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DESIGN PROJECT REPORT

1. Design of Latch jig for Oil Seal Cap

2. Low Cost Automation in Power press

Submitted by

ABHIMANYU PANDEY (20082601)

K.C.RAKESH ROSHAN (20082639)

M.KARTHIK (20082627)

In partial fulfilment for the award of the degree

Of

BACHELOR OF ENGINEERING

IN

PRODUCTION ENGINEERING

DEPARTMENT OF PRODUCTION TECHNOLOGY MADRAS

INSTITUTE OF TECHNOLOGY CAMPUS, CHENNAI-44

ANNA UNIVERSITY CHENNAI

NOVEMBER 2011

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ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

This is to certify that this project report is the bonafide work of

ABHIMANYU PANDEY (20082601)

K.C.RAKESH ROSHAN (20082639)

M.KARTHIK (20082627)

This project has been completed and submitted to The Department of

Production Technology, M.I.T, Anna University, Chennai in partial fulfilment

of the requirements for the award of the degree of BACHELOR OF

ENGINEERING in Production Engineering. Certified further that to the best of

our knowledge, the work reported herein does not form part of any thesis or

dissertation on the basis of which a degree of award was conferred on an earlier

occasion on these or any other candidates.

MR. A. JOTHILINGAM, Mr. S.GAJENDRAN,

PROFESSOR AND HEAD , ASSOCIATE PROFESSOR,

Dept. of Production Engineering, Dept. of Production Engineering,

Madras Institute of Engineering, Madras Institute of Engineering,

Anna University, Anna University,

Chennai- 600 044. Chennai- 600 044.

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ACKNOWLEDGEMENT

We wish to thank Prof. A. JOTHILINGAM, Professor and Head of

Department, Department of Production Technology, Madras Institute

of Technology, Anna University for granting permission and encouraging us

to carry out this project work.

It gives us immense pleasure to express our deep sense of gratitude to

our beloved guide, Mr. S. GAJENDRAN, Associate Professor, Department

of Production Technology, Madras Institute of Technology. We thank for his

act of benevolence on us.

We would like to convey our heartfelt thanks to Mr. S.

CHOODESWARAN, our project coordinator, Department of Production

Technology for his constant support throughout the course of the work.

We also thank our faculty advisor, Mr. P.GANESH, Assistant

Professor, Department of Production Technology, who has been extremely

supportive during the course of the project.

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ABSTRACT

The component which we selected for our design project is Oil Seal Cap. This

is used in Transfer case to prevent the Oil leak from the shafts. The

constructional aspects of this component are that it has got a circular shape with

a center hole that will fit the oil seal. The outer periphery of the oil seal cap has

got four symmetrical semi circular projections. A Hole has to be drilled in each

of the semi circular projection. These holes will become the passage for the nuts

so that this Oil Seal Cap can be fixed to the Transfer case. We are designing a

Jig for performing Drilling operation in each of the four Semi Circular

projections. The Clamp, Locators and pins used for construction of the jig are

explained below.

A Drill Jig is to be designed for the drilling of holes in semi circular projections

for inserting nuts through it. Nest locator made of Cast Iron is used for locating

the work piece. A Template made of Mild Steel is used for covering the upper

portion of the work piece. This Template has got four Renewable type drill

bushes for guiding the drill bit. Two pins are used to locate the work piece at

desired position and to provide constraint for rotation of work piece. Two

Clamping screw made of Mild Steel is used to provide adequate Clamping

force. Thus a Jig is being designed for accurate drilling of holes in Oil Seal Cap

used in Transfer Case.

INTRODUCTION

In metalworking and woodworking, a jig is a type of tool used to control the

location and/or motion of another tool. A jig's primary purpose is to

provide repeatability, accuracy, and interchange ability in the manufacturing of

products. A jig is often confused with a fixture; a fixture holds the work in a

fixed location. A device that does both functions (holding the work and guiding

a tool) is called a jig.

