PNEUMATIC HIGH SPEED HACK SAW MACHINE

Submitted in partial fulfillment of the requirement for the award of

DIPLOMA
IN
MECHANICAL ENGINEERING
BY

Under the guidance of ---------------------------

2004-2005

DEPARTMENT OF MECHANICAL ENGINEERING

 CERTIFICATE

Register number: _________________________

This is to certify that the project report titled

“PNEUMATIC HACK SAW MACHINE” submitted by the

following students for the award of the Diploma

engineering is record of bonafide work carried out by

them.

Done by

Mr. / Ms_______________________________

In partial fulfillment of the requirement for the award of

degree in

Diploma Engineering in Mechanical

During the Year – (2004-2005)

_________________ _______________
Head of Department Guide

Coimbatore –641651.
Date:

Submitted for the university examination held on

___________
_________________ ________________
Internal Examiner External
Examiner
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ACKNOWLEDGEMENT
---------------------------------------------------------------------------------
 ACKNOWLEDGEMENT

At this pleasing moment of having successfully

completed our project, we wish to convey our
sincere thanks and gratitude to the management
of our college and our beloved chairman
…………………………………………………, who provided all
the facilities to us.
We would like to express our sincere thanks to
our principal ………………………………………, for
forwarding us to do our project and offering
adequate duration in completing our project.
We are also grateful to the Head of
Department Prof. …………………………………….., for
her constructive suggestions & encouragement
during our project.
With deep sense of gratitude, we extend our
earnest & sincere thanks to our guide
…………………………………………………….., Department
of Mechanical for her kind guidance &
encouragement during this project.
 We also express our indebt thanks to our
TEACHING and NON TEACHING staffs of
MECHANICAL ENGINEERING DEPARTMENT,
……………………….(COLLEGE NAME).
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PNEUMATIC HACK SAW
MACHINE
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CONTENTS
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CONTENTS

CHAPTER
NO TITLE PAGE NO
1 Introduction
2 Literature survey
3 Components and Description
4 Design and drawings
5 Working principle
6 Fabrication
7 Applications
8 Need for automation
9 Advantages and limitations
10 Process sheet
11 List of materials
12 Cost estimation
13 Conclusion
Bibliography
Photography
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Chapter-1
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INTRODUCTION
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 CHAPTER-1

INTRODUCTION

The hacksaw is a metal cutting machine tool designed to cut metal by applying

pneumatic pressure.

The machine is exclusively intended for mass production and they represent the

fastent and more efficient way to cut a metal.

Hacksaws are used to cut thin and soft metals. The operation of the unit is

simplified to a few simple operations involving a cylinder block and piston arrangement.

There are numerous types of cutting machines in Engineering field, which are

used to fulfil the requirements. We are interested to introduce pneumatic system in

Hacksaw machine.

The main function of Pneumatic hacksaw is to cut thin and soft metals by

pneumatic power.
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Chapter-2
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LITERATURE SURVEY
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 CHAPTER-2

LITERATURE SURVEY

PNEUMATICS

The word ‘pneuma’ comes from Greek and means breather wind. The word

pneumatics is the study of air movement and its phenomena is derived from the word

pneuma. Today pneumatics is mainly understood to means the application of air as a

working medium in industry especially the driving and controlling of machines and

equipment.

Pneumatics has for some considerable time between used for carrying out the

simplest mechanical tasks in more recent times has played a more important role in the

development of pneumatic technology for automation.

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.

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.

The compressibility of the air was first investigated by Robert Boyle in 1962 and

that found that the product of pressure and volume of a particular quantity of gas.

The usual written as

PV = C (or) PıVı = P2V2

In this equation the pressure is the absolute pressured which for free is about 14.7

Psi and is of courage capable of maintaining a column of mercury, nearly 30 inches high

in an ordinary barometer. Any gas can be used in pneumatic system but air is the mostly

used system now a days.

SELECTION OF PNEUMATICS

Mechanization is broadly defined as the replacement of manual effort by

mechanical power. Pneumatic 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 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 advantage of an all pneumatic system are usually economic and

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

advantages in terms of safety.

PRODUCTION OF COMPRESSED AIR

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

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.

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 a

compressor. Warm and moist suction air will result in increased precipitation of condense

from the compressed air. Compressor may be classified in two general types.

