Arch Louie E.

Laranang
4MEC 15th of May, 2018
ME426 Design Project

A fixture or special machine is to be deisgned such that rectangular parts measuring

80mm x 60mm x 50mm can be stamped on one side, the operating sequences being
automatic.

Data:
Material: Aluminum Alloy
Required stamping force 800N
Quantity: approx. 8000 parts/day
Weight of punch approx. 80N

I. Operational Objectives

A. Working Operations

1. Feeding – A conveyor belt feeds the block into the stamping area only when the area
is empty.

2. Clamping – The block is clamped down in place to make it stable during stamping.
This makes the engravement precise.

3. Stamping – A precise figure will be engraved at a certain face of the blocks. The
stamper will only run when the material to be stamped is present. Any other objects
(hand, different material block, etc.) that will be present will stop the operation.

4. Ejecting – The block will be ejected into another conveyer belt leading to manual
checking. This is done right after stamping, making a single operation time at most 3.6
seconds per piece.
Arch Louie E. Laranang
4MEC 15th of May, 2018
B. Displacement-step diagram

C. Auxiliary requirements

System shut-off - Automatic stop when the desired operation is finished.

Selector switch - This switch determines whether the system runs in single operation or
continuously.

Emergency stop/reset - A mechanism for stopping the system in the middle of the
operation should be present in case of emergency purposes. While a reset mechanism
will bring back the actuators to their initial position, when the system is ready to run
again.
Arch Louie E. Laranang
4MEC 15th of May, 2018
Material sensor - The system should only operate when the right material is at the right
area. A sensor should detect when there is an absence of material to be stamped, making
the operation to halt.

Quick exhaust and throttling valves - These components helps assist piston action.

Alarms (buzzers, lights) - Safety components indicating whether the systems is running
or not.
Arch Louie E. Laranang
4MEC 15th of May, 2018

II. Selection and dimensioning of working elements

Computation for Stamping:

Given:

Material: Aluminum Alloy

Stamping force= 𝐹𝑐𝑟𝑖𝑡𝑖𝑐𝑎𝑙 = 800 𝑁

𝑡 = 3.6 𝑠𝑒𝑐𝑜𝑛𝑑𝑠

Product: DNC ISO 6431 Standard Festo Pneumatic Cylinder (Double-Acting)

(Aluminum Alloy)

Based from product catalogue:

Speed range= 30 to 800 mm/s

Proof pressure= 1.35 Mpa

Pressure range= 0.1 to 0.9 Mpa

As industry standard (From product Catalogue):

Arch Louie E. Laranang
4MEC 15th of May, 2018
Standard Bore = 40 mm

Standard Stroke = 80 mm

Max. Stroke = 1200 mm

Length of Rod = 420 mm

Determine: Piston Rod

tt = total time of process = 3.6 sec/part

ts = time of stamping process only = 1.2 sec

Checking for the velocity:

𝑑 500 𝑚𝑚 𝑚𝑚
𝜐= = = 417
𝑡𝑠 1.2 𝑠𝑒𝑐 𝑠

𝑚𝑚
30 < 417 < 800 ∴ 𝑝𝑜𝑠𝑠𝑖𝑏𝑙𝑒!
𝑠

J.B. Johnson’s Equation

𝐵
𝐹𝑐𝑟𝑖𝑡𝑖𝑐𝑎𝑙 = 𝐴𝑆𝑦 [ 1 − ]
4𝑘 2

𝑑
𝑘=
4

Where: d= diameter of rod

Arch Louie E. Laranang
4MEC 15th of May, 2018
n=4 for both fixed end

From AT Tables of Design of Machine Elements by Faires

𝑆𝑦𝐴𝑙𝑢𝑚𝑖𝑛𝑢𝑚 = 21 𝑘𝑠𝑖 = 21000 𝑝𝑠𝑖 = 144.79 𝑀𝑝𝑎

𝐸𝐴𝑙𝑢𝑚𝑖𝑛𝑢𝑚 = 10 𝑥 106 𝑝𝑠𝑖 = 68947.33 𝑀𝑝𝑎

144.9 𝑀𝑝𝑎 (500𝑚𝑚)2

𝐵=
𝜋 2 4 (68947.33 𝑀𝑝𝑎)

𝐵 = 13.2985 𝑚𝑚2

Using J.B Johnson’s equation:

