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Project Report on
DESIGN AND FABRICATION OF HYDRAULIC SHEET METAL
PUNCHING MACHINE USING LEVERAGE PRINCIPLES.
Submitted to
CERTIFICATE
This is to certify that Mr. Arun Singh, Mr. Harshil Sehariya, Mr. Mahendra Singh
Candrawat, Mr. Shubham Bagi, Mr. Shubham Dhaneshree and Mr. Shubham
Mathur student of B.E. (Mechanical Engineering Department) of this college has
carried out Project DESIGN AND FABRICATION OF HYDRAULIC SHEET
METAL PUNCHING MACHINE USING LEVERAGE
PRINCIPLES. It is submitted by in partial fulfillment of the
requirements for the award of Bachelor of Engineering in
Mechanical Engineering from Mahakal Institute of Technology &
Science; Ujjain affiliated to Rajiv Gandhi
ProudyogikiVishwavidyalaya, Bhopal (M.P.).
We wish to express our heartfelt appreciation to all the people who had
contributed to this project, both explicitly and implicitly.
First to all we want to thank our projects guide Prof. Pankaj Gera
for giving us this opportunity to work under his guidance. His empathy
towards us made our work easy. Many thank to him for encouraging and
supporting us to complete this project work.
In the last but not least, we are also thankful to all the persons and
colleagues who have helped us directly or indirectly during this project.
.
While for the sake of simplicity we have shown a single small piston,
(3) Reservoirs
(5) Cylinders
2.1.2) PURPOSE OF THE FLUID The hydraulic fluid has four primary
purposes:
Prevent rust
Depress foaming
Maintain its own stability and thereby reduce fluid replacement cost
Pour point
Lubricating ability
Oxidation resistance
2.2) SEALS AND PACKING: Seals are device for closing gaps to prevent
leakage or make pressure tight joints and also to prevent entry of air
and dirt from outside in to the system. A wide variety of seals of
different shapes and material are used. The material of the seal must
be compatible with the fluid medium.
2.2.1) SEAL MATERIALS Seals are device for closing gaps to prevent
leakage of make pressure tight joints and also the prevent entry of air
and dirt from outside into the system. A wide verity of seals of different
shapes and material are used Synthetic rubbers (elestomers), however,
are the most part quite compatible with oil. Elestomer can be made in
many compositions to meet various operating condition. Most of the
hydraulic equipment seals today are made of one of these elastomers:
Nit rile (Buna-N), chloroprene (Neoprene) Teflon.ERP/EPDM (also
known as EPM),of silicon.
2. Proper installation.
3. Control of operating conditions.
(2) Ram
cylinder because the swept volume is less. Which the same system
pressure, the maximum force exerted by the cylinder is also less
because of the smaller area under pressure.
2.6) DIRECTIONAL VALVES As the same name implies, directional valves
start, stop, and control the direction of fluid flow. Although they share
this common function, directional valves very considerably in
construction and operation.
graphic symbol for a check valve is a ball and sheet. A light spring,
usually
force. Most are infinite positioning that is; the valves can assume
various
positions fully closed and fully open, depending on flow rate and
pressure
differential.
Pressure control are usually named for their primary function, such a
relief
valve, sequence valve, break valve, etc. they are classified by size
pressure
The principle of the lever tells us that the above is in static equilibrium,
with all forces balancing, if F1D1 = F2D2.
In physics, a lever (from Old French levier, the agent noun to lever "to
raise", c. f. Levant ) is a rigid object that is used with an appropriate
fulcrum or pivot point to multiply the mechanical force that can be
applied to another object.
First-Class levers
A First-Class Lever is a lever in which the fulcrum is located in between the
Effort Force and the Resistance Force, and works by having a force be
applied by pulling or pushing onto a section of the bar, which causes the
lever to swing about the fulcrum, overcoming the resistance force.
Examples:
Seesaw (also known as a teeter-totter)
Crowbar (removing nails)
Pliers (double lever)
Scissors (double lever)
Second-class levers
Examples:
Wheelbarrow
Human arm
Let
W= Weight to be Lifted,
A=Area of plunger,
(2) Punch retainer of punch plate: It fits closely over the body of the
punch and holds it in a proper relative position. The retainer is turn to
bolt to the punch holder.
(3) Punch holder: It provided a wide plate surface which face against
the lower end of the press ram and is anchored to it with help of the
shank which is an integral part of the punch holder shank exactly fits in
to the ram opening, to help in properly positioning and aligning the
punch holder is made of cast steel.
7) Die shoe: Die shoe assembly consisting of die block and die. These in
turn bolted or clamped to the bolster plate.
8) Guide posts and bushing: the punch and die makers once properly
located aligned are held in aligned are held in alignment by means of
guide post and bushing which resist movement or deflection of die
members as operating pressure increase guide post and bushing are part
of the commercially available punch and die holders.
9) Stripper and stripper plate: When the punch has completed its
downward movement and start returning, the scrape strip tries to go up
along with it. The stripper plate prevents this upper movement of scrape
stripes and frees and punches of these for next stroke.
