pneumatic auto feed multi operation machine
TRANSCRIPT
1
CHAPTER 1
INTRODUCTION
2
INTRODUCTION
1.1 INTRODUCTION:
The main objective of our project is to perform various machining operations using
“Auto feed mechanism” in drilling machine with the help of pneumatic sources. For a
developing industry the operation performed and the parts (or) components produced should
have it minimum possible production cost for it to run profitability.
In small-scale industries and automobile maintenance shops, there are frequent needs
of tightening and loosening of screws, drilling, boring, grinding ,reaming ,taping and broaching
machine.
Huge and complicated designed parts cannot be machined with the help of an ordinary
machine and further for every operation separate machine is required therefore increasing the
number of machines required and increasing the area required for them to be accommodated
and hence overall initial cost required. In our project the above complicated problems are
minimized.
By the application of pneumatics, the pneumatic cylinder with piston which is operated
by an air compressor will give the successive action to operate this machine. By this we can
achieve our industrial requirements.
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1.2 AUTOMATION:
Automation is the conversion of a work process, a procedure, or equipment to
automatic rather than human operation or control. Automation does not simply transfer
human functions to machines, but involves a deep reorganization of the work process, during
which both the human and the machine functions are redefined. Early automation relied on
mechanical and electromechanical control devices; during the last 40 years, however, the
computer gradually became the leading vehicle of automation. Modern automation is usually
associated with computerization.
1.3 NEED FOR AUTOMATION:
Automation can be achieved through computers, hydraulics, pneumatics, robotics, etc.,
of these sources, pneumatics form an attractive medium for low cost automation.
The main advantage of a pneumatic system is that it is economical and simple in
construction which makes it different from other sources of automation.
Automation plays an important role in mass production. Nowadays almost all the
manufacturing process is changing to automated machines in order to deliver the products with
better quality and at a faster rate. The manufacturing operation is being automated for the
following reasons.
To achieve mass production
To reduce man power
To increase the efficiency of the plant
To reduce the work load
To reduce the production cost
To reduce the production time
To reduce the material handling
To reduce the fatigue of workers
To achieve good product quality
Less Maintenance
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1.4 PNEUMATICS:
The word ‘pneuma’ comes from Greek and means breather wind. The word pneumatics
is the study of air movement and its phenomena is derived from the word pneuma. Today
pneumatics is mainly understood to means the application of air as a working medium in
industry especially in driving and controlling of machines and equipment.
Pneumatics has been considered to be used to carry out simple mechanical tasks. But, in
today’s world it is playing an important role by becoming one of the major sources for
automation, and the recent developments in this field has made it a useful technology in the
field of complex automated applications.
Pneumatic systems operate on a supply of compressed air which must be 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 will indeed be necessary to deal with the
section of compressed air supply.
The key part of any pneumatic machine is supply of compressed air is by means
reciprocating compressor. A compressor is a machine that takes in air, gas at a certain pressure
and delivers the air at a high pressure.
Compressor capacity is the actual quantity of air compressed and delivered. And the
volume expressed is that of the air at intake conditions namely at atmosphere pressure and
normal ambient temperature.
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1.5 PNEUMATIC ACTUATOR:
Physical processes proceeding in drives are submitted to the gas laws. The gas laws are a
set of laws that describe the relationship between thermodynamic temperature (T), pressure
(P) and volume (V) of gases. Three of these laws, Boyle’s law, Charles’s law, and Gay-Lussac’s
law, may be combined to form the combined gas law
P1V1 =
P2V2
T1 T2
Which with the addition of Avogadro’s law later gave way to the ideal gas law. Other
important gas laws include Dalton’s law of partial pressures. The kinetic theory of gases,
Graham’s law of effusion and root mean square velocity explains how individual molecules act
in a gas and their relation to pressure, volume, and temperature. A gas that obeys these gas
laws is known exactly as an ideal gas (or perfect gas). An ideal gas does not exist; however,
some gases follow the laws more closely than the others in given standard conditions.
The most important gas law is the ideal gas law, which states that: PV = nRT Other gas laws, such as vander Waals equation, seek to correct the ideal gas laws to
reflect the behaviour of actual gases. Van der Waals equation alters the ideal gas law to reflect
how actual gases function using a series of calculated values called van der Waals constant
Any gas can be used in pneumatic system but air is the mostly used system now a days.
1.6 SELECTION OF PNEUMATICS:
Mechanization is broadly defined as the replacement of manual effort by mechanical
power. Pneumatic is an attractive medium for low cost mechanizations particularly for
sequential (or) repetitive operations. Many factories and plants already have a compressed air
system, which is capable of providing the power (or) energy requirements and the control
system (although equally pneumatic control systems may be economic and can be
advantageously applied to other forms of power).
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The main advantage of a pneumatic system is it is economically cheap and simple in
design, also reducing maintenance costs. It can also have an out standing advantage in terms of
safety.
1.7 PNEUMATIC POWER
Pneumatic systems use pressurised gas to transmit and control power.
Pneumatic systems typically use air as the fluid medium because air is safe, free and
readily available. 1.7.1 Advantages of Pneumatics:
1. Air used in pneumatic systems can be directly exhausted in to the surrounding
environment and hence the need of special reservoirs and no-leak system
designs are eliminated.
