FABRICATION OF PNEUMATIC PUNCHING AND RIVETING

MACHINE

SYNOPSIS

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. When the pneumatic system is being adopted for the first time, however

it wills indeed the necessary to deal with the question of compressed air supply.

The key part of any facility 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 delivered the air at a high pressure.The main purpose of this

project is punching the objects for much application, like sealing, name

punching, plate designing and etc. Here we are designing a pneumatic spiral

punching making machines are necessary for saving the manufacturing time in

the process, pneumatic is act as a main role.

 CHAPTER I

INTRODUCTION

A pneumatic punching machine is always a better choice than a hydraulic

punching machine for the production of similar products if it is suited for the

method. It is comparatively more economical for production of large quantities

of products as it uses compressed air rather than some hydraulic fluid which is

rather expensive. A pneumatic punching machine uses compressed air to

generate high pressure to be applied on the piston. A solenoid valve controls the

directional flow of air into and out of the cylinder. Polyurethane tubes are used

for pressure transmission from the pneumatic cylinder to the punch assembly.

The high pressure air fed to the punch, forces it on the material and as the punch

descends upon the sheet, the pressure exerted by the punch first cause the plastic

deformation of the sheet. Since the clearance between the punch and the die is

very small, the plastic deformation takes place in a localized area and the sheet

material adjacent to the cutting edges of the punch & die edges becomes highly

stressed, which causes the fracture to start on both sides of the sheet as the

deformation progresses.
 The pneumatic press makes an important contribution to the output of

engineering work shops and is indispensable for the cheap production of large

quantity of similar articles when the type of articles concerned is suited of this

method of production. A pneumatic press utilizes a compressed air source to

control operation of piston for high pressure to obtain desire component by using

press tools. The press includes a piston operated by the compressed air source to

drive a piston rod to operate the press. This pneumatic press is suitable for small

press tool works. It works on the principal of compressed air. A compressor

plant, pipe lines control valve, drive-members and related auxiliary application.

The air is compressed in an air compressor and for the compressor plant, the flow

medium is transmitted to the pneumatic system, it is of vital important that the

pressure drop between generation and consumption of compressed air is kept

very low, it has been seen that pipeline fittings and joints are mostly responsible

for drop in pressure, if any in pneumatic system.

This project is a study about the designing of pneumatic hole punching

machine, which shows the capability to design a concept using variety of

components. As the name implies, pneumatic systems use pressurized gases to

transmit power. Typically, pneumatic systems use air as the fluid medium,

because it is low cost, safe and easily available fluid.

The automatic pneumatic hole punching machine is designed using various

components. The components are pneumatic cylinder, pressure regulator,

solenoid valve, solar panel, and compressor. The application of solar panel is to

charge the battery that runs the compressor. The pneumatic cylinder is used to

obtain the ramming action to punch holes, and the compressor provides the

compressed air to the cylinder due to which the movement of piston cylinder

takes place. Different pneumatic systems works efficiently at different operating

pressure conditions. Therefore, the selection of suitable pressure regulator is

important for efficient working of pneumatic system.

1.1 Production of Compressed Air

Pneumatic systems operate on a supply of compressed air, which

must be made available in sufficient quantity end at a pressure to suit the

capacity of the system. When a pneumatic system is being adopted for the

time, however it wills indeed the necessary to deal with the question of

compressed air supply.

 The key part of any facility for supply of compressed air is the

compressor. A compressor is a machine that takes in air, gas or vapours at

any 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.

Clean condition of the suction air is one of the factors, which

decides the life of the compressors. Warm and moist air will result in

Compressors may be classified into two types, namely

1. Positive displacement compressors

2. Turbo compressors.

Positive displacement compressors are most frequently employed for

compressed air plants and have proved highly successful to supply air for

pneumatic control application.

 The types of positive Compressors are,

a. Reciprocating type compressors

b. Rotary type compressors.

Turbo compressors are employed where large capacity of air is

required at low discharge pressures. They cannot attain pressure

necessary for pneumatic control applications unless built in multi stage

designs are seldom en counted in pneumatic service.

1.2 Principle of Operation of a Press:

Every press has got certain basic units. They are bed frame, sliding ram,

drive for the ram and power source.

