4718 - DESIGN AND DEVELOPMENT OF PNEUMATIC PUNCHING

International Journal For Technological Research In Engineering

Volume 4, Issue 11, July-2017 ISSN (Online): 2347 - 4718

DESIGN AND DEVELOPMENT OF PNEUMATIC PUNCHING

MACHINE

Anand Kumar Singh

, Mitesh L Patel

1,2

Assistant Professor, Mechanical Engineering Department, KJ Institute Of Engineering and

Technology, Savli, Dist Vadodara Gujarat, India 391770

[email protected]; +918000154233, [email protected]; +919726765354

Abstract: Pneumatic is a branch of engineering that deals

which study of air/gas characteristic and also their use in

engineering appliances either in atmospheric or above

atmospheric pressure. Now a day number of application

increases in pneumatics system due to high carrying

capacity, low maintenance cost and most important not

dangerous. Either compressed air or inert gas are generally

used, this paper deals with different components of

punching machine (proto type) and their assembly and also

their related diagrams.

I. INTRODUCTION

Pneumatic is a branch of engineering that deals which study

of air/gas characteristic and also their use in engineering

appliances either in atmospheric or above atmospheric

pressure. Now a day number of application increases in

pneumatics system due to high carrying capacity, low

maintenance cost and most important not dangerous.

Pneumatic systems are power systems using compressed air

as a working medium for the power transmission. Their

principle of operation is similar to that of the hydraulic power

systems. An air compressor converts the mechanical energy

of the prime mover into, mainly, pressure energy of the

compressed air. This transformation facilitates the

transmission, storage, and control of energy. After

compression, the compressed air should be prepared for

desired work. A pneumatic system is a system that uses

compressed air to transmit and control energy. Pneumatic

systems are used in controlling train doors, automatic

production lines, mechanical clamps etc. Pneumatic

cylinder(s) (sometimes known as air cylinders)

are mechanical devices which use the power of compressed

gas to produce a force in a reciprocating linear motion.

Like hydraulic cylinders, something forces a piston to move

in the desired direction. The piston is a disc or cylinder, and

the piston rod transfers the force it develops to the object to

be moved. Engineers sometimes prefer to use pneumatics

because they are quieter, cleaner, and do not require large

amounts of space for fluid storage. Because the operating

fluid is a gas, leakage from a pneumatic cylinder will not drip

out and contaminate the surroundings, making pneumatics

more desirable where cleanliness is a requirement. For

example, in the mechanical puppets of the Disney Tiki

Room, pneumatics are used to prevent fluid from dripping

onto people below the puppets. A pneumatic motor (Air

motor) or compressed air engine is a type of motor which

does mechanical work by expanding compressed air.

Pneumatic motors generally convert the compressed air

energy to mechanical work through either linear or rotary

motion. Linear motion can come from either a diaphragm or

piston actuator, while rotary motion is supplied by either a

vane type air motor, piston air motor, air turbine or gear type

motor. Pneumatic motors have existed in many forms over

the past two centuries, ranging in size from hand-held motors

to engines of up to several hundred horsepower. Some types

rely on pistons and cylinders; others on slotted rotors with

vanes (vane motors) and other uses turbines. Many

compressed air engines improve their performance by

heating the incoming air or the engine itself. Pneumatic

motors have found widespread success in the hand-held tool

industry,[1] but are also used stationary in a wide range of

industrial applications. Continual attempts are being made to

expand their use to the transportation industry. However,

pneumatic motors must overcome inefficiencies before being

seen as a viable option in the transportation industry.

HVAC (Heating, Ventilation& Air Conditioning)

HVAC equipment needs a control system to regulate the

operation of a heating and/or air conditioning system.

Usually a sensing device is used to compare the actual state

(e.g. temperature) with a target state. Then the control system

draws a conclusion what action has to be taken (e.g. start the

blower).

Why we choose the Pneumatic system?

High effectiveness

High durability and reliability\

Simple design

High adaptability to harsh environmentSafety

Easy selection of speed and pressure

Environmental friendly

Economical

Punching Machine

A punching machine is a machine tool for punching.

Principle of Operation

After programming the work pieces and entering length of

bars the control automatically calculates the maximum

number of pieces to be punched (for example 18 pieces of a

bar of 6000 mm). Once the desired number of work pieces is

entered, the bar is pushed toward the stop. The machine is

fully automated once the production process is launched.