2. Pneumatic systems are simple in design and economical.
3. Control of pneumatic systems is easier.
1.7.2 Disadvantages of Pneumatics:
1. Pneumatic systems exhibit spongy characteristics due to compressibility of air. 2. Pneumatic pressures are quite low due to compressor design limitations (less
that 250 psi).
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CHAPTER 2
LITERATURE REVIEW
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LITERATURE REVIEW
2.1 AUTO INDEXING GEAR CUTTING ATTACHMENT FOR SHAPING MACHINE
M.V.N Srujan Manohar, S.Hari Krishna , University College of engineering, JNTU Kakinada, A.P, INDIA(2012) :
They have been investigated to use pneumatic shaper for high production of automatic gear cutting with auto indexing work piece. A small ratchet gear structure has been thus devised to demonstrate the gear cutting attachment in shaping machines.
The pneumatic source of power with control accessories is used to drive the ram or the cylinder piston to obtain the forward and return strokes. By this arrangement the forward/reverse stroke of the pneumatic cylinder is adjustable type when compared with the conventional machines. We desired a shaping machine which will automatically index the job and gives automatic tool feed to the pneumatic cylinder
2.2 DESIGN & FABRICATION OF PNEUMATICALLY OPERATED PLASTIC INJECTION MOULDING MACHINE Poonam G. Shukla, Gaurav , P. Shukla Nagpur, India (2013) :
This project intends to use of plastic is increased now days in many industries
like automobile, packaging, medical, etc. The reason behind this is that the plastic made things are quiet easier to manufacture, handle and reliable to use. So the plastic goods manufacturing industries are striving hard to produce good quality products at large scale and cheaper cost. The hydraulically operated machines solve the problem, but
they are too costlier for small scale and medium scale industries. This paper deals with design and fabrication of pneumatically operated injection plastic moulding machine. The manually operated machine is converted into pneumatically operated machine by applying proper design procedure. 2.3 DESIGN AND DEVELOPMENT OF SEMI-AUTOMATIC CUTTING MACHINE FOR YOUNG COCONUTS Satip Rattanapaskorn , Kiattisak Roonprasang , King Mongkut’s Institute of Technology
Ladkrabang, Bangkok 10520, Thailand (2008) :
The purpose of this research is to design, fabricate, test, and evaluate the
prototype of a semi-automatic young coconut fruit cutting machine. The design concept
is that fruit cutting is accomplished by pneumatic press on a young coconut sitting on a
sharp knife in a vertical plane. The machine consists of 5 main parts: 1) machine frame,
2) cutting base, 3) knife set, 4) pneumatic system, and 5) tanks receiving coconut juice
and cut fruits. The machine parts contacting edible parts of the fruit are made of food-
grade stainless steel. In operation, a young coconut is placed on the cutting base and
the pneumatic control is switched on. The coconut is automatically moved to the
pressing unit and cut in half by a knife set. The coconut juice flows down to the tank
while the cut fruits are separated and moved into the other tank.
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2.4 PNEUMATIC AUTO FEED PUNCHING AND RIVETING MACHINE A.S. Aditya Polapragada, K. Sri Varsha, University College of engineering, JNTU Kakinada, A.P, INDIA:
This projects intends to pneumatic system has gained a large amount of
importance in last few decades. This importance is due to its accuracy and cost. This
convenience in operating the pneumatic system has made us to design and fabricate
this unit as our project. This unit, as we hope that it can be operated easily with semi-
skilled operators.
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 2.5 CRITICAL REVIEW:
1) The above specified projects are work for only specified operations only. 2) On those machines numbers of operations are not performed. 3) Those machines are not made for multi-purpose. 4) Even similar operations also not performed on those machines, they are meant
for single operations only. 2.6 OBJECTIVE:
The main objective of pneumatic auto feed multi operation machine is numbers
of operations are performed in a single machine, they are similar and different operations are performed in a single machine
They are a) Drilling operation b) Broaching operation c) Reaming operation d) Taping operation e) Boaring operation f) Screw tightening g) Grinding operation
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CHAPTER 3
DESCRIPTION OF EQUIPMENT
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DESCRIPTION OF EQUIPMENT
3.1 PRODUCTION OF COMPRESSED AIR:
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.
The key part of any p neumatic system 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 delivers it at a higher pressure. Compressor capacity is the actual quantity of air
compressed and delivered. And the volume expressed is that of the air at intake conditions
namely at atmosphere pressure and normal ambient temperature.
Clean condition of the suction air is one of the factors, which decides the life of a
compressor. Warm and moist suction air will result in increased precipitation of condense from
the compressed air.
Positive displacement compressors are most frequently employed for compressed
air plant and have proved highly successful for pneumatic control application.
The different types of positive compressors are:
1. Reciprocating type compressor
2. Rotary type compressor
Turbo compressors are employed where large capacity of air required at low discharge
pressures. They cannot attain pressure necessary for pneumatic control application unless built
in multistage designs and are seldom encountered in pneumatic service.
