TRADE PROJECT

FABRIGATION OF COMPRESSED AIR PNEUMATIC SHEET CUTTING METAL

NAME : JAEL AUMA ADHIAMBO

COURSE : DIPLOMA IN MECHANICAL ENGINEERING PLANT

INDEX NO : 5341011151

PRESENTED TO: THE KENYA NATIONAL EXAMINATION COUNCIL IN

PARTIAL FULFILMENT FOR THE AWARD DIPLOMA IN

MECHANICAL ENGINEERING PLANT

SUPERVISOR: MR. NG’ETICH

SIRIES: NOVEMBER 2021

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DECLARATION

This research project is my original work and has never been presented anywhere.

Name: ……………………………………

Signature: __________________________ Date: ________________________

SUPERVISOR DECLARATION

This research project will be submitted for examination with my approval as the college

supervisor.

Name: ………………………………………….

Signature: _______________________________ Date: ________________________

DEDICATION

This study is dedicated to my parents, without whose prayers, support and relentless

encouragement during my class and research work, I would not have come this far.

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ACKNOWLEDGEMENT

I thank the Almighty God for enabling me and giving good health and courage throughout

my study. My sincere gratitude goes to my supervisor who challenged and guided me by

offering professional advice to carry out my research work. I also wish to acknowledge my

lecturers and classmate for willingly lending a hand and guiding me to put my work in

order. I also thank all my lecturers for teaching me and encouraging me during my studies.

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ABSTRACT

Use of aluminum is increased now days in many industries like automobile, packaging, medical

etc. The reason behind this is that the aluminum made things are quiet easier to manufacture,

handle and reliable to use. So the aluminum goods manufacturing industries are striving hard to

produce good quality products at large scale and cheaper cost. Hydraulically operated machines

are too costlier for small scale and medium scale industries. This paper deals with pneumatically

operated cutting machine. The Pneumatic compressed air machine is converted into

pneumatically operated machine by applying proper design procedure. The design was drawing

back using CREO software. At the end of task, the conclusion is made and several

recommendations are suggests to make an improvement about the result and the project for

future study.

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Table of Contents

DECLARATION ............................................................................................................................ 2

DEDICATION ................................................................................................................................ 2

ACKNOWLEDGEMENT .............................................................................................................. 3

ABSTRACT………………………………………………………………………………………
………………………………………………………5

1.1 INTRODUCTION ............................................................................................................ 7

1.2 Background information .................................................................................................. 8

1.3 Problem statement ............................................................................................................ 8

1.4 Objectives of the project .................................................................................................. 9

1.5 The scope study ................................................................................................................ 9

1.6 Justification of the project ................................................................................................ 9

1.7 Advantages ..................................................................................................................... 10

1.8 Disadvantages................................................................................................................. 10

1.9 Context model ................................................................................................................ 11

2 CHAPTER TWO ................................................................................................................... 12

2.1 LITERATURE REVIEW ............................................................................................... 12

2.2 Required components ..................................................................................................... 13

2.2.1 Electric powered motor ................................................................................................... 13

2.2.2 Air compressor .................................................................................................................. 14

2.2.3 IC Timer Circuit ............................................................................................................... 14

2.2.4 Double-acting cylinder .................................................................................................... 16

2.2.5 Pneumatic operated valves .............................................................................................. 17

2.2.6 High speed steel blade ..................................................................................................... 19

3 CHAPTER THREE ............................................................................................................... 20

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 3.1 DESIGN ANALYSIS/METHODOLOHGY ................................................................. 20

3.1.1 Introduction ....................................................................................................................... 20

3.1.2 Working flow chat ............................................................................................................ 20

3.1.3 Operation ........................................................................................................................... 21

3.1.4 Pneumatic transmission of energy ................................................................................. 21

3.1.5 Controlling ........................................................................................................................ 22

4 CHAPTER FOUR ................................................................................................................. 24