The third CNC axis always moves the cylinder exactly over

the tool, which keeps the wear on the bearings and tools to a

minimum. All pieces are sent down a slat conveyor and are

pushed sideways on a table. Any scrap is carried to the end

of the conveyor and dropped into a bin. Different workpieces

International Journal For Technological Research In Engineering

Volume 4, Issue 11, July-2017 ISSN (Online): 2347 - 4718

can be produced within one work cycle to optimize

production.

CNC Punching

Punch presses are developed for high flexibility and efficient

processing of metal stampings. The main areas of application

are for small and medium runs. Those machines are typically

equipped with a linear die carrier (tool carrier) and quick

change tools. Today the method is used where the application

of lasers are inefficient or technically impractical.

Programming

Programming is done on a PC equipped with appropriate

software that can be part of the machine or a connected

external workstation. For generating a new program

engineering data can be imported or pasted per mouse and

keyboard. Through a graphic and menu-driven user interface

previous CNC programming skills are not required. All the

punches in a work piece are shown on the screen making

programming mistakes easily detected. Ideally each program

is stored in one database, in this manner it is easy to recover

them by search and sort functions. When selecting a new

piece, all the necessary tooling changes are displayed. Before

transferring it to the control unit the software scans each

program for possible collisions. This eliminates most

handling errors.

Tool changing system

The linear tool carrier (y-axis) has several stations that hold

the punching tools and one cutting tool. Especially for

flexibility and efficient processing are setup times a crucial

cost factor. Downtimes should be reduced to a minimum.

Therefore, recent tool systems are designed for fast and

convenient change of punches and dies. They are equipped

with a special plug-in system for a quick and easy change of

tools. There is no need to screw anything together. The punch

and die plate are adjusted to each other automatically

Punches and dies can be changed rapidly meaningless

machine downtime.

II. LITERATURE REVIEW

Manish Kale, 2015 - Most of the manufacturing industries

are going for automation to increase the productivity and to

overcome shortage of skill labour. The purpose of this paper

is to reduce the cycle time by replacing drilling machine and

riveting machine by special purpose machine(SPM) for

drilling and riveting operation. The concept is that the plate

having different size and thickness are drill on drilling

spindle first and then riveted on orbital riveting spindle. Both

the operation performs on same machine having two separate

spindles. In this paper gives the detail information of design,

fabrication and analysis of special purpose machine and

compare the cycle time with conventional method. This

machine is containing automation by using pneumatic

system. Modeling is done using CAD software and analysis

by FEA tool. The design is analysed for induced stress on

work piece due to various load condition.

GirishGharat, 2015 - The 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.

P.Goyal, 2015 - This project work deals with the design of

pneumatically controlled small scale punching machine to

carry out piercing operation on thin sheets (1-2 mm) of

different material (aluminum and plastic). Reduction in

punching force requirement being the main aim of this

project work is obtained by modification in punch tool

design i.e. by provision of shear on punch face. Subsequently

it results in reduction in amount of punching force

requirement. And further a CATIA model of the machine is

developed on the basis of calculations with respect to

punching force requirement.

AMIT M. GEDAM, 2014 - In today world, due to advance

manufacturing process and advance machining process the

time of production is reduces. Thus the productivity

increases which effect on mass production and batch

production. So it is essentially to products name plate parts

to be the manufacture. There are a variety of crafts for an

embossing machine that allow you to create unusual,

signature pieces of artwork. Embossing machines come in

several varieties. There are multi-tasking embossers

available at craft and scrapbooking stores that allow you to

embellish and cut card stock and paper pieces into a variety

of different designs in a single motion. You can also use

embossing machines that feature

Custom-made thick rubber dyes secured with hand-held or

desk-mounted metal handles. These machines allow you to

create personal monogrammed or logoed designs with a

raised surface, and they can be ordered through office and

business supply stores.

Baoren Li and Jinyun Li, 2008 - The Pneumatic Center in

Huazhong University of Science and Technology (HUST) is

one of the most active research center in fluid power

transmission and control in China. The main fields of

Pneumatic Center in HUST are component development and

control technology of fluid power. Hydraulics research is the

most important part of fluid power in the Pneumatic Center

in HUST. Based on several decades of the research on the

hydraulics in HUST, the further research and new

application in this field are made, include underwater motion

platform, automatic buoyancy regulation technology and

new type hydraulic valve, etc.. From 1996, the Pneumatic

Center in HUST focuses on the combination of electronics,

computer technology and pneumatics, and the research

achievement play a very important role in some state key

engineering projects successively. The pneumatic research

International Journal For Technological Research In Engineering

Volume 4, Issue 11, July-2017 ISSN (Online): 2347 - 4718

and applications have been developed, such as the gas

temperature control technology, pressure and vacuum servo

control technology, leak-testing technology, pneumatic

muscle platform and the high pressure pneumatic valve, etc..