𝜋 2 13.2985
800 𝑁 = 𝑑 [ 68947.33 𝑀𝑝𝑎][1 − ]
4 𝑑 2
4( 4)

𝑑 = 7.29 𝑚𝑚

Checking the answer for J.B. Johnson’s equation:

𝐵 13.2985
= =4
𝑘 2
7.29 2
( 4 )

2<4 ∴ 𝑛𝑜𝑡 𝑝𝑜𝑠𝑠𝑖𝑏𝑙𝑒! 𝑈𝑠𝑒 𝐸𝑢𝑙𝑒𝑟 ′ 𝑠 𝐹𝑜𝑟𝑚𝑢𝑙𝑎

Using Euler’s Formula:

𝐴 2
𝐹𝑐𝑟𝑖𝑡𝑖𝑐𝑎𝑙 = 𝑆𝑦 [ ]𝑘
𝐵
Arch Louie E. Laranang
4MEC 15th of May, 2018
𝜋 2
4 𝑑 𝑑 2
800 𝑁 = 144.79 𝑀𝑝𝑎 [ ]( )
13.2985𝑚𝑚 4

𝒅 = 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓 𝒐𝒇 𝒓𝒐𝒅 = 𝟔. 𝟐𝟐 𝒎𝒎

Solving for the speed of conveyor:

Product:

Huzhou Jinhong Roller and Conveyor

Manufacturer

Roller length= 100 mm

Shaft diameter= 8 mm

Do=Diameter of Roller= 20 mm = 0.020 m

tt = total time of process = 3.6 sec/part

D= distance of each part= 1 m

𝜐 = velocity

𝐷 1 𝑚 𝑚
𝜐= = = 0.28
𝑡𝑡 3.6 𝑠𝑒𝑐 𝑠

Conveyor Belt: 9.0 mm industry Conveyor belt

𝑳𝒆𝒏𝒈𝒕𝒉 𝒐𝒇 𝒃𝒆𝒍𝒕 = 1𝑚 (2) + 𝜋𝐷𝑜

= 2 + 𝜋(0.02) = 𝟐. 𝟎𝟔𝟑𝒎
≈ 𝟐. 𝟏 𝒎 𝒇𝒐𝒓 𝒂𝒍𝒍𝒐𝒘𝒂𝒏𝒄𝒆
Arch Louie E. Laranang
4MEC 15th of May, 2018
Solving RPM required for conveyor motor:

𝜐 0.28 𝑚/𝑠𝑒𝑐
𝑁= = = 4.456 𝑟𝑒𝑣/ sec = 𝟐𝟔𝟕. 𝟐 𝑹𝑷𝑴
𝜋𝐷𝑜 𝜋(0.020𝑚)

Use Product:

Taiqi Seiko Small Volume AC Gear Motor

Output speed= 7 to 600 RPM

Single-Phase with output power of 0.1 - 3.7 kW

 Arch Louie E. Laranang
4MEC 15th of May, 2018
ITEM QTY. ITEM SPECIFICATIONS
1. DNC ISO 6431 Standard Festo Pneumatic Cylinder 2 Standard bore = 40 mm
Standard stroke = 80 mm
Max. stroke = 1200 mm
Length of rod = 420 mm
Diameter of rod = 6.22mm
Velocity of stroke = 417,𝑚𝑚-𝑠.
Proof pressure= 1.35 Mpa
Pressure range= 0.1 to 0.9 Mpa

2. Huzhou Jinhong Roller 4 Roller length = 100 mm

Shaft diameter = 8 mm
Diameter of Roller = 20 mm
3. Huzhou Jinhong Conveyor Belt 2 9.0 mm industry conveyor belt
Length of belt = 2.1m
4. Taiqi Seiko Small Volume AC Gear Motor 1 or 2 Speed = 267.2 RPM
Output Power = 0.1 to 3.7 kW
Arch Louie E. Laranang
4MEC 15th of May, 2018
III. 3D Representation
Arch Louie E. Laranang
4MEC 15th of May, 2018

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IV. Control Circuits

A. Purely Pneumatic
Arch Louie E. Laranang
4MEC 15th of May, 2018
B. Electro Pneumatic
Arch Louie E. Laranang
4MEC 15th of May, 2018
C. PLC Solution
Arch Louie E. Laranang
4MEC 15th of May, 2018
Arch Louie E. Laranang
4MEC 15th of May, 2018