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An example of a jig is when a key is duplicated; the original is used as a jig so

the new key can have the same path as the old one. Since the advent

of automation and computer numerical controlled (CNC) machines, jigs are

often not required because the tool path is digitally programmed and stored in

memory. Jigs may be made for reforming plastics.

Jigs or templates have been known long before the industrial age. There are

many types of jigs, and each one is custom-tailored to do a specific job. Many

jigs are created because there is a necessity to do so by the tradesmen. Some are

to increase productivity, to do repetitious activities and to do a job more

precisely.

Some types of jigs are also called templates or guides. Jigs include machining

jigs, woodworking jigs (e.g. tapering jig), welders' jigs, jewelers' jigs, and many

others.

Jigs and fixtures are production-work holding devices used to manufacture

duplicate parts accurately. The correct relationship and alignment between the

cutter or other tool, and the work piece must be maintained. To do this, a jig or

fixture is designed and built to hold, support and locate every part to ensure that

each is drilled or machined within the specified limits. Jigs and fixtures are so

closely related that the terms are sometimes confused or used interchangeably.

The difference is in the way tool is guided to the work piece.

A jig is a special device that holds, supports or is placed on a part to be

machined. It is a production tool made so that it not only locates and holds the

work piece but also guides the cutting tool as the operation is performed. Jigs

are usually fitted with hardened steel bushings for guiding drills or other cutting

tools.

A drill jig is a device for ensuring a hole to be drilled, tapped or reamed, in a

work piece will be machined in proper place. Thus, instead of laying out the

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position of each hole on each work piece with the aid of square, straight edge,

and centre punch, the operator uses a jig to guide the drill into the proper place.

Jigs makes it possible to drill ream and tap holes at much greater speed and with

greater accuracy that holes are produced by conventional method. Another

advantage is that skilled workers are not required when the jigs are used.

Responsibility for the accuracy of hole location is taken from the

operator and given to the jig. The hole pattern should be within the

required tolerance in each part. This is the basis for the interchangeable

part concept that has made Eli Whitney’s name so prominent in the

industrial history.

The term jig should be used only for devices employed while drilling reaming

or tapping holes. It is not fastened to the machining on which it is used and may

be moved around the table of the drilling machine to bring each bushing directly

under the table. Jigs physically limit and control the path of the cutting tool.

DRILL JIG

A drill jig is a type of jig that expedites repetitive hole center location on

multiple interchangeable parts by acting as a template to guide the twist drill or

other boring device into the precise location of each intended hole center. In

metalworking practice, typically a hardened drill bushing lines each hole on the

jig plate to keep the tool from damaging the jig.

Drill jigs started falling into disuse with the invention of the jig borer.

Since the widespread penetration of the manufacturing industry by

CNC machine tools, in which servo controls are capable of moving the tool to

the correct location automatically, the need for drill jigs (and for the jobs of

the drill press operators who used them) is much less than it previously was.

Different types of Drill jigs:

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1. Plate jigs or channel jig.

2. Angle plate jig.

3. Box jig.

4. Leaf or latch jig.

5. Sandwich jig.

6. Trunnion jig.

7. Jig for multi spindle machines.

8. Template jig

9. Universal Jig

MAIN ACCESSORIES OF JIG

Locators,

Clamps,

Bushing.

LOCATORS

The various forces acting upon the work piece during a machining

operation necessitate its means of clamping position after it has been correctly

located. Configuration is the major factor in determining how your work piece

will be located. Examination of a typical work piece from the metal industries

shows that the configuration is determined by a combination of flat, circular,

and irregular surfaces. A flat surface is one that lies in one plane and circular

surface that is made from the segment of the circle. The inside surface of the

circle segment may be used to form a concave surface. Irregular surfaces are

not flat or circular; they may or may not be geometrical true. Each of the three

proceeding surface types may be rough of finished.

CLAMPS

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The methods of clamping depend upon the type of locating device and in turn

it depends upon the original machining operation and the configuration of the

part. Once the work piece is located it is necessary to press it against the

locating surface and hold it there against the forces acting upon it. Tool

designer refer to this action as clamping and mechanism used for this action are

known as clamps. Numerous types of clamps have been developed. It is

sometimes difficult to choose between two types when designing a specific tool.

