PNEUMATIC PRESS MACHINE

PNEUMATIC PRESS MACHINE

CHAPTER 01
INTRODUCTION
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.

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CHAPTER 02
WORKING PRINCIPLE
Our project works on the following three basic principles.
1.

Air can flow.

2.

Air can be compressed.

3.

Difference in air pressure can cause movement.

The main objectives of our project is to punch object with the help of air.
Initially we press the lever manually and the force is transmitted from the
lever to the cylinder (Syringe-1) through a link. The air in the cylinder
(Syringe-1) gets compressed and exerts force through the pipe to the next
cylinder (Syringe-2) where the PRESS tool is connected and hence the
object is punched due to air pressure.

Thus the project is easy to operate due to its simple mechanism.

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PROJECT LAYOUT

FIG NO-01

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2 Column

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4 Column

C Frame

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CHAPTER 03
PNEUMATICS
Pneumatics is a section of technology that deals with the study and
application of pressurized gas to produce mechanical motion.
Pneumatic systems are extensively used in industry, where factories
are commonly plumbed with compressed air or compressed inert gases. This
is because a centrally located and electrically powered compressor that
powers cylinders and other pneumatic devices through solenoid valves is
often able to provide motive power in a cheaper, safer, more flexible, and
more reliable way than a large number of electric motors and actuators.
Pneumatics also has applications in dentistry, construction, mining, and
other areas.

Comparison to hydraulic and pneumatic

Both pneumatics and hydraulics are applications of fluid power.
Pneumatics uses an easily compressible gas such as air or a suitable pure
gas, while hydraulics uses relatively incompressible liquid media such as oil.
Most industrial pneumatic applications use pressures of about 80 to 100
pounds per square inch (550 to 690 kPa). Hydraulics applications commonly
use from 1,000 to 5,000 psi (6.9 to 34 MPa), but specialized applications
may exceed 10,000 psi (69 MPa).
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Advantages of pneumatics
Simplicity of Design And Control
Machines are easily designed using standard cylinders & other
components. Machines operate by simple ON - OFF type control.

Reliability
Pneumatic systems tend to have long operating lives and require very
little maintenance Because gas is compressible, the equipment is less likely
to be damaged by shock. The gas in pneumatics absorbs excessive force,
whereas the fluid of hydraulics directly transfers force.

Storage
Compressed gas can be stored, allowing the use of machines when electrical
power is lost.

Safety
Very low chance of fire (compared to hydraulic oil).
Machines can be designed to be overload safe.

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Pneumatic logic
Pneumatic logic systems (sometimes called air logic control) are often
used to control industrial processes, consisting of primary logic units such
as:
And Units
Or Units
'Relay or Booster' Units
Latching Units
'Timer' Units
Sorteberg relay
Fluidics amplifiers with no moving parts other than the air itself
Pneumatic logic is a reliable and functional control method for industrial
processes. In recent years, these systems have largely been replaced by
electrical control systems, due to the smaller size and lower cost of electrical
components. Pneumatic devices are still used in processes where
compressed air is the only energy source available or upgrade cost, safety,
and other considerations outweigh the advantage of modern digital control.

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CHAPTER 04
PRESS
Introduction
PRESS is a metal forming process that uses a punch press to force a
tool, called a punch, through the workpiece to create a hole via shearing. The
punch often passes through the work into a die. A scrap slug from the hole is
deposited into the die in the process. Depending on the material being
punched this slug may be recycled and reused or discarded. PRESS is often
the cheapest method for creating holes in sheet metal in medium to high
production volumes. When a specially shaped punch is used to create
multiple usable parts from a sheet of material the process is known as
blanking. In forging applications the work is often punched while hot, and
this is called hot PRESS.

Process
Punch tooling (punch and die) is often made of hardened steel or
tungsten carbide. A die is located on the opposite side of the workpiece and
supports the material around the perimeter of the hole and helps to localize
the shearing forces for a cleaner edge. There is a small amount of clearance
between the punch and the die to prevent the punch from sticking in the die
and so less force is needed to make the hole. The amount of clearance
needed depends on the thickness, with thicker materials requiring more
clearance, but the clearance is always less than the thickness of the
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workpiece. The clearance is also dependent on the hardness of the

workpiece. The punch press forces the punch through a workpiece,
producing a hole that has a diameter equivalent to the punch, or slightly
smaller after the punch is removed. All ductile materials stretch to some
extent during PRESS which often causes the punch to stick in the
workpiece. In this case, the punch must be physically pulled back out of the
hole while the work is supported from the punch side, and this process is
known as stripping. The hole walls will show burnished area, rollover, and
die break and must often be further processed. The slug from the hole falls
through the die into some sort of container to either dispose of the slug or
recycle it.