4.1 DATA ANALYSIS AND CONSTRUCTION .............................................................. 24

4.1.1 Construction ...................................................................................................................... 24

4.1.2 Actual diagram .................................................................................................................. 25

4.1.3 Data analysis and results ................................................................................................. 26

5 CHAPTER FIVE ................................................................................................................... 28

5.1 Introduction .................................................................................................................... 28

5.1.1 Conclusion ......................................................................................................................... 28

5.1.2 Recommendations ............................................................................................................ 29

5.1.3 Reference ........................................................................................................................... 30

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1.0. CHAPTER ONE

1.1 INTRODUCTION

This project is study about the design and fabrication of pneumatic compressed air cutting

machine which shows capability to design more than one concept and fabricate the machine

using a variety of machine. Other than that, it is important to studies on pneumatic and cutting

force analysis which are the main topic for this project. So, at the end of this project, we will

practicing on how to build and steps to follow to complete the requirement for this project.

Pneumatic systems use pressurized gases to transmit and control power. As the name implies,

pneumatic system typically use air (rather than some other gas) as the fluid medium because air

is safe, low cost and readily available fluid. The Pneumatic compressed air cutting machine is

designed using various components. The components are pneumatic cylinder, pressure regulator,

Solenoid/direction control valve, flow control valve, compressor, mounting table, Pneumatic

compressed air . The Pneumatic compressed air charge the battery that runs the compressor.

The cylinder is used for up and down motion of the cutting blade which performs the cutting

operation on the sheet of aluminium material. The compressor provides compressed air to the

cylinder, which causes movement of the piston rod. Different pneumatic systems work

efficiently at different operating pressure. Hence selection of pressure regulator of right range is

important for efficient working of pneumatic system. Pneumatic automation components

extensively use sealing material made out of rubber compounds. For efficient and trouble free

working of these seals, they need to be oiled or lubricated to reduce friction and corrosion.

Solenoid/Direction control valve is used to control the direction of the air. A device which gets

heated by the sun’s energy is called Pneumatic compressed air heating device. All the Pneumatic

compressed air heating devices are designed in such a way that they help in collecting as much

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sunlight as possible. The Pneumatic compressed air heating devices such as Pneumatic

compressed air cooker, Pneumatic compressed air water heater and Pneumatic compressed air

cells have greatly helped in solving the energy problem, its consumption and future energy

demands of our country. Pneumatic compressed air energy also reduces our dependence on fossil

fuel .It is a device which converts Pneumatic compressed air energy directly into electricity.

Since Pneumatic compressed air energy is a light energy so we can say, “Pneumatic compressed

air cell is a device which converts light energy into electrical energy.

1.2 Background information

Here is the advancement of the header which is carried out in the upward and downward

direction using the pneumatic double acting piston and cylinder unit arrangement along with the

foot operated direction control valve. In this type of machine high pressure air is used as the

working fluid for the transfer of power and the motion.

1.3 Problem statement

Compressed air quality is also affected by the presence of particles within the pneumatic system.

These particles can penetrate the system from various entry points. For instance, they may enter

through unclean compressor filters, be created through the normal production process, or even be

self-generated. The latter happens when the components within the system begin to wear out,

resulting in unwanted particles being generated as a by-product.

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1.4 Objectives of the project

 The main objective of our project is perform job holding operation effectively with less

human efforts by using a machine with the pneumatic power.

 To increase the production rate and automatically the industry will be in profit.

 To will also reduce the time required for metal cutting.

 To increase efficiency of industry.

1.5 The scope study

In this machine, compressed air is used to move the cutting tool for carrying out cutting

operation using electrical energy. After the completion of the cycle the air moves out through the

out port of Solenoid valve. This air is released to the atmosphere. In future the mechanism can be

developed to use this air again for the working of cylinder

1.6 Justification of the project

Now we know that pneumatic compressed air cutting machine is very high cheap as compared

to Hydraulic Shearing Machine. The range cutting thickness can be increased by arranging a

high pressure compressor and installing more hardened blades. This machine is advantageous to

small sheet metal cutting industries as they cannot effort the expensive hydraulic shearing.