In general, the choice of clamp is largely determined by work piece and the king

of operation.

BUSHINGS

The Bushings are used to guide drills, reamers and other cutting tools into

the proper position of the work piece; they are made of tool steels or hardened

to RC 60-64, to provide a wear resisting surface. They are precision made. The

outside being ground and the inside either ground or lapped to within 0.0003

inch concentricity.

GENERAL CONSIDERATION IN THE DESIGN OF DRILL

JIGS

LOCATION

Locating surface should be as small as possible.

Sharp corners in the locating surface must be avoided.

Locating pins should be easily accessible and visible the operator.

Adjustable locators should be provided for rough surface.

CLAMPING

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Clamping should always be arranged directly above the points

supporting the wo

Quick acting clamps should be sued wherever possible.

Position of clamps should provide best resistance to the cutting tool.

Clamps should allow rapid loading and unloading of the components.

CLEARANCE

Adequate space in the form of channel base should be provided to

enable the metal chips to be blown clear easily.

STABILITY AND RIGIDITY

Jigs should possess high rigidity to withstand the cutting force.

A lease four legs should be provided for the jigs for the stability.

HANDLING

No sharp corners are present and provide lifting points if it is heavy.

Make the equipment as rigid as is necessary for the operation.

PARTS OF JIGS

1. Jig body

2. Location Plug

3. Locking screw

4. Latch plate

5. Drill bush

6. Clamping pad

7. Wing nut

8. Workpiece

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SPECIFICATION (FROM DESIGN DATA BOOK)

1. Wing nut:

A wing nut is a type of nut with two large metal "wings," one on each side, so it

can be easily tightened and loosened by hand without tools. It is sometimes

called a thumbscrew. It is used to lock the swinging plate.

d=M8

e=40

l=35

l1=20

2. Drill Bush:

A drill bushing, also known as a jig bushing, is a tool used in metalworking jigs

to guide cutting tools, most commonly drill bits. Other tools that are commonly

used in a drill bushing include counter bores, countersinks, and reamers. They

are designed to guide, position, and support the cutting tool. It is made of Oil

hardened Non Shrinking Tool steel (OHNS)

OHNS:

It is also named as high carbon or high chromium steel. This type of steel is oil

hardened from 60 to 64 RC. It contains 1% carbon, 0.5 to 2 % tungsten and 0.45

to 1% chromium. These are used for fine parts such as taps, hand reamers,

engraving cutters etc. It is also used for fine intricate shape press tools.

Type: Fixed bush

No’s: 4

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Material: Oil hardened Non-shrinking tool steel

d1=12

l1=20

l2=16

d2=18

d3=22

With tolerances

Inner diameter: 12F7Φ

Tolerance: +0.000 to +0.012 mm

Outer diameter: 18H6Φ

Tolerance: -0.000 to -0.018 mm

3. Locator:

Locators are used to locate the components. The locator system should facilitate

easy and quick loading of the work piece. Here location plugs with stepped

diameter are used to enable locating from the internal surfaces. As pointed out

earlier, locating a work piece from an internal diameter is the most-efficient

form of location. The locater in this case has been originally cast along with jig

body and is an integral part of it. The stepped surfaces are milled and finished to

satisfaction so that the work piece when it is seated on to it is in a balanced

state.

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The bigger step supports the job while it is being drilled whereas the smaller

step enters the internal cavity of the job to arrest the translation in the plane

under consideration.

Step 1 diameter: 80 mm

Step 2 diameter: 50 mm

5. Jig body

Width of jig plate= 180 mm

Length of plate= 2xTp + Lw + allowance

Where,

Tp- thickness of jig plate=10 mm

Lw-Length of work piece= 130 mm

Length of jig was calculated to be= 180 mm

Height of jig=hw+Tp+clearance

Clearance of the ductile material= 0.5 X drill diameter

Height of jig body was calculated to be=110mm

6. Clamping screw with pressure pad:

A clamp screw is an adjustable closure with a threaded cylinder and flared head.