1. Positive displacement compressor.

2. Turbo compressor

Positive displacement compressors are most frequently employed for compressed

air plant and have proved highly successful and supply air for pneumatic control

application.
 The types of positive compressor

1. Reciprocating type compressor

2. Rotary type compressor

Turbo compressors are employed where large capacity of air required at low

discharge pressures. They cannot attain pressure necessary for pneumatic control

application unless built in multistage designs and are seldom encountered in

pneumatic service.

RECIPROCATING COMPRESSORS

Built for either stationary (or) portable service the reciprocating compressor is by

far the most common type. Reciprocating compressors lap be had is sizes from the

smallest capacities to deliver more than 500 m³/min. In single stage compressor, the air

pressure may be of 6 bar machines discharge of pressure is up to 15 bars. Discharge

pressure in the range of 250 bars can be obtained with high pressure reciprocating

compressors that of three & four stages.

Single stage and 1200 stage models are particularly suitable for pneumatic

applications , with preference going to the two stage design as soon as the discharge

pressure exceeds 6 bar , because it in capable of matching the performance of single stage

machine at lower costs per driving powers in the range .

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Chapter-3
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COMPONENTS AND
DESCRIPTION
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 CHAPTER-3

COMPONENTS AND DESCRIPTION

PNEUMATIC CONTROL COMPONENT

Pneumatic cylinder

An air cylinder is an operative device in which the state input energy of

compressed air i.e. pneumatic power is converted in to mechanical output power, by

reducing the pressure of the air to that of the atmosphere.

Single acting cylinder

Single acting cylinder is only capable of performing an operating medium in only

one direction. Single acting cylinders equipped with one inlet for the operating air

pressure, can be production in several fundamentally different designs.

Single cylinders develop power in one direction only. Therefore no heavy

control equipment should be attached to them, which requires to be moved on the piston
return stoke single action cylinder requires only about half the air volume consumed by a

double acting for one operating cycle.

Double acting cylinders :

A double acting cylinder is employed in control systems with the full

pneumatic cushioning and it is essential when the cylinder itself is required to retard

heavy messes. This can only be done at the end positions of the piston stock. In all

intermediate position a separate externally mounted cushioning derive most be provided

with the damping feature.

The normal escape of air is out off by a cushioning piston before the end of the stock

is required. As a result the sit in the cushioning chamber is again compressed since it

cannot escape but slowly according to the setting made on reverses. The air freely enters

the cylinder and the piston stokes in the other direction at full force and velocity.

VALVES

a) 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 is 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.
Working of 5/2 Solenoid Valve

The solenoid valve has 5 openings. This ensure easy exhausting of 5/2 valve. The

spool of the 5/2 valve slide inside the main bore according to spool position; the ports get

connected and disconnected. The working principle is as follows.

Position-1

When the spool is actuated towards outer direction port ‘P’ gets connected to ‘B’

and ‘S’ remains closed while ‘A’ gets connected to ‘R’

Poisition-2

When the spool is pushed in the inner direction port ‘P’ and ‘A’ gets connected to

each other and ‘B’ to ‘S’ while port ‘R’ remains closed.

Parts of Solenoid Valve

1. Coil

The solenoid coil is made of copper wire. The layers of wire are separated by

insulating layer. The entire solenoid coil is covered with an varnish that is not affected by

solvents, moisture, cutting oil or often fluids.

 Coils are rated in various voltages such as 115 volts AC, 230 volts AC, 460 volts

AC, 575 Volts AC, 6 Volts DC, 12 Volts DC, 24 Volts DC, 115 Volts DC & 230 Volts DC.

They are designed for such frequencies as 50 Hz to 60 Hz.

2. Frame

The solenoid frame serves several purposes. Since it is made of laminated sheets,

it is magnetized when the current passes through the coil. The magnetized coil attracts

the metal plunger to move. The frame has provisions for attaching the mounting. They

are usually bolted or welded to the frame. The frame has provisions for receivers, the

plunger. The wear strips are mounted to the solenoid frame, and are made of materials

such as metal or impregnated less fiber cloth.