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1.7 Advantages

 . Hydraulics present certain advantages over pneumatics, but in a given application,

pneumatic powered equipment is more suitable, particularly in industries where the

factory units are plumbed for compressed air.

 . Moreover, to avoid corrosive actions, oil or lubricants are added so that friction effects

can be reduced

 . Compressed air is used in most of the machines and in some cases compressed carbon

dioxide, whereas cutting process is become easy.

 Fast cutting action is carried out.

 Cutting without bending is achieved.

1.8 Disadvantages

 Sheet more than 2mm thickness can’t cut easily.

 Compressed air is must.

 Foundation is required also safety measure must be taken.

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1.9 Context model

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2 CHAPTER TWO

2.1 LITERATURE REVIEW

There are many sheet metal cutting processes. Laser sheet metal cutting process is one of

them. Many researchers have investigated experimentally the effect of various process

parameters on the different quality characteristics in the laser cutting of different categories of

materials. Rajaram have found the influence of laser power and feed rate (cutting

speed) on the kerf width in the laser cutting of 1.27 mm thick 4130 steel. Joseph Bramah

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patented the hydraulic press in 1795 While working at Bramah. Henry Mausdlay suggested

a cup leather packing. Because it produced superior results, the hydraulic press eventually

displaced the steam hammer from metal forging. Hydraulic power was used extensively

in Bessemer steel production. Hydraulic power was also used for elevators, to operate canal

locks and rotating sections of bridges. Some of these systems remained in use well into the

twentieth century. Harry franklin was called the "Father of Industrial Hydraulics" by ASME.

Pneumatics was first documented by Hero of Alexandria in 60 A.D, but the concept had

existed before then. Pneumatic devices are used in many industrial applications. Generally

appropriate for applications involving less force than hydraulic applications, and typically less

expensive than electric applications, most pneumatic devices are designed to use clean dry air as

an energy source. A pneumatic system is a system that uses compressed air to transmit and

control energy. In the big industries sheet metal cutting machines are very much important

to cut the sheet metal as a large amount. As a simple pneumatic sheet metal cutting machine

could not afford much in these big industries. It works for simple sheet metal cutting.

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2.2 Required components

The common components of this pneumatic sheet metal cutting machine are electrical

motor, air compressor, IC timer circuit, double acting cylinder, pneumatic operated valve and

high speed steel blade, air pipe etc.

2.2.1 Electric powered motor

The presence of the electric powered motor is used to drive the air compressor

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2.2.2 Air compressor

Air compressor is a device that convert power ( using an electric motor) into potential energy

stored pressurize air ( that is, compress air), by one of several method and air compressor force

more and more air into storage tank, increasing the pressure, when tank pressure reaches is upper

limit the air compressor shuts of the compress air, then, held in the tank until called into used

2.2.3 IC Timer Circuit

The IC 555 circuit is a highly stable controller capable of producing accurate time delays or

oscillations. In this timing operations, the time is precisely controlled by one external resistor and

a capacitor, by the operation as an oscillator, the free running frequency accurately contributed

with the external RC constants. The internal resistors act as a voltage divider network, providing

(2/3)Vcc at the non-inverting terminal of the upper comparator and (1/3)Vcc at the inverting

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terminal of the lower comparator. In most applications, the control input is not used, so that the

control voltage equals +(2/3) VCC. Upper comparator has a threshold input (pin 6) and a control

input (pin 5). Output of the upper comparator is applied to set (S) input of the flip-flop.

Whenever the threshold voltage exceeds the control voltage, the upper comparator will set the

flip-flop and its output is high. A high output from the flip-flop when given to the base of the

discharge transistor saturates it and thus discharges the transistor that is connected externally to

the discharge pin 7. The complementary signal out of the flip-flop goes to pin 3, the output. The

output available at pin 3 is low. These conditions will prevail until lower comparator triggers the

flip-flop. Even if the voltage at the threshold input falls below (2/3) VCC, that is upper

comparator cannot cause the flip-flop to change again. It means that the upper comparator can

only force the flipflop’s output high.

