Acknowledgement

The credit in accomplishing this project has the golden touch of many hands. My foremost
courtesies go to Prof. Palaskar M.P. our guide without whose painstaking efforts this project report
would never have been possible.

My deep gratitude is my professors and the entire staff of the Mechanical Engineering
department and my friends who inspired me with their knowledge and understanding of subjects as
well as encourage me to read on such enterprising topics.

We are highly obliged to the entire staff of the mechanical department for their kind co-
operation and help. We also take this opportunity to thank all our colleagues, who backed our
interest by giving useful suggestions and all possible help. At last but not least we are thankful to our
friends, colleagues and all the people directly or indirectly concerned with this project.

Submitted By

Mr Kokate Akshay. K

Mr Sonawane Ketan. P

Mr Salve Dhairyashil. R

Mr Gore Gopal. R
SR.NO TITLE PAGE NO.

1 INTRODUCTION 1

2 CONSTRUCTION & WORKING 3

3 COMPONENTS OF PROJECT 7

4 COSTING 15

5 MANUFACTURING 18

6 DESIGN OF COMPONENTS 20

7 PROCESS FLOW CHART 23

8 FABRICATION 25

9 ADVANTAGES AND DISADVANTAGES 29

10 APPLICATIONS 31

11 CONCLUSION 33

12 FUTURE SCOPE 35

13 REFERENCES 37

INDEX
 LIST OF FIGURE
FIGURE NO. TITLE OF FIGURE PAGE NO.
2.1 BLOCK DIAGRAM OF PNEUMATIC OPERATED SHEET 4
CUTTING MACHINE

2.2 CONSTRUCTION AND 5/2 DIRECTION CONTROL VALUE 5

2.3 ACTUAL MODEL OF PNEUMATIC SHEET METAL CUTTING 6

MACHINE

3.1 BASE PLATE 9

3.2(a) SUPPORT OF UPPER CUTTING PLATE 10

3.2(b) SUPPORT OF LOWER CUTTING PLATE 10

3.3 CYLINDER BRACKET 10

3.4 ACTUAL DIAGRAM OF PNEUMATIC CYLINDER 11

3.5 CONNECTING ROD 12

8.1 SCHEMATIC DIAGRAM OF ARC WELDING 28

 LIST OF TABLES

TABLE NO. TITLE OF TABLE PAGE NO.

4.1 LIST OF COSTING 16

4.2 MACHINING COST ESTIMATION 17

5.1 Machining Cost Estimation 19

7.1 PROCESS FLOW CHART 24

 PROJECT
First of all we will see what does actually project means:-

P:-planning before doing any type of work.

R:-Raw material collection that is required for work.

O:-Organizing the work.

J:-Join effort put together in the work.

E:-Estimatin of material.

C:-Cashing of work.

T:-Technique used in performing work for best output.

 ABSTRACT
The sheet metal cutting process is a main part of all industries. Normally the sheet
metal cutting machine is manually hand operated one for medium and small scale
industries. Automation in the modern world is inevitable. Any automatic machine aimed at
the economical use of man , machine and material worth the most . In our project is
solenoid valve and control timing unit is used for automation. The sheet metal cutting
machine works with the help of pneumatic double acting cylinder. The piston is connected
to the moving cutting tool. It is used to cut the small size of the sheet metal. The machine is
portable in size, so easy transportable.

The compressed air from the compressor enters to the flow control valve. The
controlled air from the flow control valve enters to the solenoid valve. The function of
solenoid valves all of air correct time interval. The 5/2 solenoid valve is used. In one position
air enters to the cylinder and pushes the piston so that the cutting stroke is obtained. The
next position air enters to the other side of cylinder and pushes the piston return back, so
that the releasing stroke is obtained. The speed of the cutting and releading stroke is varied
by the timer control unit circuit.
 CHAPTER-1
INTRODUCTION
 INTRODUCTION
In the mechanical field sheet metal cutting process is one of the most important
processes. All the small to big products need sheet metal work.

In that sheet process nowadays we use large size of two sheet cutting machine and
also the machine occupy large amount of space in the workshop.

In that project our aim is to make simple and easy operate with less space machine.
Simple in mechanism.

Therefore we all came together and planned such machine which will take less time
as well as less man power that will result cut the metal sheet ,our project machine is named
as “PENUMATIC SHEET METAL CUTTING MACHINE”.

