Design and Development of Pneumatic Punching Machine

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072

Viraj N. Suryawanshi

, Nilesh V.Wakade

, Prof. Prashant A. Narwade

1,2

Student in Mechanical Engineering, D.V.V.P.C.O.E.A’nagar, Maharashtra, India

Professor in Mechanical Engineering, D.V.V.P.C.O.E.A'nagar, Maharashtra, India

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Abstract: A pneumatic punching machine is always a better choice than a hydraulic punching machine to produce 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.

Key Words: Compressed Air, Economical, Solenoid Valve, Polyurethane tubes, Pneumatic Cylinder

INTRODUCTION

Pneumatics, from the Greek (pneumatikos, coming from the wind) is the use of pressurized gases to do work in science

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

then. Pneumatic products represent a multi-billion dollar industry today. 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. The

actuator then converts that compressed air into mechanical motion. The type of motion produced depends on the design of

the actuator. Pneumatics is employed in a variety of settings. In dentistry applications, pneumatic drills are lighter, faster

and simpler than an electric drill of the same power rating (because the prime mover, the compressor, is separate from the

drill and pumped air is capable of rotating the drill bit at extremely high rpm). Pneumatic transfer systems are employed

in many industries to move powders and pellets. Pneumatic tubes can carry objects over distances. Pneumatic devices are

also used where electric motors cannot be used for safety reasons, such as mining applications where rock drills are

Pneumatic cylinders are generally less expensive than hydraulic cylinders of similar size and capacity.

1.1

OBJECTIVE OF PROJECT

To design and develop such a pneumatic punching machine which uses compressed air to generate high pressure to be

applied on piston and this high-pressure air fed to punch, forces it on the material. And thus punching operation is

performed.

LITERATURE SURVEY

Girish Gharat et all (1): This project has met its objective to produce a C-Frame Pneumatic Press and its function is

limited to V-Bending and Punching. We designed a pneumatic press which costs less than that available in the market. We

are very good at what we have done and had fun doing it. Our pneumatic press is useful to do metal forming operations

and as it is a 2 tonne capacity press.

Anand Kumar Singh et all (2): 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

K.K.Alaneme et all (3): The failure of punch die materials used in the production of cable trays has been investigated. The

analysis show that the short service life of the indigenous die component is due to incorrect heat-treatment which did not

remove the cold-worked structure in built in the material during production, thus resulting in inferior toughness and/or

fatigue resistance .It was equally identified that occasional misalignment of the mould upper die teeth and lower die plate

due to over exertion of the machine contributes to failure of the die material.

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072

Shridhar D. R. et all (4): In this paper design and control method of sheet metal punching machine is explained. By using

Programmable Logic Controllers as the controller of the whole system, good and easy control over the system can be

achieved. Manufacturing lead time of the system is reduced by developing automatic feeding mechanism, worker safety is

increased by reducing the human participation in the process and the problem of angular misalignment of sheets is also

reduced.

EXPERIMENTAL SETUP

1. COMPRESSOR: A compressor is a machine that compresses air or another type of gas from a low inlet pressure

(usually atmospheric) to a higher desired pressure level. This is accomplished by reducing the volume of the

gas. Air compressors are generally positive displacement units.

Fig3.1. Air Compressor

2. Pneumatic Cylinder: The cylinders convert the energy of the compressed air into linear motion which extend or

retract the piston rod.

Fig3.2. Pneumatic Cylinder

Selected pneumatic cylinder is listed below-:

Type of Cylinder

Bore Diameter

Stroke Length

Double Acting Cylinder

50 mm

100 mm

3. Direction Control Valve: Direction control valve is used to give proper direction to the working fluid for extension

and retraction of the piston in cylinder. Fig.3.1 shows direction control valve selected and Fig.3.2 shows mechanism of

operation.

Fig3.3. 5/2 hand lever operated DCV

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072

Fig3.4. Mechanism of 5/2 DCV

4. Polyurethene tubes: Polyurethene tubes are used for transmission of pneumatic fluid i.e. compressed air.

Polyurethene combines the best properties of both plastic and rubber. It offers abrasion and tear resistance, high tensile

and elongation values, and low compression set.