To change the output of flip-flop to low, the voltage at the trigger input must fall below + (1/3)

Vcc. When this occurs, lower comparator triggers the flip-flop, forcing its output low. The low

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output from the flip-flop turns the discharge transistor off and forces the power amplifier to

output a high. These conditions will continue independent of the voltage on the trigger input.

Lower comparator can only cause the flip-flop to output low. it is concluded that for the having

low output from the timer 555, the voltage on the threshold input must exceed the control voltage

or + (2/3) VCC. This also turns the discharge transistor on. To force the output from the timer

high, the voltage on the trigger input must drop below +(1/3) VCC. This turns the discharge

transistor off.

2.2.4 Double-acting cylinder

Double-acting cylinders (DAC) use the force of air to move in both extend and retract strokes.

They have two ports to allow air in, one for out-stroke and one for in-stroke Stroke length for

this design is not limited, however, the piston rod is more vulnerable to buckling and bending.

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2.2.5 Pneumatic operated valves

2.2.5.1 2/2 Directional control valves

The structure of a 2/2 directional control valve is very simple. It uses the thrust from the spring

to open and close the valve, stopping compressed air from flowing

towards working tube ‘A’ from air inlet ‘P’. When a force is applied to the control axis, the

valve will be pushed open, connecting ‘P’ with ‘A’ as shown in Fig.4. The force applied

to the control axis has to overcome both air pressure and the repulsive force of the spring. The

control valve can be driven manually or mechanically, and restored to its original position by the

spring.

2.2.5.2 3/2 directional control valve

A 3/2 directional control valve can be used to control a single acting cylinder (Fig. 5). The open

valves in the middle will close until ‘P’ and ‘A’ are connected together. Then another valve

will open the sealed base between ‘A’ and ‘R’ (exhaust) as shown in Fig 5.The valves can be

driven manually mechanically, electrically or pneumatically. 3/2 directional control valves can

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further be divided into two classes: Normally open type (N.O.) and normally closed type

(N.C.).

2.2.5.3 5/2 directional control valve

When a pressure pulse is input into the pressure control port ‘P’, the spool will move to the

left, connecting inlet ‘P’ and work passage ‘B’. Work passage ‘A’ will then make release of

air through ‘R1’ and ‘R2’as shown in Fig 6. The directional valves will remain in this

operational position until signals of the contrary are received. Therefore, this type of directional

control. On the other hand there exists many important components like: High speed steel

blade, Special Air pipe, Stainless Steel and most important Air compressor.

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2.2.6 High speed steel blade

Sheet metal is a metal form by an industrial process into think, flat pieces it is one of the

fundamental forms used in metal working and it can be cut and bend every day object are

fabricated form sheet metal.

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3 CHAPTER THREE

3.1 DESIGN ANALYSIS/METHODOLOHGY

3.1.1 Introduction

The main goal of project studies is to study about pneumatic control system. Then, to study

about double acting cylinder. Then, to study about the advantage of pneumatic compressed air

sheet cutting metal valve. Then, to study about high speed blade. Then, to design &

fabrication pneumatic sheet metal cutting machine. Then, collecting the proper components.

Then, machining them. Then, assembling the all components to a proper shape. Finally,

Completion the process to make a proper pneumatic compressed air sheet cutting metal

machine.