This is accomplished by USING COMPRESSOR THE HIGH PRESSURE AIR GOES TO

PNEUMATIC CYLINDER THROUGH 5/2 SOLENIOD VALVE.
CHAPTER-2
WORKING
PRINCIPLE
 WORKING PRINCIPLE
As shown in the block diagram the working of Pneumatic operated sheet cutting machine
consists of:-

As shown in the block diagram it consists of following parts frame, cutting base, moving arm,
supporting plate, pneumatic cylinder, solenoid valve, control unite and compressor.
WORKING:

The compressor is used to store the gas with high pressure this stored gas is given as
input to the pneumatic cylinder with very high pressure and because of the piston in the
cylinder also moves in the forward direction the movement of this piston is given to the
moving arm of the cutting plate which is pressed with very high pressure and the metal
sheet which is placed in between this two plates gets cut. As shown in the block diagram we
have connected solenoid valve which is used to operate the movement of the piston arm it
can be moved in forward direction or reverse direction.

The main aim of our project is to cut the metal sheet so the project is very heavy and
made up of M.S material. As we know that energy cannot be created not be destroyed. In
our project we are using air to move the piston the air is stored in the tank with high
pressure and this air we are using to move the hand of our cutting plate. In our project we
are using 5/2 valve so that it can push the air with high pressure in the cylinder and at the
same time we can take out the air from the cylinder. And for switching the stages we are
using this. This valve is operated on A.C supply i.e. 230v 50hz
 CHAPTER-3
COMPONENTS
OF
PROJECT
 COMPONENTS OF PROJECT
1. Base
2. Cutting
3. Body
4. Cylinder bracket
5. Connecting rods
6. Rod mounting
7. Piston Cylinder
1) BASE PLATE:
The base plate of our project is also made up of M.S. material. The main use of
this base plate is to provide support to upper part of our project. On the surface of the base
we are mounding the cutting assembly with the help of this base plate with nut and bolt
assembly.

Specifications:

Length: 177mm

Width: 30mm

2) CUTTING PLATE
As we know that the main aim of this project is to cut the sheet of metal and
for cutting this metal sheet we are using two cutting plate in between this two cutting plates
we are placing our sheet which is to be cut. This cutting plates are made up of steel.

Specifications:

Length: 180mm

Width: 10mm

Height: 50mm
a) SUPPORT OF UPPER CUTTING PLATE:
The support of upper cutting plate is also made up of M.S. material. On this
supporting panel we have mounded our upper cutting plate it is tough in nature and it
provide support to our cutting plate. This plate is heavy because we have to cut the metal
sheet. Support to our cutting plate. This plate is heavy because we have to cut the metal
sheet. Specifications of this part are mentioned below.

b) SUPPORT OF LOWER CUTTING PLATE:

The support of upper cutting plate is also made up of M.S. material on this
supporting panel we have mounded our upper cutting plate it is tough in nature and
provides support to our cutting plate. This plate is heavy because we have to cut the
metal sheet. Specifications of this part are mentioned below.
3) CYLINDER BRACELET:
Cylinder bracket is also made up of M.S. Use of this bracket is for mounding the
pneumatic cylinder which will provide the necessary movement for the cutting plate so
we are using bracket, this bracket consists of four nut and bolt arrangement so that we
can fix our pneumatic cylinder

.
4) PNEUMATIC CYLINDER PN :
In our project we are using pneumatic cylinder for giving force to the cutters.
So we have selected the high speed and high pressure cylinder so that it can cut the metal
sheet.

Specifications:

Pressure: 10 bar max.

Bore: 50mm.

Stroke length: 300mm.

Piston diameter: 16mm.

Barrel: Aluminium hard anodized

End Cover: Aluminium pressed die cast

Seals: polyurethane/Buna-N/Viton

Temperature: 80-200 degree

5) CONNECTING ROD:
Connecting rod is used to fix one end of pneumatic cylinder on one end of
this connecting rod we have connected the cylinder.

The fig of this connecting rid is as shown in the picture given below and it is
also made up M.S material.

Specification:

Thickness: 3mm.

Width: 70mm
 COMPRESSOR
An air compressor is a device that convert power (usually from an electric motor, a
diesel engine or a gasoline engine) into potential energy by forcing air into a smaller
volume and thus increasing it’s pressure. The energy in the compressed air can be stored
while the air remains pressurized. The energy can be used for a variety of applications,
usually by utilizing the kinetic energy of the air as it is depressurized.

