Design and Development of Semi-Automatic Punching Machine with

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Design and Development of Semi-Automatic

Punching Machine with Feed Mechanism

Harit M. Trivedi,

Chitrang D. Rana,

Madhav K. Ghoyal,

Shivam N. Rana

Mechanical Engineers

G H Patel College of Engineering & Technology, Bakrol, Vallabh Vidyanagar-388120

Abstract:

Now world requires speed on each and every field. Hence quick work is most important New machine and

Techniques are being developed continuously to manufacture various product at cheaper rates and high quality.

This project is mainly carried out for production-based industries. Industries are basically meaning for

production cost, machinery cost and low inventory cost. Today in this world every task has been made quicker

and fast due to technology advancement but this advancement also demands huge investment and expenditure,

every industry desire to make high productivity rate maintaining the quality and standard of the product at low

average cost, but still we are using a separate machine for separate operations. This is a time and power

consuming process; it need maintenance as well as more space. Our project is to overcome above listed

problems. In our project two operations are built as a one machine tool i.e. punching and feeding of work

materials. This project we are designing and fabricating the prototype of “DESIGN AND DEVELOPMENT

OF SEMI-AUTOMATIC PUNCHING MACHINE WITH FEED MECHANISM”. This project is specially

designed for automatic punching in metal sheet. This project is to introduce automation in industries.

Keywords:

Semi-automatic feed, Punching mechanism, Gear train arrangement

Introduction:

Punching machine is one of the principle machines in paper cutting industry and sheet metal industry. It is

mainly used as the name indicated to cut strips. So, we are going to make it multipurpose and should be used

to cut the card board, asbestos sheets, papers, foam, thin plastic sheets.

Now, world requires speed on each and every field. Hence rapidness and quick working is the most important

in all field. New machine and techniques are being developed continuously and manufacture various products

at cheaper rates, high quality and less human efforts. In the convectional punching machine, the time taken for

job setting, feeding, punching operation is more. Labor cost is also more. With CAM based punching machine

this time taken for job setting, feeding, punching and reduce the labor cost, production cost and also

maintenance cost. In this project we are designing and fabricating of “Design and Development of Semi-

Automatic Punching Machine with Feed Mechanism”.

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This project is specially designed for automatic punching in metal sheet. This project is to introduce automation

in industries using mechanically arrangement. It is suitable for making mass production of the sheet metal

punching industry.

Aim:

In conventional punching machine, the time consumption for job setting, holding, marking, punching operation

is more. Labor cost and production cost are also more. Also, skilled worker required for the operation. So,

holding, feeding and injecting are operation of the sheet metal in punching machine are included in to ‘Auto

Feeding System’ by operate Cam driven. This project is specially designed for automatic punching in metal

sheet. This project is to introduce automation in industries using mechanically arrangement. It is suitable for

making mass production of the sheet metal punching industry.

Literature Review:

Every research is incomplete without suggestions from previous research work, so as with us we also referred

to the research paper and patent related to our work, along with punching machines available in our market

of our segment. Starting from PLC Based Pneumatic Punching Machine (Sudeep and Sridhar 2015) explained

about PLC controlled sheet metal punching machine with can replace existing manual feed punching

machine. After that, we came along Pneumatic Auto Feed Punching and Riveting Machine (A.S. Aditya and

K. Sri. Varsha 2012) explained about different type of punch dies can be used to attain wide range of products

and also, according to work material operating pressure can be varied. Design and development idea of the

punching machine was infused by Design and Development of Pneumatic Punching Machine (Viraj N.

Suryawanshi, Nilesh V. Wakade, Prof. Prashant A. Narwade 2019), from this research paper we got to know

that pneumatic punching machine is way to better to hydraulic punching machine in economical purposes.

In addition to that, pneumatic punching machine using compressed air generate high pressure to be applied

on piston. For the automation purpose we took insights from Design of Automatic Pneumatic Hole Punching

Machine (Utkarsh Sharma 2015). Maintenance cost of hydraulic machines are higher than pneumatic ones.

On the contrary, the production cost of pneumatics is cheaper than hydraulic. For the semi-automatic feed,

we were having numerous options like, chain drive, rollers, cam arrangement and many more however, using

rollers was the input taken from Design and Fabrication of Auto Roll Punching Machine (Kundan Kumar

2016), rollers were the cheapest and easiest mean to use for the punching machine. The rollers in

synchronization with cam arrangement were the punch is held. Calculation for the fourth requirement on

punch tool and its modification were exemplified from Review on Pneumatic Punching Machine and

Modification in Punch Tool to Reduce Punching Force Requirement (P. Goyal, G. Srivastava, R. Singh, N.