10) Stock stops & Stock guide: Fixed type of stripper sometimes are used to
guide the stock are also where as stock stops locate the work material at a
suitable position in relation to previously blanked surfaced in preparation to
the next downward movement of the punch.
11) Bed: The bed is the lower part of a press frame that serves as a
table to which a bolster plate is mounted.
12) Bolster plate: This is thick plate secured to the press bed, which is
used for locating and supporting the die assembly. It is usually 5 to 12.5
cm thick.
13) Die set: It is unit assembly, which incorporates lower and upper
shoe, two or more guidepost and guidepost bussing.
15) Lower shoe: The lower shoe of a die set is generally mounted on
the bolster plate of a press. The die block is mounted on the lower
shoe. Also, the guideposts are mounted in it.
16) Upper shoe: This is the upper part of the die set, which
contains guidepost bushing.
18) Pit man: It is connecting rod, which is used to transmit motion the
main drive shaft to the press slide.
19) Shut height: It is distance from top of the bed to the bottom of a
slide, with its stroke down and adjustment up.
20) Stroke: The stroke of a press is the distance of ram its up position to
its down position. It is equal to twice the crankshaft and eccentric
drives but it is Variable on the hydraulic press.
[B] SHEARING ACTION IN DIE CUTTING OPERATION: In die
cutting operation the sheet metal stressed in shear between two
cutting edges to the point of fracture beyond it ultimate strength. In die
cutting operation when the punch presses at various places as shown in
fig. layer below the punch are subjected to different type of stresses at
various placed shown in fig. layer below the punch are subjected to
compressive stressed and the bottom most layer of the sheet die are
subjected to tensile stresses, this leads to stretching beyond the elastic
limit. Further moment of punch leads to plastic deformation, reduction
in area and finally fracture start through cleavage planes in a reduced
area.
c) Fracture: After above stage, fracture will start in the reduced area n both
upper and lower cutting edges and if the die and punch is suitable for the
material being cut, these fracture will spread out to word each other and
eventually meet, causing complete separation. Thus the
punch penetrates the metal causing plastic deformation it then shears
it and pushes the cut piece from the sheet.
4. The distance above the bottom of the stroke where the pressure
first occurs.
6. The method of feeding, the direction of feed and the size of sheet
blank or work piece.
[D] CLEARANCE: The die opening must be sufficiently larger than
the punch to permit and clean fracture of the metal. This different is
dimensions between the mating members or a die set are called
“clearance”. This clearance is applied in the following manners. When the
holes has to be held to size, i.e., the hole in the sheet metal is to be
accurate, and slug is to be discarded, the punch is made to the size of
hole and to a die opening size is obtained by adding clearance to the
punch size. C is the amount of clearance per size of the die opening. The
clearance is function of the kind, thickness and temper of the work
material requiring larger clearance than soft material. The exception
being aluminum. The usual clearances per side of the die, for various
metals, are giving below in terms of the stock thickness, t:
The total clearance between punch and die size will be this figure.
These clearances may be determined with the help of the following
relation:
C=0.0032 t (Ts), mm
Where T0 is the shear strength of the material in N/mm2
[E] DIE: The die may be defined as the female part of complete tool
for producing work in press. It also referred to a complete tool
consisting of a pan of mating members for producing work in press.
TYPES OF DIES:
This die may be classified according to the type of press operation and
according to the method of operation.
Type of press operation: according to this to this criterion, the dies may
be classified as: cutting dies and forming dies.
Cutting dies: These dies are used to cut the metal they utilize the
cutting or shearing action. The common cutting dies are: blanking dies,
piercing dies, perforating dies, notching trimming, saving and nibbling
dies etc.
less than 20mm diameter are often made from 20mm or smaller
diameter rod and are left shoulder less until assembly when the punch
pressed tightly in to a counter sunk reamed hole in the punch plate an
the riveted our the shank of the port blow of the punch placed in the
punch plate is always made circular and larger than the piercing section
in older to facilitate assembly to 5mm and 3mm for punch dimension
up to 10mm and 4mm for dimension up to 15mm.
2. Spring
’=
Design:-F K*x
’
Total force on punch= (F-F )/n=
3. Tool Design:-
Specification and material-
4037 Alloy Steel
303-316 Stainless steel
Diameter of punch D=10mm
Length of punch=25mm
Surface hardness RC=60 minimum
Core hardness RC=47 minimum
Yield Strength Mpa
Shear stress to punch a Plate F/A=F/(πdt)
Where F= Calculated force
T=Thickness of sheet plate
Shear yield strength of punch = /2
&Hence design is safe.
4. Design of die:-Diameter of
hole=10mm Clearance C=5% of
Thickness Thickness of sheet 1.16
Therefore,
C=0.05*1.16=0.0805mm
Thus, diameter of Die= 10+2*0.0805=10.16
DRAWINGS OF MACHINE
PARTS
CONCLUSIONS
REFERENCE