3. Solenoid Plunger

The Solenoid plunger is the mover mechanism of the solenoid. The plunger is

made of steel laminations which are riveted together under high pressure, so that there

will be no movement of the lamination with respect to one another. At the top of the

plunger a pin hole is placed for making a connection to some device. The solenoid

plunger is moved by a magnetic force in one direction and is usually returned by spring

action.
 Solenoid operated valves are usually provided with cover over either the solenoid

or the entire valve. This protects the solenoid from dirt and other foreign matter, and

protects the actuator. In many applications it is necessary to use explosion proof

solenoids.

Flow control valve:

In any fluid power circuit, flow control valve is used to control the speed of

the actuator. The floe control can be achieved. By varying the area of flow through which

the air in passing.

When area is increased, more quantity of air will be sent to actuator as a

result its speed will increase. If the quantity of air entering into the actuator is reduced,

the speed of the actuator is reduced.

4. ELECTRONIC CONTROL UNIT:-

4A-230V X 3
47K

L1
TRIAC X 3
4 8 16 1N4007 X 3
3 L2
7 IC 4017
555 2
10K 6 3 14
L3
2 1 4
13 8

100µF 1N4007 X 4

1N4007
1000µF

230/9V

230V A/C I/P

 Here the 555 IC has been used as a multi vibrator. The output of IC 555 is fed to

the input pin (pin no 14) of CD 4017 continues counting. The output of the IC becomes

available at pin Nos. 3, 2 and 4. The output pulse of any one of output pin triggers (Puts

ON) the Triac and current starts flowing across the load connected. This process

continues on other pins at different time intervals and the cycle continues. The frequency

interval (Time) of the cycle can be adjusted by the pre-set look connected to pin 6 of 555

Timer IC.

IC 555 TIMER

The IC SE / NE 555 monolithic circuit is a highly stable controller capable of

producing accurate time delays or oscillations. Additional terminals are provided for

triggering or resetting if desired. In the timing operations, the time is precisely controlled

by one external resistor and a capacitor, by the operation as an oscillator, the free running

frequency and the duty cycle are both accurately contributed with the external RC

constants.

PIN DIAGRAM:
GROUND SUPPLY (Vcc)
1 8

TRIGGER DISCHARGE
2 7
IC
OUTPUT NE 555 THERSOLD
3 6

RESET CONTROL
4 5
 PIN NO: 1
It is ground terminal.

PIN NO: 2

The trigger voltage to

the lower comparator is

applied. It has constant

voltage that is atleast

one third of the supply

voltage, when trigger

voltage falls below this

level the flip-flop changes its state and output becomes high.

PIN NO: 3

It is the output terminal, in low state output is equal to zero and when at higher state

output is equal to Vcc.

PIN NO: 4

It controls the flip flop directly. It turns the device to its original position when reset

pin is connected to ground the output is approximately equal to zero. When reset is not

used it is connected to Vcc.

PIN NO: 5

It is the control voltage terminal. It is connected to ground through a capacitor of 0.01

μF. Any external voltage at pin: 5 will change both the threshold voltage and the trigger

voltage reference level.

PIN NO: 6

Threshold voltage of upper comparator is applied from this terminal. The resistor Rt

connected to Vcc and pin: 6 is grounded by an external capacitor. The output is high

capacitor charges by resistor Rt. When the capacitor changes to the threshold level, the

output becomes low.

PIN NO: 7

It is the discharge pin for external capacitor. Usually pin: 7 is connected with pin: 6

directly to by a resistor. When the output becomes low then the external capacitor

discharges by internal discharge transistor remains at cut-off and the external capacitor

charges to Vcc.

PIN NO: 8

It is the positive supply terminal. A dc voltage from +5 to + 15 can be applied.

The important features of IC555 can be summarized as follows.

1. Timing range from microseconds to hours.

2. Mono-stable and Astable operation is possible through IC555.

3. The duty cycle can be adjusted according to our necessity.

4. It has the ability to operate from a wide range of supply Voltage.

5. The output of 555 is compatible with CMOS, DTL and TTL, logic. But

when used with a 5V supply.

6. Triggering and reset inputs are logically compatible.

7. Output can be operated as normal ON and normal OFF.

8. High temperature stability.

9. Unlike RC timers, 555 provide a time intervals that is virtually

independence of supply voltage Vcc. This because that, the charge rate of CT and

the reference voltage to the threshold comparator are all directly proportional to

the supply voltage.