Base or bed is the lower part of the press frame. A thick plate called

bolster plate is placed on the top of the bed. A die is fitted on the top of the

bolster plate. The driving mechanism is mounted on the frame. The frame has got

guide ways for the sliding movement of the ram. The driving mechanism is

connected to the ram. The punch is fitted at the bottom of the ram. The die and

punch are correctly aligned. The work piece is in the form of sheet metal. It is fed
over the die. When the ram comes down, the punch presses the sheet metal. The

required operation is carried out.

As said earlier the force from the press is used to do a particular operation.

This is done by two main parts die and punch.

1.3Mechanical Advantage

Mechanical advantage can be defined as the ratio or the load lifted to the

power or the effort applied in the system to overcome the load successfully.

Principle of Levellers

The points A and B through which the load and effort is applied are

known as load and effort point respectively. F is the fulcrum about which

the lever is capable of turning. The perpendicular distance between the

load point and the fulcrum is known as the load arm. The perpendicular

distance between the effort point and the fulcrum is called as effort arm.

Taking moments about the fulcrum points,

W * L1 = P * L2
 The ratio of effort arm to parallel arm L2/L1 is called as leverage.

The displacement of effort to the displacement of load is called as

the Displacement Ratio.

 CHAPTER II

LITERATURE SURVEY

In a blanking or punching operation, the sheet gets deformed gradually

during the forward punch stroke. At times, there is a much localized plastic

deformation near the punch and die edges. At a certain stage of the punch travel,

thislocalized deformation gives way to origination of cracks. With a further

forward punch travel, these tool edge cracks propagate through the sheet

thickness leading to complete separation. J. Gresham, W. Cantwell, M.J. Cardew

Hall, P. Compston, S. Kalyanasundaram [1], experimentally found that blank-

holder force has a significant effect on the failure mode of the metal–composite

system with lower forces resulting in wrinkling as the dominate mode and higher

forces resulting in splitting and fracture.

A. A. Ambekar, S. K. Maiti, U. P. Singh, P. P. Date, K. Narasimhan [2],

showed the influence of various process parameters on sheet metal blanking.

Most machining operations do not often produce smooth or well-finished edges

on parts. Instead, parts will most likely end up exhibiting ragged, protruding,

sometimes hardened, material along edges, known as burrs. Burr formation

affects work piece accuracy and quality in several ways; dimensional distortion

on part edge, challenges to assembly and handling caused by burrs in sensitive

locations on the work piece and damage done to the work surface from the

deformation associated with burr formation. A typical burr formed on a metal

component due to the exit of a cutting edge can range in shape and size from

small and uniform (as in a “knife burr”) to rather large, non-uniform in shape and

many millimetres in length. D. Dornfeld and S. Min [3] explained the burrs in

conventional machining, process planning for burr minimization as well as

micromachiningapplications. Prof. T. Z. Quazi, R. S. Shaikh [4] discussed the

effect of potential parameters influencing the blanking process.

2.1 OBJECTIVE

Hydraulically operated machines are expensive and their maintenance cost

is high, which makes the manufacturing ofaluminum as well as plastic goods a

challenge for small scale industries. This project deals with pneumatically

operated hole punching machine.

 CHAPTER III

DESIGNING PROCESS

To make any machine part, the material should be properly and carefully

selected, considering safety. The selection of materials for engineering

applications is governed by the factors like availability, cost of the material & the

suitability of the material required for the components.

3.1 SELECTION OF MATERIAL

To prepare any machine part, the type of material should be properly

selected considering design and safety .The selection of material for engineering

application is given by the following factors:-

1) Availability of material

2) Suitability of the material for the application of the product.

3) Suitability of the material for the desired working conditions,

4) Cost of the materials.

The machine is basically made up of mild steel.

The reasons for the selection are:

 1. Mild steel is readily available in market

2. It is economical to use

3. It is available in standard sizes

4. It has good mechanical properties i.e. it has good machinability

5. It has moderate factor of safety, because high factor of safety results in

unnecessary wastage of material and heavy selection. Low factor of safety

results in unnecessary risk of failure

6. It has high tensile strength

7. Low coefficient of thermal expansion

The materials of the sheets to be punched are taken as aluminium and

plastic as they are replacing many metals in the present scenario because of their

distinguished properties and features.

I have selected mild steel, because it is readily available in the market,

economical for use and is available in standard sizes. Its mechanical properties

are good i.e. it is easily machinable, has moderate factor of safety. It also has

high tensile strength and low coefficient of thermal expansion. The sheet metal
which I have assumed to be punched are aluminum and plastic as I have designed

the machine keeping these two as reference.