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3.1 .A RECIPROCATING COMPRESSORS:
Built for either stationary (or) portable service the reciprocating compressor is by far the
most common type. Reciprocating compressors deliver more than 500 m³/min. In single stage
compressor, even if the air pressure is of 6 bar, the machines can discharge pressure of 15 bars.
Discharge pressure in the range of 250 bars can be obtained with high pressure reciprocating
compressors that of three & four stages. Single stage and 1200 stage models are particularly
suitable for pneumatic applications , with preferences going to the two stage design as soon as
the discharge pressure exceeds 6 bar, because it in capable of matching the performance of
single stage machine at lower costs per driving powers in the range
Fig 3.1 Air Compressor
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3.2 PNEUMATIC CONTROL COMPONENT: 3.2.1 PNEUMATIC CYLINDER
An air cylinder is an operative device in which the state input energy of compressed air
i.e. pneumatic power is converted in to mechanical output power, by reducing the pressure of
the air to that of the atmosphere.
3.2.1.A DOUBLE ACTING CYLINDERS:
A double acting cylinder is employed in control systems with the full pneumatic
cushioning and it is essential when the cylinder itself is required to retard heavy loads. This can
only be done at the end positions of the piston stock. In all intermediate positions a separate
externally mounted cushioning device must be provided with the damping feature.
The normal escape of air is out off by a cushioning piston before the end of the stock is
required. As a result the sit in the cushioning chamber is again compressed since it cannot
escape but slowly according to the setting made on reverses.
The air freely enters the cylinder and the piston stokes in the other direction at full force
and velocity.
Fig 3.2 Double Acting Cylinder
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3.2.1.B SINGLE ACTING CYLINDER:
Single acting cylinder is only capable of performing an operating medium in
only one direction. Single acting cylinders are equipped with one inlet for the operating air
pressure, and can be produced in several designs. Single cylinders develop power in one
direction only.
Therefore no heavy control equipment should be attached to them, which is required to
be moved on the piston return stoke. Single action cylinder requires only about half the air
volume consumed by a double acting for one operating cycle.
Fig 3.3 Single Acting Cylinder
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3.2.3 GENERALLY USED MATERIALS FOR CYLINDERS:
Table 3.1 End Cover Materials
Table 3.2 Cylinder Tube Materials
S.NO LIGHT DUTY MEDIUM DUTY HEAVY DUTY
1. Plastic Hard drawn brass tube Hard drawn brass tube.
2. Hard drawn
Aluminium tube Aluminium Castings Hard drawn steel tube
3. Hard drawn Brass tube
Brass, bronze, iron or castings, welded steel tube
Table 3.3 Piston Materials
S.NO LIGHT DUTY MEDIUM DUTY HEAVY DUTY
1. Aluminium Castings
Aluminium Castings Brass (Fabricated)
Aluminium Forgings, Aluminium Castings.
2. Bronze (Fabricated) Bronze (Fabricated)
3.
Iron and Steel Castings
Brass, Bronze, Iron or Steel Castings.
Table 3.4 Mount Materials
S.NO LIGHT DUTY MEDIUM DUTY HEAVY DUTY
1. Aluminium stock
(Fabricated) Aluminium stock
(Fabricated) Hard tensile Castings
2. Brass stock (Fabricated)
Brass stock (Fabricated)
3. Aluminium Castings Aluminium, Brass,
iron or steel Castings.
S.NO LIGHT DUTY MEDIUM DUTY HEAVY DUTY
Aluminium Aluminium, Brass High Tensile 1.
Castings And Steel Castings Steel Castings
Light Alloy High Tensile 2. (Fabricated) Steel Fabrication
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Table 3.5 Piston Rod Materials
S.NO MATERIAL FINISH REMARKS
MILD STEEL
Ground and polished hardened, Generally preferred chrome
1. ground and polished. Plated
2. STAINLESS STEEL Ground and Polished Less scratch resistant than chrome plated piston rod
3.3 VALVES:
3.3.1 SOLENOID VALVE:
The directional valve is one of the important parts of a pneumatic system. Commonly
known as DCV, this valve is used to control the direction of air flow in the pneumatic system.
The directional valve does this by changing the position of its internal movable parts.
This valve was selected for speedy operation and to reduce the manual effort and also for the
modification of the machine into automatic machine by means of using a solenoid valve.
A solenoid is an electrical device that converts electrical energy into straight line motion
and force. These are also used to operate a mechanical operation which in turn operates the
valve mechanism. Solenoids may be push type or pull type.
The push type solenoid is one which the plunger is pushed when the solenoid is
energized electrically. The pull type solenoid is one is which the plunger is pulled when the
solenoid is energized.
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Fig 3.4 5/2 WAY Solenoid Valve
3.3.2 PARTS OF A SOLENOID VALVE:
3.3.2.A. COIL:
The solenoid coil is made of copper wire. The layers of wire are separated by insulating
layer. The entire solenoid coil is covered with a varnish that is not affected by solvents,
moisture, cutting oil or often fluids. Coils are rated in various voltages such as 115 volts AC, 230
volts AC, 460 volts AC, 575 Volts AC, 6 Volts DC, 12 Volts DC, 24 Volts DC, 115 Volts DC & 230
Volts DC. They are designed for such frequencies as 50 Hz to 60 Hz.