PRESS Characteristics
PRESS is the most cost effective process of making holes in strip or
sheet metal for average to high fabrication
It is able to create multiple shaped holes
Punches and dies are usually fabricated from conventional tool steel
or carbides
Creates a burnished region roll-over, and die break on sidewall of the
resulting hole.

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CHAPTER 05

Geometry
The workpiece is often in the form of a sheet or roll. Materials for the
workpiece can vary, commonly being metals and plastics. The punch and die
themselves can have a variety of shapes to create an array of different
shaped holes in the workpiece. Multiple punches may be used together to
create a part in one step.

Equipment
Most punch presses are mechanically operated, but simple punches
are often hand-powered. Major components of this mechanical press are the
frame, motor, ram, die posts, bolster, and bed. The punch is mounted into the
ram, and the die is mounted to the bolster plate. The scrap material drops
through as the workpiece is advanced for the next hole. A large computer
controlled punch press is called a computer numerical controlled turret. It
houses punches and their corresponding dies in a revolving indexed turret.
These machines use hydraulic, pneumatic, or electrical power to press the
shape with enough force to shear the metal.

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Forces
The punch force required to punch a piece of sheet metal can be
estimated from the following equation:

Where t is the sheet metal thickness, L is the total length sheared (perimeter
of the shape), and UTS is the ultimate tensile strength of the material.
Die and punch shapes affect the force during the PRESS process. The punch
force increases during the process as the entire thickness of the material is
sheared at once. A beveled punch helps in the shearing of thicker materials
by reducing the force at the beginning of the stroke. However, beveling a
punch will disort the shape because of lateral forces that develop. Compound
dies allow multiple shaping to occur. Using compound dies will generally
slow down the process and are typically more expensive than other dies.
Progressive dies may be used in high production operations. Different
PRESS operations and dies may be used at different stages of the operation
on the same machine.

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Cylinders Data
Force = Pressure Area
2 diameter piston
Area = 3.14 12 = 3.14 in2
Pressure = 60 psi
3.14 in2 60 psi = 188 lbs
Force while extending
greater than while retracting
Main decisions: Length and diameter
Diameter based on required force
Larger diameter: more force, but more air
Introduction
Components
Mechanisms
Resources.

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The Three Principles

There are three scientific principles involved in each type of fluid systems.
These include the following:
1) Fluids can be compressed
2) Fluids can flow
3) Pressure differences can cause movement
Fluids can flow relates to my subject because for pneumatic systems to
work, it needs the compressed air to flow through something in order to do a
job right.

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CHAPTER 06
LIST OF COMPONENTS / ACCESSORIES
USED IN THE PROJECT
1.

PRESS Tools

2.

Pneumatic Cylinder

3.

Lever

4.

Sprocket

5.

Wooden Surface / Frame

6.

Clamp / Dies (Male / Female)

7.

Spring

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PRESS TOOLS / ACCESSORIES

A punch is a hard metal rod with a shaped tip at one end and a blunt butt end
at the other, which is usually struck by a hammer. Most woodworkers prefer
to use a ball-peen hammer for using punches. Punches are used to drive
objects, such as nails, or to form an impression of the tip on a workpiece.
Decorative punches may also be used to create a pattern or even form an
image.
Punches and dies are necessities in a metal shop. They will help to make
work more efficient in the realm of modular home construction to auto body
repair and restoration. Whether in need of a punch for a variety of metal
work tasks or for more specific needs in auto body shops, variety of punches
and dies, that are capable of PRESS through a variety of metals.

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PNEUMATIC CYLINDER

Pneumatic cylinders (sometimes known as air cylinders) are

mechanical devices which use the power of compressed gas to produce a
force in a reciprocating linear motion.:85 Like hydraulic cylinders,
pneumatic cylinders use the stored potential energy of a fluid, in this case
compressed air, and convert it into kinetic energy as the air expands in an
attempt to reach atmospheric pressure. This air expansion forces a piston to
move in the desired direction. The piston is a disc or cylinder, and the piston
rod transfers the force it develops to the object to be moved. :85 Engineers
prefer to use pneumatics sometime because they are quieter, cleaner, and do
not require large amounts of space for fluid storage.
Because the operating fluid is a gas, leakage from a pneumatic cylinder will
not drip out and contaminate the surroundings, making pneumatics more
desirable where cleanliness is a requirement. For example, in the mechanical
puppets of the Disney Tiki Room, pneumatics are used to prevent fluid from
dripping onto people below the puppets.
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Operation General
Once actuated, compressed air enters into the tube at one end of the
piston and, hence, imparts force on the piston. Consequently, the piston
becomes displaced (moved) by the compressed air expanding in an attempt
to reach atmospheric pressure.