3.1.2 Working flow chat

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3.1.3 Operation

The most common cutting processes are performed by applying a shear force, and are therefore

sometimes referred to as shearing processes. Cutting processes are those in which a piece of

sheet metal is separated by applying a great enough force to cause the material to fail .When a

great enough shearing force is applied, the shear stress in the material will exceed the

ultimate shear strength and the material will fail and separate at the cut location. This

shearing force is applied by two tools, one above and one below the sheet. Whether these tools

are a punch and die or upper and lower blades, the tool above the sheet delivers a quick

downward blow to the sheet metal that rests over the lower tool. A small clearance is present

between the edges of the upper and lower tools, which facilitates the fracture of the

material. The effects of shearing on the material change as the cut progresses and are

visible on the edge of the sheared material. When the punch or blade impacts the sheet, the

clearance between the tools allows the sheet to plastically deform and “rollover” the edge. As

the tool penetrates the sheet further, the shearing results in a vertical burnished zone of

material, finally, the shear stress is too great and the material fractures at an angle with a

small burr formed at the edge. The height of these portions of the cut depends on several

factors, including the sharpness of the tools and the clearance between the tools.

3.1.4 Pneumatic transmission of energy

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The reason for using pneumatics, or any other type of energy transmission on a machine, is to

perform work. The accomplishment of work requires the application of kinetic energy to a

resisting object resulting in the object moving through a distance. In a pneumatic system,

energy is stored in a potential state under the form of compressed air. Working energy

(kinetic energy and pressure) results in a pneumatic system when the compressed air is allowed

to expand. For example, a tank is charged to 100 psi with compressed air. When the valve at the

tank outlet is opened, the air inside the tank expands until the pressure inside the tank equals the

atmospheric pressure. Air expansion takes the form of airflow. A positive displacement

compressor basically consists of a movable member inside a housing. The compressor has a

piston for a movable member. The piston is connected to a crankshaft, which is in turn

connected to a prime mover (electric motor, internal combustion engine). At inlet and outlet

ports, valves allow air to enter and exit the chamber.

3.1.5 Controlling

3.1.5.1 Controlling of pneumatic energy

Working energy transmitted pneumatically must be directed and under complete control at all

times. If not under control, useful work will not be done and machinery or machine

operators might be harmed. One of the advantages of transmitting energy pneumatically is

that energy can be controlled relatively easily by using valves.

3.1.5.2 Control of pressure

Pressure in a pneumatic system must be controlled at two points - after the compressor and

after the air receiver tank. Control of pressure is required after the compressor as a safety for

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the system. Control of pressure after an air receiver tank is necessary so that an actuator

receives a steady pressure source without wasting energy.

3.1.5.3 Control of pressure after a compressor

In a pneumatic system, energy delivered by a compressor is not generally used immediately,

but is stored as potential energy in air receiver tank in the form of compressed air. In most

instances, a compressor is designed into a system so that it operates intermittently. A

compressor is a device that usually delivers compressed air to a receiver tank until high

pressure is reached, then it is shut down. When air pressure in the tank decreases, the

compressor cuts in and recharges the tank. Intermittent compressor operation in this manner is

a power saving benefit for the system. A common way of sensing tank pressure and controlling

actuation and de-actuation of relatively small (2-15 HP) compressors, is with a pressure

switch.

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4 CHAPTER FOUR

4.1 DATA ANALYSIS AND CONSTRUCTION

4.1.1 Construction

The pneumatic compressed air sheet cutting metal is supported by a table includes with support

arms to hold the sheet. The table also includes the two way directional control valve. The two

way directional control valve is also known as solenoid control valve. We used two way

directional control valve that is connected with the compressor by air pipe. The compressor

has a piston for a movable member. The piston is connected to a crankshaft, which is in turn

connected to a prime mover. At inlet and outlet ports, valves allow air to enter and exit the

chamber. When the compressor is switched ON, the compressed air is flow to inlet of the

pneumatic cylinder. The sheet is placed between the upper and the lower blade. The lower blade

remains stationary while the upper blade is forced downward. The upper blade is slightly offset

from the lower blade, approximately 5 – 10% of the sheet thickness. Also the upper blade is

usually angled so that the cut progresses from one end to the other, thus reducing the required

force. pneumatic compressed air sheet cutting metal solenoid valve is moved forward, the

piston starts moving in the forward direction. The upper blade which are then forced against

the sheet, cutting the material. When the pneumatic compressed air sheet cutting metal lever is

moved backward, the upper blade will come to the original position (i.e., the upper blade will

move upwards).After the material is cut, adjust the pneumatic compressed air sheet cutting metal

solenoid valve to the mid position (i.e., normal position) and then the compressor is switched off.