3.3.2.B. FRAME:
The solenoid frame serves several purposes. Since it is made of laminated sheets, it is
magnetized when the current passes through the coil. The magnetized coil attracts the metal
plunger to move. The frame has provisions for attaching the mounting. They are usually bolted
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or welded to the frame. The frame has provisions for receivers, the plunger. The wear strips are
mounted to the solenoid frame, and are made of materials such as metal or impregnated less
fiber cloth.
3.3.2.C. SOLENOID PLUNGER
The Solenoid plunger is the mover mechanism of the solenoid. The plunger is made of
steel laminations which are riveted together under high pressure, so that there will be no
movement of the lamination with respect to one another. At the top of the plunger a pin hole is
placed for making a connection to some device. The solenoid plunger is moved by a magnetic
force in one direction and is usually returned by spring action.
Solenoid operated valves are usually provided with cover over either the solenoid or the
entire valve. This protects the solenoid from dirt and other foreign matter, and protects the
actuator. In many applications it is necessary to use explosion proof solenoids.
3.3.3 WORKING OF SOLENOID VALVE:
The solenoid valve has 5 openings. This ensures easy exhausting of 5/2 valve. The spool
of the 5/2 valve slide inside the main bore according to spool position; the ports get connected
and disconnected. The working principle is as follows
POSITION-1
When the spool is actuated towards outer direction port ‘P’ gets connected to ‘B’ and ‘S’
remains closed while ‘A’ gets connected to ‘R’
POISITION-2
When the spool is pushed in the inner direction port ‘P’ and ‘A’ gets connected to each
other and ‘B’ to ‘S’ while port ‘R’ remains close
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Fig 3.5 5/2 Way Soleniod Valve Sectional View
3.3.4 SOLENOID VALVE (OR) CUT OFF VALVE:
The control valve is used to control the flow direction is called cut off valve or solenoid
valve. This solenoid cut off valve is controlled by the electronic control unit.
In our project separate solenoid valve is used for flow direction of vice cylinder. It is
used to flow the air from compressor to the single acting cylinder.
3.3.5 FLOW CONTROL VALVE:
In any fluid power circuit, flow control valve is used to control the speed of the actuator.
The flow control can be achieved by varying the area of flow through which the air in passing.
When area is increased, more quantity of air will be sent to actuator as a result its speed
will increase. If the quantity of air entering into the actuator is reduced, the speed of the
actuator is reduced.
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Fig 3.6 Flow Control Valve
Flow control valves facilitate high precision adjustment of flow volumes and are used to
precisely control the piston speed of a drive.
For adjustable speed via exhaust air flow control. The piston moves between air
cushions created through freely flowing supply air and restricted exhaust air. The benefit is
improved operating behaviour, even in the event of load changes
For adjustable speed via supply air flow control. The piston is moved via an air cushion
at one end, created by freely flowing exhaust air and restricted supply air. In contrast with
exhaust air restriction, there is a tendency towards a stick-slip effect.
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Fig 3.7 Flow Control Valve For Pneumatic Cylinder
3.4 PNEUMATIC MOTOR
It is a pneumatic motor which runs by supplying by compressed air , for performing any
operation the pneumatic motor , when compressed air impinges on rotor of the motor it
rotates and the barel which was connected to rotor is rotated, there by various operations are
performed by changing various tool bits from the barrel.
With its industrial grade 3/8" chuck, this economical choice includes high quality
features for general drilling and hole sawing jobs. The planetary gear reduction balances the
load on bearings and gears for increased tool life
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Fig 3.8 Pneumatic Motor
3.5 HOSES
Hoses used in this pneumatic system are made up of polyurethane. These hose can with
stand at a maximum pressure level of 10 N/m². Polyurethane combines the best properties of
both plastic and rubber. It offers abrasion and tear resistance, high tensile and elongation
values, and low compression set.
Polyurethane is naturally flexible and exhibits virtually unlimited flexural abilities.
Combining good chemical resistance with excellent weathering characteristics sets
polyurethane apart from most other thermoplastics. It has exceptional resistance to most
gasolines, oils, kerosene, and other petroleumbased chemicals, making it an ideal choice for
fuel lines (although additives in today’s gasoline and petroleum products warrant field testing).
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Fig 3.9 Poly Urathane Tubes
3.5.1 APPLICATIONS OF PU TUBE
• Any time condensation can occur with small actuators, air grippers and air operated
valves. Condensation in a pneumatic system will cause operating failure and affect
the life of pneumatic equipment.
• Manufacturers of electrical components.
• When you need to eliminate water condensation but you can not use a membrane or
desiccant dryer (as you cannot use a fast exhaust).
3.5.2 BENEFITS OF PU TUBE:
• Longer life of other pneumatic equipment.
• Prevents operational failure of small actuators, air grippers and pilot operated valves
due to condensation.
• Avoids corrosion in other pneumatic equipment.
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• Diffuses water vapour in the piping to the outside before it liquefies, so we avoid
problems such as dried grease or ozone when using other types of dryers.