Compressibility of gasses
One major issue engineers come across working with pneumatic cylinders
has to do with the compressibility of a gas. Many studies have been
completed on how the precision of a pneumatic cylinder can be affected as
the load acting on the cylinder tries to further compress the gas used. Under
a vertical load, a case where the cylinder takes on the full load, the precision
of the cylinder is affected the most. A study at the National Cheng Kung
University in Taiwan, concluded that the accuracy is about 30mm, which
is still within a satisfactory range but shows that the compressibility of air
has an effect on the system.

Fail safe mechanisms

Pneumatic systems are often found in settings where even rare and
brief system failure is unacceptable. In such situations locks can sometimes
serve as a safety mechanism in case of loss of air supply (or its pressure
falling) and, thus,remedy|remedy]] or abate any damage arising in such a
situation. Due to the leakage of air from input or output reduces the pressure
and so the desired output.

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Types
Although pneumatic cylinders will vary in appearance, size and
function, they generally fall into one of the specific categories shown below.
However there are also numerous other types of pneumatic cylinder
available, many of which are designed to fulfill specific and specialized
functions.

Single-acting cylinder
Single-acting cylinders (SAC) use the pressure imparted by
compressed air to create a driving force in one direction (usually out), and a
spring to return to the "home" position. More often than not, this type of
cylinder has limited extension due to the space the compressed spring takes
up. Another downside to SACs is that part of the force produced by the
cylinder is lost as it tries to push against the spring. Because of those factors,
single acting cylinders are recommended for applications that require no
more than 100mm of stroke length :85

Double-acting cylinders
Double-acting cylinders (DAC) use the force of air to move in both
extend and retract strokes. They have two ports to allow air in, one for
outstroke and one for instroke. Stroke length for this design is not limited,
however, the piston rod is more vulnerable to buckling and bending.
Addition calculations should be performed as well. :89

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SPROCKET

A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs, or even

sprockets that mesh with a chain, track or other perforated or indented
material. The name 'sprocket' applies generally to any wheel upon which are
radial projections that engage a chain passing over it. It is distinguished from
a gear in that sprockets are never meshed together directly, and differs from
a pulley in that sprockets have teeth and pulleys are smooth.
Sprockets are used in bicycles, motorcycles, cars, tracked vehicles, and other
machinery either to transmit rotary motion between two shafts where gears
are unsuitable or to impart linear motion to a track, tape etc. Perhaps the
commonest form of sprocket is found in the bicycle, in which the pedal shaft
carries a large sprocket-wheel which drives a chain which in turn drives a
small sprocket on the axle of the rear wheel. Early automobiles were also
largely driven by sprocket and chain mechanism, a practice largely copied
from bicycles. Sprockets are of various designs, a maximum of efficiency
being claimed for each by its originator. Sprockets typically do not have a
flange. Some sprockets used with timing belts have flanges to keep the
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timing belt centered. Sprockets and chains are also used for power
transmission from one shaft to another where slippage is not admissible,
sprocket chains being used instead of belts or ropes.

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LEVER

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A lever is a machine consisting of a beam or rigid rod pivoted at a

fixed hinge, or fulcrum. It is one of the six simple machines identified by
Renaissance scientists. The word comes from the French lever, "to raise", cf.
a levant. A lever amplifies an input force to provide a greater output force,
which is said to provide leverage. The ratio of the output force to the input
force is the ideal mechanical advantage of the lever.

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Force and levers

A lever is a beam connected to ground by a hinge, or pivot, called a
fulcrum. The ideal lever does not dissipate or store energy, which means
there is no friction in the hinge or bending in the beam. In this case, the
power into the lever equals the power out, and the ratio of output to input
force is given by the ratio of the distances from the fulcrum to the points of
application of these forces. This is known as the law of the lever.

Classes of Lever
Levers are classified by the relative positions of the fulcrum and the
input and output forces. It is common to call the input force the effort and
the output force the load or the resistance. This allows the identification of
three classes of levers by the relative locations of the fulcrum, the resistance
and the effort:

Class 1: Fulcrum in the middle: the effort is applied on one side of the
fulcrum and the resistance on the other side, for example, a crowbar or a pair
of scissors.
Class 2: Resistance in the middle: the effort is applied on one side of the
resistance and the fulcrum is located on the other side, for example, a
wheelbarrow or a nutcracker or a bottle opener.

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Class 3: Effort in the middle: the resistance is on one side of the effort and
the fulcrum is located on the other side, for example, a pair of tweezers or
the human mandible.
These cases are described by the mnemonic "fre 123" where the fulcrum is
in the middle for the 1st class lever, the resistance is in the middle for the
2nd class lever, and the effort is in the middle for the 3rd class lever.