Many clamp screws have a similar appearance to a common bolt when they are

detached from the clamp assembly. Clamp screws are often tightened by hand

for fine adjustments to the tension of a clamp. The size of a clamp opening

gradually decreases as the clamp screw is twisted farther into place. Speed of

operation, operator fatigue and strategic positioning are other important

considerations for choosing a clamping system.

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From design data book 5.104

D1=88 mm

D2=11.2 mm

D3= 23 mm

D4= 28 mm

H= 20 mm

7. Jig Feet:

The entire body of jig should not be rest on the machine table directly.

Therefore jig feet are used at the bottom of the jig. The jig feet are either cast

with the jig body or detachable or welded to the base. They are usually

hardened and ground to have flat bottom. In this case the jig feet are cast as an

integral part of the jig body.

CALCULATION:

DETERMINATION OF AXIAL THRUST:

Axial thrust = 630 K z d s^0.85 N

where,

K = material factor

z = number of cutting edges in contact

d = diameter of drill, mm

s = feed, mm

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From P.S.G DESIGN DATA BOOK (page nos. 12.1, 12.2, 12.22),

K = 1.88 (for Steel)

z = 2

d = 10mm

s = 0.125mm

Axial thrust = 630 * 1.88 * 2 * 10 * (0.125^0.85) N

Axial thrust = 4044.84 N.

DETERMINATION OF POWER:

Power = (2.82 * 10^-6) * K n z (d^2) * (0.15 + 7.87s) kW

where,

n = speed, rpm

From P.S.G DESIGN DATA BOOK (page nos. 12.1, 12.2, 12.22),

n = 700 rpm

Power = (2.82 * 10^-6) * 0.55 * 2750 * 2 * (10^2) * [0.15 + (7.87 * 0.1)] kW

Power = 0.850 kW

COST ESTIMATION

SNo Name Amount (Rs)

1 Material 1500

2 Wing nut 150

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3 Clamp 150

4 Milling 200

5 Welding 200

Total 2200

CONCLUSION

The leaf jig is designed for an oil seal cap which is used in transfer cases of

automobiles and four holes of 10 mm diameter are drilled.

As explained, it could be seen that this is a manual jig which as well is simple.

This can very well be put into use for mass production also, if used in a proper

way. Automatic jigs or similar manual jigs with different locators and clamping

are very costly. Viability and elimination of tedious procedures are the order of

the day. Hence a cost-effective and easy-to-handle drill jig has been designed to

produce four holes on the given work piece of required dimensions.

REFERENCES

1. Jig and fixture design

-by Edward Hoffman

2. Website: nptel.iitm.ac.in

LOW COST AUTOMATION IN A POWER PRESS

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2.1 NEED FOR AUTOMATION

The aim of this project is to design a hydro-pneumatic power press using

low cost automation.

This project mainly emphasizes on reduction of working time and labor

cost. The working time should be reduced in order to increase the productivity

of any industry. Labor cost reduction is also very important nowadays, so that

even small scale industries can afford to go for automation.

The press that we have designed has proved to provide large tonnage

capacity in small size. It also decreases the fatigue of the operator by reducing

the consumption of human work. This device also ensures safety of the

operator’s hand as Two Hand Safety system is included in the circuit.

Pneumatic power is used in this press for all movements as air is a cheap

power source and also it is readily available. Pneumatics also ensures safer

operation and ease of fabrication of components. For Punching operation alone

hydraulic power is used in order to obtain very high pressure and to avoid

fluctuation.

2.2 HYDRO PNEUMATIC PRESS

Many Industries are using manual presses like toggle presses, fly presses,

arbor presses for blanking, piercing, riveting, bending, embossing, etc., It is also

used for forming two or more components in Manufacturing Industry.

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Manual operation of these presses gives fatigue to the operator, since he

has to exert physical energy. Due to this the efficiency also gets lowered down.

Considering these facts, the Hydro pneumatic press has been designed,

which will reduce the wastage of human energy and increase the production

rate.