Fig3.5. Polyurethene Tube

5. Bed and Frame: Frame is the structure used for supporting pneumatic cylinder and Bed is the structure used for

handling the material to be punched.

For bed

Material

Length(cm)

Width(cm)

Height(cm)

Mild Steel

For frame

Material

Length(cm)

Width(cm)

Height(cm)

Mild Steel

6. Punch and Die: The sheet metal used is called strip or stock. The punch which is held in the punch holder is bolted to

the press ram while die is bolted on the press table. During the working stroke, the punch penetrates the strip, and on

the return stroke of the press ram the strip is lifted with the punch, but it is removed from the punch by the stripper

plate. The stop pin is a gage and it sets the advance of the strip stock within the punch and die. The strip stock is butted

against the back stop acting as a datum location for the center of the blank.

4. Working of system

The compressed air from the compressor at the pressure of 8 to 10 bar is passed through a pipe connected to the hand

lever operated valve with one input. The hand lever operated valve has two outputs pressure below the piston is more

than the pressure above the piston. So these move the piston rod from BDC to TDC. This force acting is passed on to punch

which also moves downwards. The punch is guided by a punch guide who is fixed such that the punch is clearly guided to

the die. The materials are in between the punch and die. So as the punch comes down the materials are sheared to the

required profile and one input. The air entering into the input goes out through two outputs. When the hand lever valve is

pressed, due to the high air pressure at the BDC of the piston, the air of the punch and the blank is moved downwards

through the die clearance. When the piston is at the extreme point of the stroke length, the exhaust valve is opened and the

air is exhausted through it and when hand lever operated valve is release the pressurized air come in at the TDC of the

piston and it pushes the piston from

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072

TDC to BDC. So the one side of the air is pulled downwards and the other side is lifted upwards. So the punch is therefore

pulled upwards from the die. Now the piston reaches the BDC of the required stroke length. Now the material is fed and

the next stroke of the piston is made ready.

5. Assembly

Fig.5 Assembly of Project

6. Simulation

Automation Studio is a circuit design, simulation and project documentation software for fluid power systems and

electrical projects conceived by Famic Technologies Inc.. It is used for CAD, maintenance and training purposes. Mainly

used by engineers, trainers and service and maintenance personnel.

Fig. 6.1 Extension of Cylinder

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072

Fig. 6.2 Retraction of Cylinder

Conclusions: This project has met its objective to produce a hole by pneumatic force. We are very good at what we have

done and had fun doing it. We can do simple operations like punching, which is very useful and helpful to do small works

at our college. We chose a simple c-frame machine which occupies less space which any one can operate.

We tested our project by punching the sheet metal. As our project is based on manufacturing of pneumatic punching

further modifications can be done and increase its applications.

Future Extension:

We contemplate the following future features which can be incorporated into this project:-

1) Automation of pneumatic punching machine

2) Accident avoiding systems by adding LDR sensors

3) Improvements in pneumatic machine by adding components like timers, silencers, etc.

References:

(1) Design and Fabrication of Pneumatic Punching and Bending Machine, 2015,IJSRD,Vol.3,Issue02,2015

(2) Design and Development of Pneumatic Punching machine , Anand Kumar Singh,IJTRE,Volume4,Issue 11,July2017

(3) Failure analysis of mould dies of an industrial punching machine, K.K.Alaneme,ELSEVIER,14 January

2009,Enginnering Failure Analysis 16(2009)2043-2046

(4) PLC Based Pnenumatic Punching Machine, Sridhar D.R.,2015,Journal of Mechanical Engineering and

Automation2015,5(3B):76-80

(5) 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.

(6) 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.

(7) Development of Micro Punching System”, B. Y.Joo', S. I. Oh, B. H. Jeon.1980

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072

BIOGRAPHIES:

Viraj Narayan Suryawanshi

B.E. Mechanical Engineering (2015-2019) D.V.V.P.C.O.E.Ahmednagar Maharashtra

India

Nilesh Vijay Wakade

B.E. Mechanical Engineering (2015-2019) D.V.V.P.C.O.E.Ahmednagar Maharashtra

India

Guided by:

Prof. Prashant A. Narwade Asst. Professor

Dept. of Mechanical Engineering D.V.V.P.C.O.E.Ahmednagar Maharashtra

India