IC 555 SPECIFICATION

Supply Voltage (Vcc) = 4.5 to 15V

Supply Current (Vcc=5V/2) = 3 to 6mA

Supply Current (Vcc=25V/2) = 10 to 15mA

Output Current = 200mA (maximum)

Power dissipation = 600mw

Operating temperature = 0-70 degree Celsius.

 SPECIFICATION OF THE FITTINGS

Body Material : High Strength Plastic

Collet/Collet Holder/Threaded Nipple : Brass

Seal : Nitrate, Rubber, Neoprene

Fluid Used : Air

Max. Operating Pressure : 10 bar

Ambient Temperature : 5 to 60 C

Max. Air Temperature : 60C

Pipe Threads : Male – BSPT

Female - BSP

Tolerance on OD of the tubes : 0.10mm

Min. Wall thickness of tubes : 1mm

Bulk Head Union:

It is the one type of fitting to joint the two independent flexible hoses. It is used to

connect tubes in panel installations. It is easy to install hoses as well as remove it from

maintenance purpose.
Female Elbow:

This type of fitting is instead of where the pneumatic bend circuit is required.

Connect the tubes at the right angles (90) to male connections.

Flexible Hoses:

. Hose is fabricated in layer of elastomer or synthetic rubber and braided fabric,

which permits operation at higher pressure. The standard tubing outside diameter is 1/16

inch. If the hose is subject to rubbing, it should be encased in a protective sleeve.

AIR COMPRESSOR:

The main function of the air compressor is to compress the air up to the required

pressure. The maximum capacity of the compressor is 12kg/cm². The power rating is

1HP. This is a two stage or two cylinders are for low and high compression. The air

pressure is measured at various places by the use of pressure gauges. The power rating

and speed of the motor that is fitted to the compressor in 3 HP and 2880 RPM

respectively V-belt and the pulley are used to drive the compressor.
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Chapter-4
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DESIGN AND DRAWING

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 CHAPTER –4

DESIGN OF EQUIPMENT AND DRAWING

Pneumatic components and its specification

The pneumatic auto feed drilling machine consists of the following components to

full fill the requirements of complete operation of the machine.

1. Double acting pneumatic cylinder

2. Solenoid Valve

3. Flow control Valve

4. Connectors

5. Hoses

1. Double acting pneumatic cylinder

Technical Data

Stroke length : Cylinder stoker length 170 mm = 0.17 m

Piston rod : 18 mm = 18 x 10ˉ³ m

Quantity : 1

Seals : Nitride (Buna-N) Elastomer

End cones : Cast iron

Piston : EN – 8

Media : Air

Temperature : 0-80 º C

Pressure Range : 8 N/m²

2. Solenoid Valve

Technical data

Size : 0.635 x 10 ˉ² m

Part size : G 0.635 x 10 ˉ² m

Max pressure range : 0-10 x 10 ⁵ N/m²

Quantity : 1

3. Flow control Valve

Technical Data
Port size : 0.635 x 10 ֿ² m

Pressure : 0-8 x 10 ⁵ N/m²

Media : Air

Quantity : 1

4. Connectors

Technical data

Max working pressure : 10 x 10 ⁵ N/m²

Temperature : 0-100 º C

Fluid media : Air

Material : Brass

5. Hoses

Technical date

Max pressure : 10 x 10 ⁵ N/m²

Outer diameter : 6 mm = 6 x 10 ˉ ³m

Inner diameter : 3.5 mm = 3.5 x 10 ˉ ³m

 PNEUMATIC CYLINDER

Design of Piston rod:

Load due to air Pressure.