3.2 FORCE CALCULATION FOR EXISTING PUNCH DESIGN

Terms and formulae used:

• Cutting force: - The force which has to act on the stock material in order to

cut the blank or slug.

• Stripping force: - The force developed due to the spring back (or

resiliency) of the punched material that grips the punch.

• Cutting force = L x t x Tmax

• Stripping force =10% -20% of cutting force

• L= Length of periphery to be cut in mm

• t= Sheet thickness in mm

• Tmax= Shear strength in N/mm2

• The formula to calculate the press force is as follows

 Press force = cutting force + stripping force

Sample Calculation for Aluminium Sheet

Here is a sample calculation to calculate the punching force required for different

thickness of aluminium sheet.

• Total length of cut, L =50 mm.

• If Sheet thickness, t = 1mm.

• Maximum tensile strength of aluminium, Tmax = 180 N/mm2

• Total cutting force = L x t x Tmax

• Total cutting force = 50 × 1 × 180

• Total cutting force = 9000 N

• Stripping force = 15% of the cutting force= 1350 N

• Press force = Cutting force + Stripping force= 9000 N + 1350 N= 10350 N

Sample Calculation for Plastic Sheet

Here is a sample calculation to calculate the punching force required for different

thickness of plastic sheet.

• Total length of cut L = 50 mm.

• If Sheet thickness, t = 1mm.

• Maximum tensile strength of plastic, Tmax = 90 N/mm2

 • Total cutting force= 4500 N

• Stripping force = 675 N

• Press force = Cutting force + Stripping force= 4500 + 675 N= 5175 N

3.3 DESIGN MODEL

3.4 DESCRIPTION OF MACHINE

The Pneumatic punching machine is developed using various components.

The components are pneumatic cylinder, pressure regulator, Solenoid/direction

control valve, flow control valve, compressor, mounting table. The cylinder is

used for up and down motion of the punch tool which performs the punching

operation on the sheet of aluminium/plastic material. The compressor provides

compressed air to the cylinder, which causes movement of the piston rod.

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. To lubricate

compressed air actuated equipment, the most efficient and economical method is

to inject the lubricant in to the compressed air that powers this equipment.

Solenoid/Direction control valve is used to control the direction of the air.

3.5 PNEUMATIC CONTROL COMPONENTS

Selection of Pneumatics
 Mechanization is broadly defined as the replacement of manual effort by

mechanical power. Pneumatics is an attractive medium for low cost

mechanization particularly for sequential or repetitive operations. Many factories

and plants already have a compressed air system, which is capable of providing

both 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).

The main advantages of an all-pneumatic system are usually economy and

simplicity, the latter reducing maintenance to a low level. It can also have

outstanding advantages in terms of safety.

The pneumatic punching and riveting machine consists of the following

components to fulfil the requirements of complete operation of the machine.

3.6 Solenoid valve:

5/2 Double Acting 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 in which the plunger is pushed

when the solenoid is energized electrically.

 The pull type solenoid is one in which the plunger is pulled when the

solenoid is energized. The name of the parts of the solenoid should be learned so

that they can be recognized when called upon to make repairs, to do service work

or to install them.

3.7 CYLINDER

An (pneumatic) air cylinder is an operative device in which the state input

energy of compressed air; (i.e.) pneumatic power is converted into mechanical

output power, by reducing the pressure of the air to that of the atmosphere. The

bore of the cylinder has very smooth finishing reduces friction and losses. There

are to angle plates welded to the cylinder as fitting means.

DOUBLE ACTING CYLINDER

A double acting cylinder is employed in a control system with a full

pneumatic cushioning and it is essential when the cylinders itself is required

heavy masses. The normal escape of air is out by ‘cushioning piston’.

PUNCH AND DIE

Die and punch are known as ‘press tools’. Die is the lower part of press

tool. It is clamped on the bolster plate of the press. It remains stationary during

the operation. The die has a cavity to receive the punch. The cavity may be with

clearance or without clearance.

Punch is the upper part of the press tool. It is attached to the lower end of

the ram of the press. It sheds with the ram during the operation and is forced into

the die cavity. Die and punch must be in prefect alignment for proper operation.

Die and punches are always used together. Dies are classified according to

either the type of construction or operation to be performed. High speed steel,

satellite or cemented carbide is the materials used for making dies and punches.

The die materials selected depend on the type of production, operation, sheet

metal thickness and accuracy.