We know that hydraulic system is applied to attain precise movement.

But in Pneumatics, due to the compressibility characteristic of the air, the air

cylinder tends to slow down on meeting an increase in load and to accelerate or

jump forward when working against a load which suddenly decreases. So,

pneumatic actuators are not suitable for the finer movement of the machine tool

movements.

These problems can be solved by combining the two fluids – air and oil.

By the use of these two media, the quick action of air and the smooth high

pressure action of oil blend ideally to provide a concept for the design of new

Hydro-Pneumatic press. It should be made clear that although the two fluids are

used in the circuit they are not to be mixed. In fact every precaution is taken to

keep them separated.

The basic laws of Hydraulic and Pneumatics are Pascal’s law, Boyle’s

law, Charles’ law, and Gay lussac’s law. These laws are obeyed by our

Hydro-Pneumatic press.

2.3 ADVANTAGES OF FLUID POWER SYSTEMS;

The fluid power drives are more compact than a mechanical dirve

because it eliminates the need for links like cams and gears.

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Multiplication of small forces to achieve greater forces for performing

work.

It easily provides infinite and step-less variable speed control which is

difficult to botain from other drives.

Accuracy in controlling small or large forces with instant reversal if

possible with hydraulic systems.

Constant force is possible in fluid power system regardless of spcial

motion requirements, whether the work output moves a few millimeters

or several meters per minute.

As the medium of power transmission is a fluid, it is not subjected to

any breakage of parts as in a mechanical transmission.

The parts of hydraulic system are lubricated with the hydraulic liquid

itself.

COMPARISON OF PNEUMATIC AND HYDRAULIC

SYSTEM:

For automation, most of the trade-offs favour pneumatic actuators

since pneumatic system have low weight and leakage co-effificent.

The most significant difference between hydraulic and pneumatic

system is compressibility, which usually signifies disadvantage.

Further, the stiffness or impedence of the pneumatic system can be

controlled more easily than with hydraulic counterpart.

Moreover, a pneumatic system allows easy energy storage. The

mechanical energy for automation can be stored as compressed air at a

high pressure. A regulator can expand the stored air to proper working

pressure.

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2.4 CONSTRUCTION OF HYDRO-PNEUMATIC PRESS:

Basically the hydro-pneumatic press consists of the following parts,

Hydro-pneumatic cylinder

Cylinder mounting plate

Supporting pillars

Base plate

Pneumatic control systems

Electrical control panel

Pneumatic pipelines

1. Hydro-pneumatic cylinder:

The main pressing operation of the press is given by this cylinder and

hence it is also known as actuating cylinder. This hydro-pneumatic cylinder is

the active component in the press and it consists of the below parts,

Cap nut

Top end plate

Top barrel

Primary stroke piston

Top partition block

Middle barrel

Secondary stroke piston

By pass rod

Bottom partition block

Bottom barrel

Power stroke piston

Bottom end plate

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O-rings

2. Cylinder mounting plate:

It is a mild steel block which is capable to withstand a high pressure

caused by the hydro-pneumatic cylinder. It consisting of drilled hole of

diameter 32mm at extreme ends for accommodating the supporting pillars. It

also consists of drilled hole at the centre of the plate for the reciprocation of the

power stroke piston and for fixing the cylinder to the base structure. This plate

is of 38mm thickness.

3. Supporting pillars:

The supporting pillars are made up of mild steel of diameter 32mm. the

whole weight of the cylinder and the cylinder mounting plate will act on these

shafts. Usually the raw material is of greater diameter and then it is turned to

the required diameter.

4. Base plate:

This is the plate where the job will be placed and the operation is

performed. For facilitating the clamping operation a T-slot has been provided.

This block is of thickness 40mm and cross-section 350mm x 240mm. It

consists of holes for accommodating the supporting pillars.

5. Pneumatic control systems:

This system includes various DCV’s, FRL unit, Mufflers, etc. They are

used to regulate and direct the flow of air in the respective pipelines.