Diameter of the Piston (d) = 40 mm

Pressure acting (p) = 6 kgf/cm²

Material used for rod = C 45

Yield stress (σy) = 36 kgf/mm²

Assuming factor of safety = 2

Force acting on the rod (P) = Pressure x Area

= p x (Πd² / 4)

= 6 x {( Π x 4² ) / 4 }

P = 73.36 Kgf

Design Stress(σy) = σy / F0 S
 = 36 / 2 = 18 Kgf/mm²

= P / (Π d² / 4 )

∴d = √ 4 p / Π [ σy ]

= √ 4 x 75.36 / {Π x 18}

= √ 5.33 = 2.3 mm

∴ Minimum diameter of rod required for the load = 2.3 mm

We assume diameter of the rod = 15 mm

Design of cylinder thickness:

Material used = Cast iron

Assuming internal diameter of the cylinder = 40 mm

Ultimate tensile stress = 250 N/mm² = 2500 gf/mm²

Working Stress = Ultimate tensile stress / factor of safety

Assuming factor of safety = 4

Working stress ( ft ) = 2500 / 4 = 625 Kgf/cm²

According to ‘LAMES EQUATION’

Minimum thickness of cylinder ( t ) = ri {√ (ft + p) / (ft – p ) -1 }

Where,

ri = inner radius of cylinder in cm.

ft = Working stress (Kgf/cm²)

p = Working pressure in Kgf/cm²

∴ Substituting values we get,

t = 2.0 { √ (625 + 6) / ( 625 – 6) -1}

t = 0.019 cm = 0.19 mm

We assume thickness of cylinder = 2.5 mm

Inner diameter of barrel = 40 mm

Outer diameter of barrel = 40 + 2t

= 40 + ( 2 x 2.5 ) = 45 mm
Design of Piston rod:

Diameter of Piston Rod:

Force of piston Rod (P) = Pressure x area = p x Π/4 (d²)

= 6 x (Π / 4) x (4)²

= 73.36 Kgf

Also, force on piston rod (P) = (Π/4) (dp)² x ft

P = (Π/4) x (dp)² x 625

73.36 = (Π/4) x (dp)² x 625

∴ dp² = 73.36 x (4/Π) x (1/625)

= 0.15

dp = 0.38 cm = 3.8 mm

By standardizing dp = 15 mm

Length of piston rod:

Approach stroke = 160 mm

Length of threads = 2 x 20 = 40mm

Extra length due to front cover = 12 mm

Extra length of accommodate head = 20 mm

 Total length of the piston rod = 160 + 40 + 12 + 20

= 232 mm

By standardizing, length of the piston rod = 230 mm

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Chapter-5
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WORKING PRINCIPLE
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 CHAPTER-5

WORKING PRINCIPLE

PNEUMATIC CIRCUIT:
 Since pneumatic circuit plays a vital role in this device, it is very necessary to

explain the working of this circuit.

Initially starting with air compresses, its function is to compress air from a low

inlet pressure (usually atmospheric) to a higher pressure level. This is an accomplished

by reducing the volume of the air.

Air compressors are generally positive displacement units and are either of the

reciprocating piston type or the rotary screw or rotary vane types. The air compressor

used here is a typically small sized, two-stage compressor unit. It also consists of a

compressed air tank, electric rotor and pulley drive, pressure controls and instruments for

quick hook up and use. The compressor is driver by a 10HP motor and designed to

operate in 145 – 175 PSI range. If the pressure exceeds the designed pressure of the

receiver a release value provided releases the excesses air and thus stays a head of any

hazards to take place.

The stored air from compressor is passed through an air fitter where the

compressed air is filtered from the fine dust particles. However, before the suction of air

into compressor a filter process take place, but not sufficient to operate in the circuit here

the filter is used.

 Then having a pressure regulator where the desired pressure to the operated is set.

Here a variable pressure regulator is adopted.

Through a variety of direction control value are available, a hand operated spool

value with detent is applied.

The spool value used here is 5 ports, 3 positions. There are two exhaust ports, two

outlet ports and one inlet port. In two extreme positions only the directions can be

changed while the Centro ore is a neutral position and no physical changes are incurred.

The 2 outlet ports are connected to an actuator (Cylinder). The pneumatic

activates is a double acting, single rod cylinder. The cylinder output is coupled to further

purpose. The piston end has an air horning effect to prevent sudden thrust at extreme

ends.

PRINCIPLES OF WORKING

 The compressed air from the compressor reaches the solenoid valve. The solenoid

valve changes the direction of flow according to the signals from the timing

device.
 The compressed air pass through the solenoid valve and it is admitted into the

front end of the cylinder block. The air pushes the piston for the cutting stroke. At

the end of the cutting stroke air from the solenoid valve reaches the rear end of the

cylinder block. The pressure remains the same but the area is less due to the

presence of piston rod. This exerts greater pressure on the piston, pushing it at a

faster rate thus enabling faster return stroke.

