fig.

Rizvi College of Engineering, Bandra, Mumbai.

ASME Paper No. 57-A-15 (1957)

Rizvi College of Engineering, Bandra, Mumbai.

Rizvi College of Engineering, Bandra, Mumbai.

Rizvi College of Engineering, Bandra, Mumbai.

Rizvi College of Engineering, Bandra, Mumbai.

The machine is basically made up of mild steel.

Rizvi College of Engineering, Bandra, Mumbai.

Figure 3.1: Heat treatment chart

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GENERAL CONSIDERATION IN MACHINE DEVELOPMENT

Rizvi College of Engineering, Bandra, Mumbai.

Rizvi College of Engineering, Bandra, Mumbai.

1. Calculate the area of the cylinder piston

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= .64 x .228 = 0.145 cm

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MACHINING TIME ESTIMATION

Rizvi College of Engineering, Bandra, Mumbai.

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Rizvi College of Engineering, Bandra, Mumbai.

Implementation & Technologies Used

Rizvi College of Engineering, Bandra, Mumbai.

Implementation & Technologies Used

Rizvi College of Engineering, Bandra, Mumbai.

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Figure 5.1: Machine Cost chart

1.3 CALCULATION OF MATERIAL COST:

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Figure 5.2: Labour Cost chart

Hence the total labour cost incurred = 1395/- Rs.

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Labour cost is classifies as:

Rizvi College of Engineering, Bandra, Mumbai.

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Rate= 40/- per kg.

Rizvi College of Engineering, Bandra, Mumbai.

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