Solenoid Operated Direction Control Valve:

A very common way to actuate a spool valve is by using a solenoid.

When the electric coil (solenoid) is energized it creates a magnetic force that

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pulls the armature in to the coil. This causes the armature to push to the push

rod to move the spool. There are no seals around the armature to wear or restrict

its movement; this allows all the power developed by the solenoid to be

transmitted to the valve spool without having to overcome seal friction. Impact

loads which frequently cause pre mature solenoid valve failure are eliminated

with construction. Thus both the DCV’s used here are solenoid operated.

WORKING:

The Working of the Hydro-Pneumatic press comprises of four stages.

Start Position

Low Force High Speed approach

High force short travel power stroke

Low force Rapid retraction

Start Position:

In this stage all the pistons are in their respective TDC positions. The air

is sent into the port 3 of the press and the air from both 1 and 2 ports are

exhausted. The oil is filled into top barrel through the bore in the primary stroke

piston rod. Simultaneously oil gets filled in the bottom barrel through the

bypass rod. In this position, the oil remains static and no pressure is exerted to

it. The punch head remains in the maximum distance from the base plate.

Low Force High Speed Approach:

When the DCV A is actuated, the compressed air flows through the port

1. This results in the extension of the Primary stroke piston. So the primary

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stroke piston makes the oil to exert pressure on the Power stroke piston. Thus,

the rapid extension of the punch head takes place.

High Force Short Travel Power Stroke:

When the DCV B is also actuated along with the DCV A, the compressed

air is made to enter into the port 2. This extends the secondary stroke piston.

The rod of this secondary stroke piston enters into the bore in the Power stroke

piston. The same force is exerted in the very small area which results in a very

high pressure. This very high pressure is capable of doing the punching

operation.

Low Force Rapid Retraction:

When both the solenoids are de-energized, both the DCV’s come to their

offset mode, thus exhausting the ports 1 and 2, and sending air into the port 3.

This results in the retraction of all the three pistons to their initial positions.

Two Hand Safety Operation:

Push Buttons are provided to energize the solenoids. When the first

button is pressed, Rapid extension takes place. By keeping the first button

down, if the second button is also pressed, punching operation takes place. If

both the buttons are released, then the retraction takes place. If only button 2 is

pressed, the ram goes to its initial position. Thus, to make the press working, the

worker has to use both of his hands. So, safety is ensured for the worker’s

hands.

2.6 PNEUMATIC ELEMENTS SPECIFICATIONS

Differential Pressure : 2 to 10 bar

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Design : Disk Seat.

Type of Reset : Spring

Standard Nominal Flow rate : 900 1/min

Weight : 280 grams

Housing : Die Cast Aluminum

Seals : Polyurethane

FRI, max supply pressure : 1Mpa/10 bar

Drain : Automatic

Regulator exhaust capacity : Less than 0.25 SCFM

Max supply pressure 10 bar

Solenoid type : 2/2 solenoid

Stainless Steel

Temperature Range 10 to 55 deg C

Power 24V DC

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2.8 SPECIFICATIONS

Size : 350mm x 250mm x 1000mm

Material : All steel body

Input air : 6.2 kg/cm2

Electric power : For timer 12V DC or 24V DC

For solenoid 48V AC or 220V AC

Bed to Ram Height : 150mm

Bed Size : 350mm x 240mm

Bed Plate Thickness : 40mm

Stroke Length : 72mm

2.9 CIRCUIT EXPLANATION

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The DCV A is two position five port solenoid operated spring offset

valve. The port 1 and 3 of the cylinder are connected in the offset position of the

valve A. The DCV B is two position three port solenoid operated spring offset

calve, which connects the opening 2 of the cylinder in the offset port condition

initially. Input source to both the valves are given in a single line. An

emergency unit is set up which consist of a solenoid actuated two position two

port DCV. The input unit includes compressor, FRL unit, and pressure

regulator. The exhaust port of each DCV is connected with muffler.