 The weight attached at the end of the hacksaw frame gives constant loads which

lower the hacksaw to enable continuous cutting of the work.

 The stroke length of the piston can be changed by making suitable adjustment in

the timer.
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Chapter-6
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FABRICATION
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 CHAPTER-6

FABRICATION

COMPONENTS:

 Piston

 Actuating rod

 Base Plate

 Bush

 Hacksaw Frame

 Vise

 Solenoid Valve

 Timing Device

 Flexible hoses

 Cylinder block

Piston:

The piston is fitted in the cylinder block and reciprocates inside. When the

solenoid valve supplies the air in the front end of the piston, the piston is pushed forward.

This moves the hacksaw and the cutting stroke takes place. Then the solenoid valve

supplies air to the rear end of the piston. The pressure is same but the contact area is less
due to the presence of the piston rod and pushes the piston at a greater pressure thus

resulting in a fast return stroke. The material for the piston is Aluminum.

Actuating Rod:

The actuating rod is fitted inside the bush. It is connected at one end to the piston

rod and at the other end it is connected to the hacksaw frame. It reciprocates inside the

bush. The material for the actuating rod is mild steel.

Base Plate:

All the components of the machine are mounted on the base plate. It withstands

the vibrations encountered during machining. It is mounted on the bench.

Hacksaw Frame:

The hacksaw frame is connected to one end of the actuating rod and the weights

are mounted at the other end. The hacksaw is fitted in the slots provided in the frame.

The material for the frame is mild steel.

Vise:

The vise is mounted on the base plate below the hacksaw frame. It is used for

holding the work piece. It should have sufficient strength to withstand the cutting forces.

The material for vise is cost iron.

Solenoid Valve:

It is a 2x3 positional control valve. It receives the compressed air from the

compressor and supplies to the cylinder block according to the signal, given by the timing

device. During one position it supplies air to the frond end of the cylinder block. During

the next position it supplies air to the rear end of the cylinder block.

Timing Device:

The timing device supplied signal alternatively to the solenoid valve. The clock

fitted in the device actuates the operation of the valve. The timing can be changed to

obtain different speeds.

Flexible Hose:

The flexible hoses connect the solenoid valve and the cylinder block. Hoses are

made of in layer of elastomer (or) synthetic rubber and braided fabric which takes up the

higher pressure. If the hose is subjected to rubbing, it should be enclosed in a protective

sleeve.

Cylinder block:

The cylinder block has two opening for admitting air inside the block for

achieving the reciprocation motion of the piston. The material for cylinder block is

Aluminium.

Bush:
 It is cylindrical in shape with a central hole. It supports the actuating rod. The

actuating rod reciprocates in the bore at the bush. The material for the bush is mild steel.

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Chapter-7
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APPLICATION
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 CHAPTER-7

APPLICATIONS

1. Agriculture:

 Crop forming

 Stock breeding

 Animal food industries

 Foresting

2. Utilities:

 Power Station

 Nuclear Engineering

 Water Supply

3. Mining

4. Chemical Industry

5. Plastics and rubber industries

6. Stone, Ceramic and glass industries

7. Metal Industries:

 Iron and Steel

 Non-ferrous metals

 Foundries

 Scrap and recycled metals

8. Leather Industry

9. Textile Industry

10. Paper and Printing Industry

---------------------------------------------------------------------------------------
Chapter-8
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 NEED FOR AUTOMATION
---------------------------------------------------------------------------------------

CHAPTER-8

NEED FOR AUTOMATION

Nowadays almost all the manufacturing process is being atomized in order to

deliver the products at a faster rate. The manufacturing operation is being atomized for

the following reasons.

 To achieve mass production

 To reduce man power

 To increase the efficiency of the plant

 To reduce the work load

 To reduce the production cost

 To reduce the production time

 To reduce the material handling

 To reduce the fatigue of workers

 To achieve good product quality

  Less Maintenance

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Chapter-9
---------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------
ADVANTAGES AND
LIMITATIONS
---------------------------------------------------------------------------------------

CHAPTER-9

ADVANTAGES AND LIMITATIONS

ADVANTAGES:

 There is no need of giving feed during every cut due to the presence of weight.