A lever is a mechanical devices used to lift heavy loads by application of a

small effort. It is a rigid rod or bar, which turns about a fixed point called
fulcrum. A lever may be straight or curved. Lever works on the same principle as

that of principle of moments.

The load W is applied to the point A and hence the point A is known as

load point and point B is effort point. The point F is fulcrum. The perpendicular

distance (L1) between the load point A is load arm and L2 between is known as

effort arm.

The ratio of effort arm and load arm is called as leverage. The ratio of load

lifted and the effort applied is mechanical advantage.

Taking moments about fulcrum P*L2 =W*L1

COMPRESSOR

The compressor forms the main part of the pneumatic system by producing

the compressed air. Compressor capacity is the actual quantity of air compressed

and delivered and the volume expressed is that of the air intake conduction,

namely at atmospheric pressure and normal ambient temperature. The clear

conduction of the suction air one of the factors which decide the life of a

compressor. Compressor is generally classified into two types, namely

1. Positive displacement compressor

2. Turbo compressor

DIRECTION CONTROL VALVES

Direction control valves control the way the air passes and used for

controlling the commencements, termination and direction of air flow.

Depending on the number of paths the air is allowed to pass, directional valves

termed two way, three way, and four way or multi way valves.

The different number of rays by means the number of controlled

connection of the valve. Inlet connection to the compressed air supplies outlet

connections to the air consumer and exhaust connection to the atmosphere.

The solenoid valve is used to control the air flow direction. This is the

direction control valve in our project.

 CHAPTER IV

WORKING PRINCIPLE

The main components of pneumatic punching machine is

 Compressor.

 Pneumatic Cylinder

 control valve

 Pressure gauge

 Die(male, female)clamp

The main objective is to designing and developing a very compact, punch

making machine. Initially the switch unit operates the compressor which delivers

the air to the solenoid valve at certain pressure. The solenoid controls the flow

direction of air to the pneumatic cylinder. Thus the reciprocating motion of the

pneumatic cylinder creates high force to punch the work piece. This part consists

of two parts one is fixed called upper die, at the base and other is fixed called

lower die at the end of piston rod. This part is moved up and down to provide the

force on the object.

 Here we used for carrying the objects from one side to another side the

object when it comes, if it detects the object means it will out puts a low pulse to

the controller. Pneumatic is act as punching equipment. We can connect seal or

cup cast with the pneumatic for cup production. Different seals and casts are used

for punching the different shapes. When control unit detects the low pulse from

then that will ON the pneumatic for Punch. After a second the controller will

OFF the pneumatic. After getting the punch from the pneumatic spiral punch

making.

The Pneumatic punching machine is developed using various components.

The components are pneumatic cylinder, pressure regulator, Solenoid/direction

control valve, flow control valve, compressor, mounting table. The cylinder is

used for up and down motion of the punch tool which performs the punching

operation on the sheet of aluminium/plastic material.

The compressor provides compressed air to the cylinder, which causes

movement of the piston rod. 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. To lubricate compressed air actuated equipment, the most efficient and

economical method is to inject the lubricant in to the compressed air that powers

this equipment. Solenoid/Direction control valve is used to control the direction

of the air.
 CHAPTER V

ADVANTAGES AND DISADVANTAGES

5.1 ADVANTAGES

• It reduces the manual work

• It reduces the production time

• Uniform application of the load gives perfect removing of the bearing.

• Damages to the bearing due to the hammering is prevented

• It occupies less floor space

• Less skilled operator is sufficient

5.2 LIMITATIONS

• Initial cost is high

• Cylinder stroke length is constant

• Need a separate compressor

 CHAPTER VI

APPLICATIONS

6.1 APPLICATIONS

• Pressing Operation in all industries

• Paper punching industries

• Leather washer operation in all industries

• Punching operation also done

 CHAPTER VII

CONCLUSION

Pneumatically operated punching machine is suitable for small scale

andmedium size industries. Based on the shear provided on the punch face the

punching force reduction of 25% to 60% thereby increasing tool life and

reducing tool machining cost. Therefore with this force reduction we are able to

easily punch sheets. Circularity of various material sheets punched is

proportional to the blanking pressure and further investigation revealed that the

circularity embed on a plastic sheet material is more favorable than Aluminium

and Galvanized Iron as the ability to resist same pressure is less in plastic

material comparable to Aluminium and Galvanized Iron .

.
 CHAPTER VIII

FUTURE SCOPE

In this machine, compressed air is used to move the punch tool for

carrying out punching operation. 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.
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