Circuit performance:

When DCV A is energized, hence it shifts to position of the valve. Thus

the pressurized air supply is given to opening 1 of the cylinder and the air

exhaust from the opening 3 of the cylinder. When DCV B is energized and

hence supply is given to opening 2 of the cylinder. When both the DCV’s are in

de-energized condition, the supply is given only to opening 3 and hence it helps

in retraction of the piston. When the emergency valve is energized the supply

to the entire unit is stopped immediately.

Relay diagram:

The electrical diagram is called the relay diagram. PB1 (NO) is a push

button when pressed, SOL A gets actuated and hence extension takes place.

When PB2 (NO) is pressed, SOL B gets actuated and hence power stroke takes

place, when stop button is NC condition. When it is pushed, the 1-CR gets de-

energized, this breaks 1-CR and de-energizes it, and hence SOL C is de-

activated.

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2.12 CALCULATION OF TONNAGE:

Material Factor:

For Mild Steel : 0.95

For Aluminium : 0.5

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For High Carbon Steel : 1.4

Shear Factor:

For Flat Bottom Dies : 1

For Concave Surface Dies : 0.6 to 0.9

Perimeter:

According to the geometry of the surface to be punched

Eg : For Circular Hole =3.14 x diameter

Tonnage =Material Factor x Shear Factor x Perimeter x Thickness x 0.102

=0.95 x 1 x 3.14 x

SALIENT FEATURES:

Fast Action

Compact, Light Weight and vibration free pneumatic valves

Force and speed infinitely adjustable

Energy efficient: 50% to 70% raising over equivalent hydraulic and

pneumatic systems

Low cost up to 60% cheaper than equivalent hydraulic press

Safety: true non tie down, interlocked two handed safety operation.

Optimally adapted to individual requirements due to its modular

design 

High flexibility and economic efficiency due to short changeover

times 

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Easy and accurate positioning of tools due to the precise alignment

between ram bore and the ground press table 

The force output pre selector allows reducing the pressure for the

power stroke to 1 bar / 15.4 ps i. This reduces the nominal press force

to 1/6 of the maximum force.

No mechanical compression spring in the cylinder of the hydro-

pneumatic system, providing a long service life

Low maintenance resulting in high productivity 

Long service life and precision due to maintenance-free guides 

Tool protection due to smooth switchover from rapid approach stroke

to power stroke 

Additional safety when using heavy tools due to the optional ram drift

lock device for retention of ram in home position. 

Low noise level (< 75 dBA)

APPLICATIONS:

Assembling, riveting, staking, swaging, crimping, marking, numbering,

deforming, stamping, dismantling

High force over a short distance

2.13 COST ESTIMATION:

Cylinder expenses :

Solenoid operated DCVs :

FRL Unit

Air Compressor

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Other expenses

Total Cost

2.14 CONCLUSION:

All Basic expectations of today’s industry such as automation increased production, low cost, and appreciable quality are met by this Hydro-Pneumatic press. Low cost is proves by using Pneumatic source and getting the same tonnage capacity of Hydraulic press.

A single compressor is enough to run two or more Hydro-Pneumatic presses. The safety of the worker is also ensured by employing the Two Hand Safety System in the fluid circuit.

This press is also portable and reliable as it has very small machine structures and can give the large tonnage. So this press is expected to meet today’s Industrial Manufacturing scenario.

REFERENCES

1. “Fluid power with applications” by “Anthony Esposito” , Pearson education, Inc. 2000

2. “A text book of production technology” by “D. O.P.Khanna”, Dhanpat Rai publications, 2005

3. “PSG Design Data Book” by “Faculty of Mechanical Engineers”, Kalaikathir publications, 2005

4. “Hydraulic and pneumatic controls” by “Srinivasan R”, Vijay Nicole Private Ltd.

5. “A textbook of Machine Design” by “Khurmi R S, Gupta J K”, S. Chand & company Ltd, 2005.

6. “Press tool Design and Construction” by “Prakah H.Joshi”, Wheeler Publishing, 1996.

7. “Pneumatic Technical Data”, Trade and Technical Press Ltd, England.