In this paper the main research and application of hydraulic

and pneumatic in Pneumatic Centre in HUST are introduced.

Also some practical examples research projects and subjects

in above fields are presented.

Yunxu SHI, 2005 - The air with certain pressure in a

pneumatic cylinder is usually exhausted into the atmosphere

after work process. It is of significant that the air energy can

be saved and re-used. In this paper, the constitution of an

exhausted-air reclaiming system for pneumatic cylinders is

studied. To find the possible influence on the cylinder work

process, the effect of the system on the cylinder velocity

characteristics is also researched and different control switch

points are tested. Experimental results show that attaching a

reclaiming device would not cause bad influence on the

velocity stability if the switch point could be properly

controlled. Experiments also indicate that the switch control

differential pressure ΔPsw varies with Pc in the receiver and

the supply pressure Ps would affect the velocity stability of

cylinders. Therefore to reclaim more energy and make less

influence on the cylinder velocity characteristics, the suitable

differential pressure ΔPsw and switching-point are also tested

and suggested.

III. PROBLEM STATEMENT

Hand operated punching has many advantage and

disadvantages, like hand punching has accuracy and job

availability but due to late work complete, accident and high

cost, alternate source of operation started.

Pneumatic punching machine give us high accuracy with

before time completion and second most important, it is not

dangerous and second does not worried about slot of jobs.

COMPONENT

Double Acting Cylinder

120psi Pneumatic double acting cylinder(60*80)

2. Solenoid valve

3. Solenoid coil

4. Solenoid valve wide switch

5. Tank- 120psi plastic round with 3 out put

6. Pipe- 190psi ,6mm pipe (air)

International Journal For Technological Research In Engineering

Volume 4, Issue 11, July-2017 ISSN (Online): 2347 - 4718

7. 12v D.C coil

8. Compressor – 12v D.C , 300psi

Working Layout

MODELING

Solid works is a computer graphics system for modeling

various mechanical designs for performing related design and

manufacturing operations.

The system uses a 3D solid modeling system as the core, and

applies the feature base parametric modeling method.

Solid works is a feature based parametric solid modeling

system with many extended design and manufacturing

application.

Desire model of project

Final model of project

IV. CONCLUSION

Pneumatic system is better than hydraulic system and

mechanical system in terms of maintenance, cost, accuracy,

Productivity. Based on calculation project model work on

max 42 bar punching force.

REFERNCES

[1] Design of a Pressure Observer and its Application

to a Low CostPneumatic Control System”, Takahiro

Kosaki and Manabu Sano, year 2011 , Int. J. of

Automation TechnologyVol.5No 4.

[2] Design and applications of a pneumatic accelerator

for high speed punching” ,Su¨leymanYaldız ,

HacıSag˘lam, Faruk U nsacar, HakanIsik , 2007,

Materials and Design 28. 889–896.

[3] Development of a micro-forming system for micro-

punching process of micro-hole arrays in brass foil”

, JieXu, Bin Guo, Debin Shan, Chunju Wang, Juan

Li , YanwuLiuc, DongshengQu , 2012 ,Journal of

Materials Processing Technology 212 ,2238– 2246.

[4] A new design method for single DOF mechanical

presses with variable speeds and length-adjustable

driving links” ,Ren-Chung Soong ,2010

,Mechanism and Machine Theory 45, 496–510.

[5] Development of Micro Punching System” , B. Y.

Joo', S. I. Oh, B. H. Jeon.1980

[6] Comparison of three advanced hard coatings for

stamping applications”X.T. ZengU, S. Zhang, T.

International Journal For Technological Research In Engineering

Volume 4, Issue 11, July-2017 ISSN (Online): 2347 - 4718

Muramatsu ,2000, Surface and Coatings Technology

127/38-42.

[7] Flexible punching method using an elastic tool

instead of a metal punch” presented by

HisakiWataria, Hiroshi Onab, Yu Yoshida, 2003,

Journal of Materials Processing Technology

137,151–155.

[8] Thermal behavior of aluminum-coated 22MnB5 in

hot stamping under dry and lubricated conditions” ,

Akira Azushimaa, KosukeUdab, Hiroki Matsudaa,

2014 , Journal of Materials Processing Technology

214,3031– 3036.