• Easy mounting
3.6 CONNECTORS:
In our system hose connectors are used . Hose connectors normally comprise an
adoptee hose nipple. These types of connectors are made up of brass (or) Aluminum (or)
hardened pneumatic steel. For these type hose connectors no need of hose clamp these are
self-locking hose connectors. a Multi way four way hose connecter
The universal combination at an attractive price. Can be widely used thanks to resistant
materials. Easy to install thanks to optimised bending radii. Limited reset effect.Attractively
priced: the universal solution for metal fittings. Perfect for standard pneumatic applications – in
many different fields. Wide range of variants Over 1000 types for maximum flexibility in
standard applications. Hydrolysis resistant For applications in damp environments or in contact
with water at up to 60 °C. Resistant to pressure Secure connection when used with pressure
ranges of up to 14 bar. Economical for pneumatic installations in the high pressure ranges.
Fig 3.10 Hose Connector
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The powerful combination for applications involving pressure ranges up to 16 bar For
example, for applications with the pressure booster Robust, flexible and reliable connection for
the automotive industry. Fulfils the requirements Heat resistant For reliable compressed air
supply in high temperature ranges. Whether with 10 bar at 80 °C or 6 bar at 150 °C – always
delivers maximum process security.Anti-static Electrically conductive tubing combined with a
solid-metal fitting Approved for the food Industry Food and Drug Administration certification
for use in the food industry:
Fig 3.11 Four way hose connector
The hydrolysis-resistant combination with increased functions. Designed to meet the
highest demands, This combination shines in applications which require the highest possible
hygiene standards for food. The cost-effective alternative to stainless steel, perfect for e.g.
critical environments such as the splash zone: resistant to practically all common cleaning
agents, with maximum corrosion protection. Resistant to media Completely resistant to all
cleaning agents and lubricants and even permits the transportation of acids and lyes without
any problems.
Flame-retardant Safe in areas where there is a risk of fire thanks to flame-retardant
properties to Resistant to welding Spatter The economical combination for applications not in
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close proximity to welding applications. Also reliable for applications in direct proximity to
welding splatter Double-sheathed tube and special fitting.
3.7 CONTROL UNIT
A pneumatic multipurpose device is an air-operated device used for many small
operations. It is a portable one. Compressed air is the source of energy for this device. The
compressed air is allowed to pass through the nozzle in such a way that the rotation obtained is
utilized for machining.
The nozzles welded to the fan can be rotated in either direction. The rpm and torque of
the shaft depends upon the pressure of the air admitted so by varying the pressure, the RPM
and torque can be varied. Thick tubes interconnect the parts. The Clamps are used at the
connecting parts to prevent leakage. In thread parts seals are used to prevent leakage.
The compressed air from the compressor first enters the control unit. In the control
unit the pressure of the air is controlled and sent to the barrel to rotate the fan in the required
direction. The gate valve controls the pressure and volume of air. Then the pressure is read by a
pressure gauge. Later the air is admitted to the barrel, a shaft is placed and it carries the fan.
The shaft is supported by bearing. The bearings are placed in the couplings, which
covers the end of barrel.
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CHAPTER 4
DESIGN & DRAWING OF
EQUIPMENT
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DESIGN OF EQUIPMENT AND DRAWING
4.1 Pneumatic Components And Its Specification
The pneumatic auto feed multi operation machine consists of the following pneumatic components: 1. Double acting pneumatic cylinder 2. Single acting pneumatic cylinder 3. Solenoid Valve 4. Flow control Valve 5. Connectors 6. Hoses
4.1.1.Double acting pneumatic cylinder: Stroke length
: 160 mm = 0.16 m
Piston diameter : 50 mm
Piston rod : 15 mm
Quantity : 1
Seals : Nitride (Buna-N) Elastomer
End cones : Cast iron Piston
: EN – 8
Media
: Air
Temperature
: 0-80 º C
Pressure Range: : 8 N/m²
Fig 4.1 Double Acting Cylinder Drawing
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4.1.2.single acting pneumatic cylinder: Stroke length
: 175 mm = 0.175 m
Piston diameter : 35 mm
Piston rod : 15 mm
Quantity : 1
Seals : Nitride (Buna-N) Elastomer
End cones : Cast iron Piston
: EN – 8
Media
: Air
Temperature
: 0-80 º C
Pressure Range: : 8 N/m²
Fig 4.2 Single Acting Cylinder Drawing
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Fig 4.3 solenoid valve
4.1.4 Flow Control Valve Port size : 0.635 x 10 ² m
Pressure : 0-8 bar Media
: Air
Quantity : 4
4.1.3 5/2 way solenoid valve