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4.1.2 Actual diagram

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4.1.3 Data analysis and results

4.1.3.1 Cylinder thrust

Cylinder thrust for double acting in forward stroke.

Then,

Cylinder thrust for double acting in return stroke -

2
𝐹 = (𝜋 /4) × (𝐷 – 𝑑) ×𝑃

where D = Diameter of bore in mm.

2
P = Pressure in bar. (1 bar = 0.1N/mm )

d = Piston rod diameter in mm.

After putting corresponding values according to the equation we can get that as per our

consideration the maximum force exerted by our cylinder is 10381.625N

4.1.3.2 Theoretical air consumption

2
𝐶 = {(π /4) × 𝐷 × (P + 1) × L}/1000

where, P= pressure in bar

D= Diameter of bore in cm.

L= Length of stroke in cm.

Theoretical Air Consumption of our pneumatic machine was, C= C = 22.85litres.

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4.1.3.3 Sheet metal cutting force

Cutting force = 𝐿 × 𝑆 × 𝑇𝑚𝑎𝑥

Stripping force =10% -20% of cutting force

𝐿 = Length of periphery to be cut in mm

𝑆 = Sheet thickness in mm

2
𝑇𝑚𝑎𝑥 = Shear strength in N/mm

𝑇𝑚𝑎𝑥 = 80% of tensile strength

After putting corresponding values according to the equation we can get that aggregated cutting

force of our Pneumatic compressed air sheet cutting metal Machine was F= 10080 N

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5 CHAPTER FIVE

5.1 Introduction

This chapter majors mainly on conclusion, recommendation and references of the project

5.1.1 Conclusion

Pneumatic systems are used in controlling train doors, automatic production lines, and

Mechanical clamps. The sheet metal cutting process is a main part of the all industries.

Normally the sheet metal cutting machine is Pneumatic compressed one for medium and small

scale industries. The sheet metal cutting machine works with the help of pneumatic double

acting cylinder. The piston is connected to the moving cutting tool. Sheet metal cutting machine

can be used to cut the sheet metal of minimum thickness without

manual hard work. This machine can also be installed in the lab for the experiment and

demonstration to engineering students. In this project I have tried my best to fabricate a

pneumatic sheet metal cutting machine which can cut the sheet metal in small pieces.

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5.1.2 Recommendations

Pneumatic compressed air sheet cutting metal machine is very cheap as compared to hydraulic

cutting machine or laser cutting machine. The range of the cutting thickness can be increased

by arranging a high pressure compressor and installing more hardened blades. This machine is

advantageous to small sheet metal cutting industries as they cannot afford the expensive

machine. Pneumatic compressed air sheet cutting metal machine can be used in various

industries or workshops.

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5.1.3 Reference

Prof. M. W. Andure, Suraj V Bhosale “Design and Fabrication of Pneumatic compressed air

sheet cutting metal Machine ” ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.88;

Volume 6 Issue 1, January 2018.

Suraj V Bhosale, Gajanan S Ghute, “Design and Fabrication of Pneumatic compressed air sheet

cutting metal-A review” e-ISSN: 2395-0056 p-ISSN: 2395-0072 Volume : 05; Issue: 01, 2018.

Asst.Prof. Raj Reddy, “Fabrication of Pneumatic Sheet Metal Cutter” ISSN NO. (print) : 0975-

8364; ISSN NO. (online) : 2249-3255

Pneumatic System: Principle & Maintentance by S.R.Mujumadhar

Machine Design by R. S. Khurmi

Manufacturing Process by O. P. Khanna and Lal [7] Machine Tool Design Handbook

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