THERE ARE NUMEROUS METHODS OF AIR COMPRESSION.

1) POSITIVE DISPLACEMENT
2) NEGATIVE DISPLACEMENT

POSITIVE DISPLACEMENT:-

Positive displacement compressor work by forcing air into a chamber whose volume is
decreased to compress the air.

THERE ARE THREE TYPES OF POSITIVE DISPLACEMENTCOMPRESSOR

1) PISTON TYPE
2) ROTARTY TYPE
3) VANE TYPE

NEGATIVE DISPLACEMENT

Negative displacement compressor include centrifugal compressors these use centrifugal

force generated by a spinning impeller to accelerate and then decelerate captured air,
which pressurizes it.
CHAPTER-4
COSTING
 Costing

Table NO.4.1-List of cost

 Machining Cost Estimation
This cost estimation is attempt to forecast the total expenses that may
include to manufacture apart from material cost. Cost estimation of manufactured parts can
be considered as judgement on and after careful consideration which includes labour,
material and factory services required to produce the required components.
 CHAPTER-5
MANUFACTURING
 MANUFACTURING PROCESS SHEETS
MANUFACTURING PROCESS SHEET-01

NAME OF PART-FOUNDATION FRAME

SIZE-310*230*445

MATERIAL-MILD STEEL ANGLE

QUANTITY-01

TABLE NO.5.1-Machine Cost Estimation

Sr.no Machine Operation Tool Accessories Measuring Time(min)

used Instruments
1 - Selection of Steel Rule 5
M.S. Round bars
of required sizes
and marking
them for
required length
2 Power Cutting of shaft Hacksaw M/C. Vice - 20
hacksaw material of blades
required size.
3 Centre Facing and HSS M/C. Vice & Vernier 30
Lathe straight turning Tools Chuck calliper
of shaft up to
required
dimensions.
4 Centre Centre drilling Centre M/C. Vice & - 10
Lathe on both ends of Drill Chuck
shaft.
5 Centre Step turning at HSS M/C. Vice & Vernier 20
Lathe both ends of the Tools Chuck calliper
shaft
accumulating
rollers.
CHAPTER-6
DESIGN
OF
COMPONENT
 Design of Component
Piston cylinder is the main component of our project so we have to design it, so we will
design it.

Specifications-

Maximum Pressure-10 bar

Bore Diameter-50mm

Stroke Length-300mm

Piston Diameter-16mm

Given Data-

D=Diameter of piston

=50mm

D=Diameter of piston rod

=16mm

L=Length of stroke

=300mm

Area of cylinder=π/4(D2)

=π/4(0.050)2

=1.963*10-3m2

Volume of cylinder=Stroke length*Area

=300*1.963*10-3

=0.5890 m2/s

Q=Volume/Time

=0.5890/3.12 (Assuming Time=3.12 sec)

Q=0.1887 m3/s

Velocity of piston rod=Q/A

=0.1887/1.963*10-3

=96.17 m/sec

Power developed by piston (P) =F*V

….Take force=Pressure on piston

=10 bar

=10*105 N/mm2

=10*10 N/m2

So,

=F*V

=10*102*96.17

P=96.17*103 Nm/sec

=96.17*103 J

P=96.17 KJ

Power developed by piston should be greater than required to cut the metal sheet. So,

Design is safe.
 Design of nut

Given Data

D=Diameter of nut

=24 mm

P=Power developed by piston

=18.61*103/4523.89

=41.137 N/mm2

=41.137 N/mm2<490 N/mm2

So, Design is safe.

Torsional shear stress for mild steel=1500 N/mm2

τs =P/A

τs=18.61*103/π/4(242)

τs= 41.137 N/mm2<1500 N/mm2

So, Design of nut is safe.

 CHAPTER-7

PROCESS FLOW

CHART
 PROCESS FLOW CHART

The below flow chart shows the sequential operation/steps that will be performed during

the project process flow chart.

CHAPTER-8
FABRICATION
 FABRICATION
Manufacturing involved in conversion of raw/race material into the finished
product.

To understand the manufacturing system in a better way, it is divided into three

parts.