Size :
0.635 x 10 ¯² m
Part size :
G 0.635 x 10 ¯² m
Max pressure range : 0-10 bar
Quantity :
2
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4.1.5. Hose Connectors
Max working pressure :
10 bar
Temperature : 0-100 º C
Fluid media :
Air
Material :
Brass
Diameter : 08 mm
Locking : Self-locking
4.1.6. Hoses:
Max pressure :
10 bar
Outer diameter :
8 mm = 8 x 10 ¯ ³m
Inner diameter :
3 mm = 3 x 10 ¯ ³m
Material : Poly urathene
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4.2 GENERAL MACHINE SPECIFICATIONS :
4.2.1 Barrel unit
Short capacity : 0.635 x 10-² m Barrel diameter (ID)
: 40 mm = 40 x 10¯ ³m
Drill capacity : 1.5-10mm
4.2.2 Clamping unit
Clamping : Manual clamping
Max Clamping Size : 100 mm = 0.1m
4.2.3 Pneumatic unit
Type of cylinder
: Double acting cylinder
Type of valve
: Flow control valve & solenoid valve
Max air pressure : 8 bar 4.2.4 Foundation Basement depth : 1.5ft
Length of beam : 4.5ft
Breadth of beam : 2.5ft
Height of the beam : 3.0ft
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4.2.5 Design calculations Maximum pressure appilied in the cylinder(P)
: 8bar
Area of cylinder (A) : (3.14 D²) / 4 Force exerted in the piston (F)
: Pressure applied x area of cylinder
Force extraction (FE)
: ( 4)×(D2) P ( 4)×(52)×8=157.07Kg
Force retraction (FR)
: ( 4)×(D2-d2) P ( 4)×((52)-(1.52))×8=142.94Kg
4.2.6 Air consumption Consumption of air in extraction(CE)
: (( 4)×(D2) (P ) L) (( 4)×(52) ( ) ) . lt min
Consumption of air in retraction (CR)
: (( 4)×(D2-d2) (P ) L) (( 4)×(52-1.52) ) . lt min
Fig 4.4 Base Frame
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CHAPTER 5
LIST OF MATERIALS
35
LIST OF MATERIALS
5.1FACTORS DETERMINING THE CHOICE OF MATERIALS:
The various factors which determine the choice of material are discussed below. 5.1.1. Properties:
The material selected must posses the necessary properties for the proposed
application. The various requirements to be satisfied can be weight, surface finish, rigidity,
ability to withstand environmental attack from chemicals, service life, reliability etc.
The following four types of principle properties of materials decisively affect their
selection
a. Physical
b. Mechanical
c. From manufacturing point of view
d. Chemical
The various physical properties concerned are melting point, Thermal
Conductivity, Specific heat, coefficient of thermal expansion, specific gravity, electrical
Conductivity, Magnetic purposes etc.
The various Mechanical properties Concerned are strength in tensile, compressive
shear, bending, torsional and buckling load, fatigue resistance, impact resistance, elastic limit,
endurance limit, and modulus of elasticity, hardness, wear resistance and sliding properties.
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The various properties concerned from the manufacturing point of view are.
• Cast ability,
• weld ability,
• Brazability,
• Forge ability,
• merchantability,
• surface properties,
• shrinkage,
• Deep drawing etc.
5.1.2. Manufacturing Case:
Sometimes the demand for lowest possible manufacturing cost or surface qualities
obtainable by the application of suitable coating substances may demand the use of special
materials.
5.1.3. Quality Required:
This generally affects the manufacturing process and ultimately the material. For
example, it would never be desirable to go for casting of a less number of components which
can be fabricated much more economically by welding or hand forging the steel.
37
5.1.4. Availability of Material:
Some materials may be scarce or in short supply. It then becomes obligatory for the
designer to use some other material which though may not be a perfect substitute for the
material designed.
The delivery of materials and the delivery date of product should also be kept in mind. 5.1.5. Space Consideration:
Sometimes high strength materials have to be selected because the forces involved
are high and the space limitations are there.
5.1.6. Cost:
As in any other problem, in selection of material the cost of material plays an
important part and should not be ignored.
Some times factors like scrap utilization, appearance, and non-maintenance of the
designed part are involved in the selection of proper materials.
38
5.2 LIST OF METERIALS USED
Table 5.1 List Of Materials Used
SNO DESCRIPTION QUANTITY MATERIAL
1 DOUBLE ACTING PNEUMATIC CYLINDER
1 Aluminium
2 5/2 WAY SOLENOID VALVE 1
Aluminium
3 HOSE COLLAR 8
Brass
4 PNEUMATIC MOTOR 1
M.S
5 4 WAY CONNECTOR 1
PU
6 PU TUBES 15mtr
Polyurethane
7 BASE FRAME &STRUCTURE 1
Iron
8 VICES 2 M.S
9 AIR FILTER & DRIER 1
Al
10 COLUMN SUPPORT 1
M.S
11 AIR COMPRESSOR 1
12 FLOW CONTROL VALVES 4 Brass
13 DRILL BIT SET 1 H.S.S
14 REAMING BIT SET 1
C.I
15 BOARING BIT 1
H.S.S
16 GRINDING WHEEL 1
ABR:SI
17 TAP SET 1
H.S.S
18 BROACHING BIT SET 1
H.S.S
19 BOLTS & NUTS 30 Iron
39
CHAPTER 6
COST ESTIMATION
40
COST ESTIMATION
6.1 COST ESTIMATION
SNO DESCRIPTION QUANTITY MATERIAL RATE AMOUNT
1 DOUBLE ACTING PNEUMATIC CYLINDER
1 AL 2000.00 2000.00
2 SINGLE PASS SOLENOID VSLVE
1 AL 1600.00 1600.00
3 5/2 WAY SOLENOID VALVE 1 AL
1800.00 1800.00
