Project Guide :Dr. KL. Hari Krishna, M.Tech., Ph. D.

Team Members:
V.M.Marimurugan-312216114062
V.Mathiazhagan-312216114063
K.Jayasundaram-312216114305
ABSTRACT:
Pneumatics systems are extensively used in a wide range of industries and factories
and manufacturing sector entities. Pneumatics system are noted for their simplicity,
reliability, and ease of operation. Also they are suitable for fast and rapid
application of force.
The purpose of this project is to design a simple, easily operated pneumatic
punching machine that is sturdy and strong. The pneumatic press tool has an
advantage of working in low pressure, that is even a pressure of 6 bar is enough for
operating the unit. The pressurized air passing through the tubes to the cylinder,
forces the piston out whose power through the linkage is transmitted to the punch.
The work piece thus got is for required dimensions and the piece can be collected
through the land clearance provided in the die. The die used in this is fixed such
that the die of required shape can be used according to the requirement. This
enables us to use different type punch dies resulting in a wide range of products.
Different types of punch as requirement can be thus got. According to the work
material the operating pressure can be varied.
 OBJECTIVE:
To find an alternative way for flywheel punching system

Utilization of air as a working fluid which is abundant in nature

To fabricate less maintenance punching system

To fabricate a simple and effective mechanism for pneumatic punching

To create a workless and cheap method of punching system

METHODOLOGY:
Referring to
Find The
Other
Problem
Solutions

Establishment Design
of Idea. calculations

CAD Fabrication
modeling And Testing
INTRODUCTION:
•Punching is a metal forming process that uses a punch press to force a
tool, called a punch, through the work piece to create a hole via shearing

•In Industries , punching machine are operated with the help of

flywheel. but , it is slow process and takes more time. So, the pneumatic
system is introduced

•Pneumatic punching system in which the flywheel and motor is

replaced with double acting cylinder and air compressor. It is fast and
efficient process when compared to flywheel punching machine
Why pneumatics?
Pneumatics is an attractive medium for low cost mechanization
particularly for sequential and repetitive operations.

Many factories and plant already have a compressed air system,

which is capable of providing energy requirements and control
system

The main advantage of pneumatics system are usually economic

and simplicity the latter reducing maintenance to a low level.

It can have outstanding advantages in term of safety.

Drawbacks in flywheel system
They can take a lot of space

They are expensive to manufacture

Building material is always a limitation for it

It’s heavy, which increases fuel consumption.

 It has a high rotational inertia, which reduces how fast engine revs can
come up, or slow down, which latter increases stress on the engine.

 It has to be exactly balanced to avoid severe vibration.

 Slowing a flywheel wastes the energy used previously to accelerate it,

unless special provision is made to recapture the energy.
DESIGN CALCULATION
1. Shear Force:

Shear strength of Aluminum 6063 = 160MPa

Perimeter of hole = 5.5mm
Thickness of Aluminum sheet = 1.5mm

Shear force = shear strength x perimeter of hole x thickness

= 160 x П x 5.5 x 1.5
= 4146.902N
DESIGN CALCULATION
2.Piston Diameter:

Applied pressure = 7 Bar

Shear force = 4146.902N
Area of cylinder =(shear Force/Applied Pressure)

Piston Diameter =86.84 mm

Standard piston Diameter = 100mm

CALCULATION:
THEORITICAL AIR CONSUMPTION
𝐶 = [(A1² + A2 ² )× ((𝑃a + Patm ) / Patm) × 𝐿] /1000

Where, Pa = Applied pressure in bar

A1 = Area of piston while punching
A2 = Area of piston while return stroke
L = Length of stroke in cm.

𝐶 = [𝜋/4 × 196× ((7 + 1.013) / 1.013 )× 12.5] / 1000

C =15.3938 liters/cycle
CAD MODEL ISOMETRIC VIEW
CAD MODEL FRONT VIEW
COMPONENTS USED
 Double acting pneumatic cylinder
 ¾ DC Solenoid valve
 Hoses
 Connectors
 Silencers
 Punch
 Punch Die
 Aluminum sheet
 Bolts
FABRICATION
• After the procurement of necessary parts such as mild steel,
cylinder ,solenoid valve etc., the arrangement was first
modeled and assembled using a standard modeling software’s
like Solid works.
• First the base was fabricated to the required dimensions and the
arc welding was done and then rigidity and the integrity of the
base was confirmed by the square scale and dimension was
checked
• The support columns were fixed to the base and the arc
welding was done.
• The pneumatic cylinder was fixed on the support column
using bolts
FABRICATON PICTURES
TECHNICAL DISCUSSION
FRAMES:

It is the set up of mild steel over which every component is placed. Moreover,
it provides the stability to the machine. It is present at the base helps in
curbing the vibration if any occurs, during the operation of the cycle

PNEUMATIC CYLINDERS:

Pneumatic cylinder is a mechanical device which uses the power of the

compressed gas to produce a force in a reciprocating linear motion. This force
produced helps to punch a hole in metal sheet
 COST ESTIMATION
SL NO COMPONENTS QUANTITY COST
1 Double acting cylinder 1 3000
2 3/4 DCV 1 1500
3 Tools Rent 600
4 Connector 5 200
5 Hose 3 MTRS 200
6 Frame 1 1500
7 Silencer 2 150
8 Bolt &nut 4 80
9 Labour charge 1500
10 Transportation 500
11 Report 200
TOTAL 9430
ADVANTAGES
 The outstanding advantage of pneumatic system is the control valve which
consistently applies a specified load with minimum effort.
 From thin foils to metal sheets can be pierced according to desirable shapes.
 It can be modified to any extend to bring out the required effort.
 Its outcome can be utilized properly in the extensive mechanical field.
 In modern payer plants this pneumatic system can be used for loading press roll.
 Simple construction than the mechanical and hydraulic presses.
 Compared to hydraulic and mechanical presses pneumatic press is economical.
 It does not require current carrying cables.
 No extra skill is required for operating this system.
 Operation is very smooth and in this system we can get more output by applying
less effort.
 This system can be effectively used for punch mark in industrial materials such
as industries name, address or number of product.
CONCLUSION
The project carried out to made an impressing task in the
field of small scale industries and automobile maintenance
shops. It is very usefully for the workers to carry out a
number of operations in a single machine , when
upgraded. This project has also reduced the cost involved
in the concern. Project has been designed to perform the
entire requirement task which has also been provided.
REFERENCES
 J. Gresham, W. Cantwell, M.J. Cardew Hall, P. Compston, S.
Kalyanasundaram. Drawing behaviour of metal–composite sandwich
structures, Volume 75, Issues 1–4, Pages 305–312, September 2006
 A.A. Ambekar, S.K Maiti, U.P Singh, P.P Date, K Narasimhan,
Assessment of influence of some process parameters on sheet metal
blanking,” Volume 102, Issues 1–3, Pages 249–256, 15 May 2000.
 D. Dornfeld and S. Min, A Review of Burr Formation in Machining,
Consortium on Deburring and Edge Finishing, Laboratory for
Manufacturing and Sustainability, UC Berkeley, 2007.
 Prof. T. Z. Quazi, R.S.Shaikh, “An Overview of Clearance
Optimization in Sheet Metal Blanking Process,”IJMER, Vol.2,
Issue.6, pp-4547- 4558, Nov-Dec. 2012.
THANK YOU