Singh 2015). Solid-works software was used for the simulation of the punching machine also, helped us to

design 3D view of our machine. For the smooth working of roller and its automation we helped out ourselves

through Autoroll Punching Machine (S.M. Kadu, A.P. Hingane, V.V. Dhon, R.B. Bahekar, Y.S. Chaware

2016). For the costing and components, we reviewed Automatic Punching Machine: A Low-Cost Approach

(Arun S, Sree Rajendra, Vijayavithal Bongale 2014). This research paper provided valuable insights on the

components and its costing. From this we also got to know the minimum number of components should be

use i.e. optimality should be attained. We also referred to the various punching machine available in our

surrounding and also hand zoned the same. We deduced flaws and advantages of the machines, used them

for our machine. We got ourselves helped from the book Design of Machine Elements (V.B. Bhandari) and

also used Theory of Machine by (R.S. Khurmi , J.K. Gupta).

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Component Details:

Table-1: Components

Closed Joint

Chain

Closed joint

chain is

connected to

the sprocket

wheel to

transmit the

power

between the

rollers.

Figure-2: Closed Joint Chain

Star

Coupling

The primary

purpose of

coupling is to

join two

pieces of

rotating

equipment. It

is used to

connect motor

and gear box

shaft.

Figure-3: Star Coupling

Sr. No.

Part Name

Quantity

Description

Figure

Gear Box

It is used for

speed

reduction to

get sufficient

output. 1:60 is

the gear speed

ratio.

It is attached

with the motor

with help of

star coupling.

Figure-1: Gear Box

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Sprocket

Sprocket is

used as the

power

transmitting

medium. The

sprocket

wheel is

placed at the

roller end to

connect the

closed joint

chain.

Figure-4: Sprocket

Free Wheel

Free wheel is

used to

provide the

particular

angle rotary

motion. It is

attached with

the spring and

rotating wheel

arrangement.

Figure-5: Free Wheel

Main Shaft

Bearing

Main shaft

bearing is

used to

provide the

rotary motion

in main shaft.

Figure-6: Main Shaft Bearing

CAM

Cam is placed

at the main

shaft. It is

used to

convert the

rotary motion

into

intermediate

motion.

Figure-7: CAM

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Feed Rollers

Roller is made

of mild steel

and shaft is

covered with

rubber

coating. The

roller is used

to feed the

workpiece.

Figure-8: Feed Rollers

Bearing

Roller ball

bearing is

used to

produce the

smooth rotary

motion on the

shaft.

The bearing is

placed at the

rollers end to

provide rotary

motion

without

friction.

Figure-9: Bearing

Step Up

Mechanism

It is used to

maintain the

punching hole

distance. We

have 4 variety

of distance in

this wheel. It

is attached

with main

shaft.

It is connected

with the

freewheel and

spring

arrangement

using closed

joint chain.

Figure-10: Step Up Mechanism

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Motor

In this

machine we

used single

phase AC

motor having

1440rpm with

0.5hp.

The motor is

main power

supply source

Figure-11: Motor

Assembly:

First the base plate was fitted with the supports under it. Then motor and shaft assembly separately were fixed

to the base plate. Motor and Gearbox is connected using start coupling. Cam drive fixed on main shaft and

attached with punching machine. Feed roller is fixed on frame with bearings. Auto feed is provided using Free

wheel and spring arrangement attached to roller. Other two rollers are connected using closed joint chain.

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Design Assembly:

Figure-12: Assembly of Components

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Top View:

Figure-13: Top View of Assembly

Left Hand Side View:

Figure-14: Left hand side view of assembly

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Right Hand Side View:

Figure-15: Right hand side view of assembly

3D Model of Assembly:

Figure-16: 3D Model of Assembly

Methodology:

This project consists by the designed with using Cam drive mechanism moving arrangement and punching

mechanism. Punching machine is designed with mechanical arrangement in which movements are controlled

by using Cam mechanism.

Auto roll punching machine consists of two sections. One section is Auto Feeding System and the second

section is conversion of rotary motion into linear reciprocating motion of punching tool. The first section

consists of Cam drive keyed to main shaft on the center it has attached punching tool with it. The end of main

shaft is connected with chain sprocket wheel. Sprocket will transfer the power from the gearbox and motor

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to main shaft. Main shaft will rotate with the Cam mechanism and the other end is connected with mechanism

which is providing the auto feed by the free wheel and the spring and the spring is connected with main shaft

threw closed joint chain and it is going through free wheel. The free wheel is rotating which is attached with

the main roller arrangement and roller start rotating with these and another chain is attached at the other end

two rollers will rotate with that arrangement. using this the auto feed will be provided to the rollers.

The second section consists of electrically operated DC motor, cam with a gear box and closed joint chain is

attached at the main shaft by using sprocket wheel. The second section is used to convert the rotary motion

of the cam into reciprocating motion of punching tool. The rotating shaft is keyed to the cam at the center

and the other end is connected to DC motor and gear box arrangement by chain’s sprockets. The punch tool

slide is reciprocated by the connecting the cam through the main shaft. The sheet is fed automatically by the

rotation of Cam. Punching operation will generate by the arrangement of cam and punching tool arrangement.