4 SINGLE ACTING CYLINDER 1 AL 1950.00 1950.00
5 HOSE COLLAR 8 BRASS
125.00 1000.00
6 PNEUMATIC MOTOR 1 M.S
2000.00 2000.00
7 4 WAY CONNECTOR 1
PU 60.00 60.00
8 PU TUBES 10MTR
PU 30.00 300.00
9 FRAME STAND 1
M.S 600.00 600.00
10 PLATES 2
M.S 100.00 200.00
11 COLUMN SUPPORT 1
M.S 200.00 200.00
12 AIR COMPRESSOR 1
AVAILABLE AT THERMAL LAB
13 FLOW CONTROL VALVES 2 BRASS 250.00 500.00
14 REAMING BIT 1
H.S.S 200.00 200.00
15 DRILL BIT SET 1
H.S.S 450.00 450.00
16 BOARING BIT 1
H.S.S 1500.00 1500.00
17 GRINDING WHEEL 1
ABR:SI 350.00 350.00
18 TAP SET 1
H.S.S 2500.00 2500.00
19 BROACHING BIT SET 1 H.S.S 180.00 180.00
TOTAL 17390.00
LABOUR CHARGES 4500.00
MACHINING CHARGES 3450.00
GRAND TOTAL 25340.00
41
CHAPTER 7
FABRICTION
42
FABRICATION
7.1 METHOD OF FABRICATION:
The stand (or) base carries the whole machine. The whole machine is installed on the
foundation .A circular column having length of 90cm about one third part of its length is in the
foundation the remains part is above the foundation, from the upper end of the vertical
column 50cm is machined by performing turning operation, a bush with having length 7.5cm is
machined and slides over the machining parts of rod.
The horizontal rod is slider over the, vertical column by means of bush. A double acting
cylinder is connected to horizontal column by using clamp for feeding of the machine.
A Pneumatic motor with chuck is connected to the horizontal column normally. A 5/2
way solenoid value is connected to control the double acting cylinder to upward &downward
motion.
A single acting cylinder and a movable jaw is fixed to the base of the machine it will act
as a work holding device
By changing toll bits from the chuck for performing different opertions
43
Fig 7.1 Pneumatic Auto Feed Multi Operation Machine
44
CHAPTER 8
WORKING PRINCIPLE
45
WORKING PRINCIPLE
8.1 WORKING PRINCIPLE
The compressed air from the compressor is used as the force medium for this
operation. One Single acting and double acting cylinder is used in this machine .The air from
the compressor enters into the flow control Valve.
Air enters in to the barrel unit through one way and the other way of air enters to the
solenoid valve. When air enters to the cylinder 1, due to pressure difference work blank is
clamped and when air enters to the other cylinder due to pressure difference drilling
operation takes place as the drilling head comes down and drills the work piece.
After this operation the cylinder releases the clamping and drilling head comes to its
original position.
By changing the tool bits from the chuck we can perform different operations they are:
A. Drilling operation B. Reaming operation C. Taping operation D. Screw tightening E. Broaching operation F. Grinding operation G. Hole saw cutting H. Puffing
46
8.1.A DRILLING OPERATION Drilling is a process of producing round holes in a solid material or enlarging
existing holes with the use of multitooth cutting tools called drills or drill bits. Various cutting
tools are available for drilling, but the most common is the The twist drill does most of the
cutting with the tip of the bit. It has two flutes to carry the chips up from the cutting edges to
the top of the hole where they are cast off. The standard drill geometry
Some standard drill types are,
v straight shank: this type has a cylindrical shank and is held in a chuck;
v taper shank: his type is held directly in the drilling machine spindle.
Drills are normally made of HSS but carbide-tipped drills, and drills with mechanically
attached carbide inserts are commonly used in many operations, especially on CNC drilling
machines
Fig 8.1 Drilling Bit
47
8.1.B REAMING OPERATION:
Reaming is a process of improving the quality of already drilled holes by means of
cutting tools called reamers. Drilling and reaming are performed on a drilling press, although
other machine tools can also perform this operation, for instance lathes, milling machines,
machining centres.
In drilling and reaming, the primary motion is the rotation of the cutting tool held in
the spindle. Drills and reamers execute also the secondary feed motion. Some finishing
reaming operations are manual.
Different types of reamers used are Hand Reamers,Machine Reamers with taper shank,
straight shank, Shell Reamers, Arbors , Bridge Reamers ,Taper Pin Reamers,Taper Pin Reamers,
quick spiral style,Machine Reamers Solid Carbide,,Carbide Tipped
Fig 8.2 Reaming Bit
48
C.TAPPING OPERATION:
These are straight flute general purpose tools which can be used for both machine or
hand tapping. They are generally the most economical tool for use on production runs, but are
best on materials that produce chips, or where the swarf breaks readily. Where deep holes are
to be tapped, in materials which produce stringy swarf, other types of taps may be needed,
especially for coarse threads. Hand taps can be supplied in sets of three; bottom, second and
taper leads, or individually.
8.C.1BOTTOM TAPS:
It has a chamfer (lead) of 1–2 threads, the angle of the lead being around 18 degrees
per side. They are used to produce threads close to the bottom of blind holes.