 The cutting speed can be varied according to our needs by adjusting the timer.

 It is portable

 It does not have any Prime mover, like electric motor related to the unit.

 As the air is freely available, we can utilize the air to cut the metal and hence it is

economical.

 Simple in construction than mechanical hacksaw

 It is a compact one

 Less Maintenance
LIMITATIONS

 Only smaller size and soft metal can be cut

 It is costlier than the mechanical hacksaw because of compressor unit.

 Less efficiency when compressed to mechanical device.

 Leakage of air affects the working of the unit.

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Chapter-10
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---------------------------------------------------------------------------------------
PROCESS SHEET
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CHAPTER-10

PROCESS SHEET

FABRICATED PARTS:
Sl. PART OPERATION MACHINE TOOL GAUGES
No. DESCRIPTION
1. i) Turning Lathe Turning Tool Micrometers
ii) Shaping Shaper
iii) Drilling Drilling Right hand -
Ф8x22.5mm Machine Round nose Plug Gauge
tool
Drill bit
2. Bush
D-53mm (i) Turning Lathe Turning Tool Micrometer
d-30mm (ii) Drilling Drilling Drill Bit Plug Gauge
I-70mm (iii) Boring Machine Boring Bar Inside
Lathe Micrometer
3. Base Plate
L-722 mm
 B-254mm Bending Bending Bending Tool --
H-78mm Machine

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Chapter-11
---------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------
LIST OF MATERIALS
---------------------------------------------------------------------------------------

CHAPTER-11

LIST OF MATERIALS

PROCURED PARTS:

Sl. No. PARTS Qty. MATERIAL

i. Cylinder block (with piston) 1 EN8
ii. Solenoid valve 1 ALU.
iii. Machine vice 1 C.I
iv. Timing control unit 1 -
v. Flexible hoses 2 Meter POLYURETHENE
vi. Hack Saw frame 1 M.S
vii. Bolts & Nuts - M.S
viii. PU Connectors - BRASS
ix. Flow Control Valve 1 ALU.
---------------------------------------------------------------------------------------
Chapter-12
---------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------
COST ESTIMATION
---------------------------------------------------------------------------------------
 CHAPTER-12

COST ESTIMATION

Sl. No. PARTS Qty. Cost

i. Cylinder block (with piston) 1
ii. Solenoid valve 1
iii. Machine vice 1
iv. Timing device 1
v. Flexible hoses -
vi. Hack Saw frame 1
vii. Bolts & Nuts -
viii. PU Connectors -
ix. Flow Control Valve 1
TOTAL

LABOUR COST

LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS CUTTING:

Cost =

OVERHEAD CHARGES

The overhead charges are arrived by “Manufacturing cost”

 Manufacturing Cost = Material Cost + Labour cost
=
=

Overhead Charges = 20% of the manufacturing cost

=

TOTAL COST

Total cost = Material Cost + Labour cost + Overhead Charges

=
=

Total cost for this project =

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Chapter-13
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---------------------------------------------------------------------------------------
CONCLUSION
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 CHAPTER-13

CONCLUSION

In the pneumatic hacksaw variable speeds can be obtained by adjusting the timer

device and pressure of the compressed air. Since the mechanism is so simple and

versatile it can be handled by any operator, constriction of the unit is very simple.

Handling the machine is easy and smooth operation is achieved.

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BIBLIOGRAPHY
--------------------------------------------------------------------------------
 BIBLIOGRAPHY

Antonio Esposito - Fluid power with application. Prentice hall of India private

limited, 1980.

Bolton,W.,Pneumatic and hydraulic systems,Butterworth-Heinemann,Jordan Hill,

Oxford,1997.

Catalogue of Janatics pneumatic product, Janatics Private Limited Coimbatore.

Design data book –compiled by faculty of mechanical engineering

P.S.G. college of technology,Coimbatore

Festo Didactic KG – Fundamentals of control technology, Esslingen-1998.

Festo Pneumatic Catlogue - Festo Pvt Ltd. – Bangalore.

Werner Deppert/Kurt Stoll., Cutting Cost With Pneumatics, Vogel Buchverlag

Wurzburg, 1998.
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PHOTOGRAPHY
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PHOTOGRAPHY