In this project, we can modify the heights of rollers by just adjusting screw arrangement over the rollers. The

punching operation can be done by using the Cam arrangement on the main shaft. The punching tool use

being guided by the guide block on the center of the frame. This guide will provide the proper direction to

the punching tool and punching will done properly.

Advantages:

 Reduction in production Time: Having a machine that definitely speeds up the production time seen

no thinking is needed by the machine, there is better repeatability and less human error.

 Less human error: No one is perfect, and we are all prone to making mistakes. Which is why a

machine that performs repeated task is less likely to make mistakes than employees.

 Less employee cost: By adding automated machines to an operation, means less employees are

needed to get the job done. It also indicates less safety issues, which leads to financial saving.

 Increased safety: Having automated machines means having less employees who perform task that

can be dangerous and prone to injury, which can make the work environment safer.

 Higher volume production: Investing in automated equipment creates a valuable resource for large

production volume, which in turn, will increase profitability.

 Increase the accuracy and repeatability: When an automated machine is programmed to perform

task over and over again, the accuracy and repeatability compared to an employee far greater.

Disadvantages:

 Less versatility: by having a machine that can perform a certain task limits to the flexibility and

variety of tasks that an employee could do.

 Increase in unemployment: by increasing the amount of automation, there are less employees

required causing high unemployment rates.

 Unpredictable costs: there can be several unpredictable costs that may exceed the actual cost saved

by the automation itself. Some cost of the design and fabrication of precise sized gears.

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Comparison with Conventional Machine:

Radius of hole punched (r) = 5mm

Thickness of sheet (t) = 2mm

Following table shows reading for punching 5 holes in series

Table-2: Comparison Between Convectional and Auto feed Punching Machine

Sr No.

Distance

between two

consecutive

punches

(millimeter)

Time required

for

Convectional

Punching

machine

(Second)

Time required

for Auto feed

Punching

machine

(Second)

Time saved in

Auto feed

punching

machine

(Second)

Conclusion:

The project carried out by us is used to make punching on G.I. Sheet with more prescribed than a conventional

punching machine. As conventional punching machine takes more time for Job setting, Holding, Marking,

Punching operation. Labor cost and production cost are also more. With this Cam based Auto Feed Punching

machine the time taken for all this process can be reduced and production time also reduced and production

rate will be high. No extra skill is required for operating this system. Operation is very smooth and, in this

system, we can get more output by applying less effort. It is more suitable for the mass production in industry.

It is very much useful for making series of holes of same diameter and constant pitch. Thus, it can be useful

for punching application.

Future Scope:

 In this project, we had modified the regular manual punching machine into the Auto Feed Punching

machine and we had used Cam mechanism to provide the timing and accuracy of the punching

operation.

 It can provide good work efficiency with less timing of job settling.

 Using for Higher production in Industries.

 Operation being fully automatic using less skilled employees and less labor cost.

 We can do punching operation in mass production by increasing power, more punching tool and cam

arrangement.

 Much useful for making series of holes of same diameter with constant pitch.

 We can also do blanking operation with this punching machine and we can increase it into mass

production.

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References:

1. Sudeep Kelaginamane, Sridhar D. R. “PLC Based Pneumatic Punching Machine” 2015, 5(3B): 76-80

2. A.S. Aditya Polapragada, K. Sri Varsha “Pneumatic Auto Feed Punching and Riveting Machine”, Vol.

1 Issue 7, September-2012 ISSN: 2278-0181

3. Viraj N. Suryawanshi, Nilesh V. Wakade, Prof. Prashant A. Narwade “Design and Development of

Pneumatic Punching Machine”, Vol. 06 Issue 05, May-2019 e-ISSN:2395-0056

4. Utkarsh Sharma “Design of Automatic Pneumatic Hole Punching Machine”, Vol. 02 Issue 09,

December-2015 e-ISSN: 2395-0056

5. Kundan Kumar “Design and Fabrication of Auto Roll Punching Machine”, Vol. 5 Special Issue 8, May-

2016 ISSN: 2319-8753

6. P. Goyal, G. Srivastava, R. Singh, N. Singh “Review on Pneumatic Punching Machine and

Modification in Punch Tool to Reduce Punching Force Requirement”, Vol. 2 Issue 2, February-2015

ISSN: 2394-3386

7. S.M. Kadu, A.P. Hingane, V.V. Dhon, R.B. Bahekar, Prof. Y.S. Chaware “Autoroll Punching

Machine”, Vol.4 Issue 1, 2016 ISSN: 2321-0613

8. Arun S, Sree Rajendra, Vijayavithal Bongale “Automatic Punching Machine: A Low-Cost Approach”

Vol. 4 Number 5, 2014 ISSN: 2250-3234

9. R.S. Khurmi, J.K. Gupta “Theory of Machines” Eurasia Publishing House 2005

10. V.B. Bhandari “Design of Machine Elements”, McGraw Hill Education