Fig 8.3 Bottom Tap 8.C.2SECOND TAPS :
It has a lead of 3-5 threads at 8 degrees per side. They are the most popular and can be
used for through holes, or blind holes where the thread does not need to go right to the
bottom.
Fig 8.4 Second Tap
49
8.C.3THIRD TAPS:
It has a lead of 7-10 threads at 5 degrees per side. The taper lead distributes the
cutting force over a large area, and the taper shape helps the thread to start. They can
therefore be used to start a thread prior to use of second or bottom leads, or for through
holes.
Fig 8.5 Third Tap D. SCREW TIGHTENING;
For tightening of the screws the screw bit is attached to the chuck of the motor , air
motor starts running when throttle lever is operated. The screw bit rotates when operator's
push or axial pressure is applied. The output torque can be adjusted by turning regulator to
control spring compression or by changing the springs.
Fig 8.6 Screw Tightening Bit
50
E.BROACHING OPERATION:
Broaching is a machining process for removal of a layer of material of desired width
and depth usually in one stroke by a slender rod or bar type cutter having a series of cutting
edges with gradually increased protrusion as indicated in Fig. 4.10.1. In shaping, attaining full
depth requires a number of strokes to remove the material in thin layers step – by – step by
gradually infeeding the single point tool .
Whereas, broaching enables remove the whole material in one stroke only by the
gradually rising teeth of the cutter called broach. The amount of tooth rise between the
successive teeth of the broach is equivalent to the in feed given in shaping.
Fig 8.7 Broaching Bit
51
F.GRINDING OPERATION:
Grinding is a material removal and surface generation process used to shape and finish
components made of metals and other materials. The precision and surface finish obtained
through grinding can be up to ten times better than with either turning or milling.
Grinding employs an abrasive product, usually a rotating wheel brought into controlled
contact with a work surface. The grinding wheel is composed of abrasive grains held together
in a binder. These abrasive grains act as cutting tools, removing tiny chips of material from the
work As these abrasive grains wear and become dull, the added resistance leads to fracture of
the grains or weakening of their bond. The dull pieces break away, revealing sharp new grains
that continue cutting.
Fig 8.8 Grinding Wheel
52
8.1.G.HOLE SAW CUTTING:
Hole saw cutting is also one form drilling operation , in which generally drilling
operation is performed in specified range of hole sizes , but we don’t have a drill bit with in
the intermediate range of specified drill bits in such cases hole saw cutting will plays the main
role , in which it extends the hole size to our requirement
Fig8.9 Hole Saw Cutting Tool
8.1.H.PUFFING OPERATION:
Puffing is operation is performed for surface finishing , the puffing tool is nothing but a
set of emery papers are arranged to stud as shown in fig, which is arranged to a chuck of a
pneumatic motor
Fig 8.10 Puffing Tool
53
CHAPTER 9
MERITS AND DEMERTIES
54
9.1MERITS
It reduces the manual work.
Quick in operation
Accuracy is more
Low cost machine
In a single machine no.of operations are performed, like, drilling ,taping, reaming
,grinding etc.,
Consumption of electric power is less when compare with manual machines
Cost for reaming all machines are optimized
Floor space for reaming machines are reduced
Low cost automation, man power for performing operations are reduced
Work holding device is also automatic
9.2 DEMERITS
Tool changing foe every operation is manual
noise in operation
constant pressure maintenance is required for thought operation
connections are may be leak
pressure drop occur in the pipelines
55
CHAPTER 10
APPLICATIONS
56
10.APPLICATIONS Applications :
Used in automobile workshops for drilling carburettor holes
Used in small scale industries
It can be used as machine with fixed mounting and as a portable
machine because it is flexible to move
In welding shop for grinding
For performing the operations in huge numbers which cannot be done in ordinary
machines, Since it’s portable.
In such places where frequent change in operation is required
It will used in where no.of operations are performed
57
CHAPTER 11
CONCLUSION
58
CONCLUSION
11.1 CONCLUSION:
The project carried out by us 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. Automation can be possible for large scale
industries but not for small scale industries so we adopt low cost automation and medium
of actuation is also is freely available.
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.
11.2 FUTURE SCOPE:
The following modifications are also to be done in this machine inn future They are
1. Tool changing also to be done automatically by using pick and place robot
2. So many no of operations can be performed in a same machine
3. This multipurpose machine can be modified into universal machine
4. By changing the work holding device we can perform radial drilling operation
radial drilling
5. By constrain the tool bit rotary motion we can perform shaping operation
6. Gear cutting is also possible by changing the work holding device
59
CHAPTER 12 REFERANCES
60
REFERANCE 12.1 REFERANCE
Auto indexing gear cutting attachment for shaping machine by M.v.n srujan manohar, S.hari Krishna (2012)
Design & fabrication of pneumatically operated plastic injection moulding machine By Poonam g. Shukla, gaurav , p. Shukla (2013)
Design and development of semi-automatic cutting machine for young coconuts Satip rattanapaskorn , kiattisak roonprasang (2008)
Pneumatic auto feed punching and riveting machine A.s. Aditya polapragada, k. Sri varsha (2012)
Pneumatic hand book by R.H.WARRNING
Festo catalogues
Janatics catalogues
Strength of materials by R.S KHURMI