Law of the Lever

The lever is a movable bar that pivots on a fulcrum attached to a fixed
point. The lever operates by applying forces at different distances from the
fulcrum, or pivot.
Assuming the lever does not dissipate or store energy, the power into the
lever must equal the power out of the lever.

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SPRINGS
DEFINITION FOR SPRING:
Springs are elastic bodies (generally metal) that can be twisted, pulled,
or stretched by some force. They can return to their original shape when the
force is released. In other words it is also termed as a resilient member.

CLASSIFICATION OF SPRINGS:
Based on the shape behavior obtained by some applied force, springs are
classified into the following ways:
SPRINGS

HELICAL SPRINGS

TENSION HELICAL

LEAF SPRINGS

TORSION SPRING

SPRING
COMPRESSION HELICAL SPRING

I. HELICAL SPRINGS:

DEFINITON:
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SPIRAL SPRINGS

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It is made of wire coiled in the form of helix.

CROSS-SECTION:
Circular, square or rectangular

CLASSIFICATION:
1) Open coil springs (or) Compression helical springs
2) Closed coil springs (or) Tension helical springs

1) HELICAL TENSION SPRINGS:

CHARACTERISTICS:
Figure1 shows a helical tension spring. It has some means of
transferring the load from the support to the body by means of
some arrangement.
It stretches apart to create load.
The gap between the successive coils is small.
The wire is coiled in a sequence that the turn is at right angles to
the axis of the spring.
The spring is loaded along the axis.
By applying load the spring elongates in action as it mainly
depends upon the end hooks as shown in figure.

FIGURE TENSION HELICAL SPRING

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FIGURE.TYPES OF END HOOKS OF A

HELICAL EXTENSION SPRING

APPLICATIONS:
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1) Garage door assemblies

2) Vise-grip pilers
3) carburetors

2) HELICAL COMPRESSION SPRINGS:

CHARACTERISTICS:
The gap between the successive coils is larger.
It is made of round wire and wrapped in cylindrical shape with
a constant pitch between the coils.
By applying the load the spring contracts in action.
There are mainly four forms of compression springs as shown
in figure3.. They are as follows:
1) Plain end
2) Plain and ground end
3) Squared end
4) Squared and ground end
Among the four types, the plain end type is less expensive to
manufacture. It tends to bow sideways when applying a
compressive load.

FIGURE.COMPRESSION HELICAL SPRING

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APPLICATIONS:
1) Ball point pens
2) Pogo sticks
3) Valve assemblies in engines

3) TORSION SPRINGS:
CHARACTERISTICS:
It is also a form of helical spring, but it rotates about an axis to
create load.
It releases the load in an arc around the axis as shown in
figure4.
Mainly used for torque transmission
The ends of the spring are attached to other application objects,
so that if the object rotates around the center of the spring, it
tends to push the spring to retrieve its normal position.
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FIGURE.TORSION SPRING
APPLICATIONS:
Mouse tracks
Rocker switches
Door hinges
Clipboards
Automobile starters

4) SPIRAL SPRINGS:
CHARACTERISTICS:
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It is made of a band of steel wrapped around itself a number of

times to create a geometric shape as shown in figure5.
Its inner end is attached to an arbor and outer end is attached to
a retaining drum.
It has a few rotations and also contains a thicker band of steel.
It releases power when it unwinds.

CHAPTER 07
ADVANTAGES
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It reduces the manual work.

It reduces the production time.
Uniform application of the load gives perfect removing of the bearing.
Damages to the bearing due to the hammering is prevented.
It occupies less floor space.
Less skilled operator is sufficient.

LIMITATIONS
Initial cost is high
Cylinder stroke length is constant
Specific Size PRESS operation only.
Can work only on thin papers / sheets.

APPLICATIONS
Pressing Operation in all industries
Paper industries.
Leather SS washer operation in all industries.
Sheet Metal PRESS.

CHAPTER 08
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CONCLUSION
Our team has made this project with utmost dedication which will help
common people. This project has been made for the first time and this the
pneumatic PRESS machine can easily punch the papers, metals, plastics etc.
Initially we press the lever manually and the force is transmitted from the
lever to the cylinder (Syringe-1) through a link. The air in the cylinder
(Syringe-1) gets compressed and exerts force through the pipe to the next
cylinder (Syringe-2) where the PRESS tool is connected and hence the
object is punched due to air pressure.
Thus the project is easy to operate due to its simple mechanism.

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REFERENCES
www.engineering.world.edu/me
www.blown-film-machine.com/mechanical-type-pneumatic-typemanual-PRESSmachine.htm
www.howstuffworks.com
www.100projects.org
www.technocrats.com/projects/mechanical-project/
www.students360.in

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