1. Input
2. Process
3. Output

1. Input: Man, machine and energy.

2. Output: Related to design, the product and production management.
3. Output: Finished product or service.

PROCESS PLANNING:-
Process planning is an important function, which takes place directly after the design
of a product. It takes thee information received and creates plan for manufacture. The
process planning involves an application of systematic procedures, which involves following
steps.
A. PRELIMINARY PART PRINT ANALYSIS:-
1. Size configuration
2. Material
3. Dimension relationship and identification of various reference surfaces.
4. Implicit and explicit remark regarding from error and finish.
B. LOGICAL SEQUENCE OF OPERATIONS
1. Identification of surface to be machined, selection of machine tool.
2. Supporting accessories, picture, gauges etc.
Now to make machine tool for reducing vibrations great extent and
increase strength casting (gear box casting) is the method mostly adopted
but for our purpose casting is not economical as generality is it is adapted for
man production and for one piece it is too much costly so alternative is only
wielding. This technique gives maximum efficiency of joints and strength if
proper care is taken at the time of wielding.
It is economical and easy for manufacturing.
Fabrication by wielding results in higher construction thus there is
also saving of material and the time required is also less.
Here material for fabrication is mild steel of different tip of sheets,
Pipes, Bars and Blocks.

So two types of welding are adapted:-

1. Electric arc welding

2. Gas oxyacetylene welding

Mostly round in flat section used in manufacturing so electric arc welding is used.
ARC WELDING
 Basically, an electric arc is used to heat base material and consume filler rod.
 This is the most common form of welding and is used in about half of all
applications.
 A power supply is used to high potential between an electrode (guided by
welder) and metal work piece. When moved close enough electrode breaks
down air and start to flow. Local current of flow is so high that heats metal up
to 33000o c or 54000oF.
 CHAPTER-9
ADVANTAGES
AND
DISADVANTAGES
ADVANTAGES
A. Simple construction.
B. High power
C. More efficient
D. Anything can be cut
E. Less space is required

DISADVANTAGES
A. It requires power supply
B. Failure of compressor system does not work
C. It requires more space
D. High investment cost
E. Jerky in motion
F. Cutting size is limited
CHAPTER-10
APPLICATION
 APPLICATIONS
 Cutting the metal sheets for manufacturing car bodies
in automobile industries.
 Cutting the metal sheets for food drinking can in food
industries.
 Cutting the sheet metal for workshop purpose.
 Use for fabrication purpose.
 Cutting the sheets in construction work.
CHAPTER-11
CONCLUSION
 CONCLUSION
Now we know that pneumatic shearing machine is very cheap as compared
to hydraulic shearing machine. The range of cutting thickness can be
increased by arranging a high pressure compressor this machine is
advantageous to small sheet metal cutting industries as they do not have rely
expensive hydraulic shearing machine…….
CHAPTER-12
FUTURE
SCOPE
 FUTURE SCOPE
Since old age man is always trying to gain more and more luxurious. Man is always
trying to develop more and more modified technique with increasing aesthetic and
economic consideration. Hence there is always more and more scope. But being the
diploma Engineers and having the ability to think and plan. But due to some time
constraints, and also due to lack of funds, we only have thought and put in the report the
following future modification:-

1) It can be made to run has bottle cap sealing machine. The stationary can be made
auto swivelling type by installing the timer and heat sensor arrangement on the
platform. It can be done such that when the bottle mouth is sealed up to the desired
temperature electrical heater circuit gets cut off. At the same time the motor
installed in the reduction gear box starts operations the level gearing and the
platform starts rotating thus it can be made auto rotating type.
2) It can be made hydraulically operated type by replacing the hand lever by hydraulic
cylinder and along with ratchet and Paul arrangement….
3) It can be made hydraulically power operated by installing the gear oil pump at the
place of the air compressor and Pneumatic cylinder arrangement.
4) It can be made rack and pinion or spring and lever operated, by replacing the
Pneumatic circuit by rack and pinion arrangement by the square threaded screw
and nut arrangement.
5) The place where there is scare city of the electricity the electric motor operated
compressor is replaced by an I.C.Engine installed compressor.
Thus in future there are so many modifications, which we can make to survive the
huge global world of competition.
REFERENCES
 REFERENCES
[1] J.P.Den hartog advance strength of material (McGraw-Hill New
york1952) author name, Conference name year etc.
[2] E.W Coming high pressure technology (McGraw-ill New york 1956)
author name, Conference name year etc.

[1] Machine Design by R.S.Khurmi

[2] Workshop Technology by R.K.Jain
[3] Machine tool design hand book
[4] P.S.G Design data book