Dr.N.G.P.

INSTITUTEOFTECHNOLOGY,COIMBATORE-48
DEPARTMENTOFMECHANICALENGINEERING

DESIGN AND FABRICATION OF PNEUMATIC SHEET METAL BENDING

AND BEND REMOVING PROJECT.

NAME OF THE STUDENTS

Name:1.MITHRESH KANNA K (710716114044)

2.MOHAMMED RIYAS A. (710716114045)

3.NATHIN BHARATH M (710716114047)

Class :B.EMechanicalEngineering

Sem : VI
-----------------------------------------------------------------------------

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 Dr.NALLA
G. PALANISWAMI, who provided all the facilities to
us.
We would like to express our sincere thanks to
our principal Dr.K.PORKUMARAN,for forwarding us to
do our project and offering adequate duration in
completing our project.
We are also grateful to the Head of
Department Dr.V.S.SREEBALAJI, for his constructive
suggestions & encouragement during our project.
With deep sense of gratitude, we extend our
earnest & sincere thanks to our guide Dr.P.GOPI
KRISHNAN, Department of Mechanical for his kind
guidance & encouragement during this project.
We also express our indebt thanks to our
TEACHING and NON TEACHING staffs of
MECHANICAL ENGINEERING DEPARTMENT, Dr.N.G.P
Institute of Technology.

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--

PNEUMATIC SHEET BENDING/BEND

REMOVING MACHINE
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-

---------------------------------------------

CONTENTS
---------------------------------------------

CHAPTER

1. SYNOPSIS

2.INTRODUCTION

3.SELECTION OF PNEUMATICS

4.COMPONENTS AND DESCRIPTION

 5.DESIGN AND DRAWINGS

6.PRINCIPLE OF OPERATION

7.AIR LEAKS

8.PROCESS SHEET

9.MERITS AND DEMERITS

10.LIST OF MATERIALS

11.COST ESTIMATION

12.CONCLUSION

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Chapter-1
-------------------------------------
---------------------------------------
SYNOPSIS
---------------------------------------

CHAPTER-1

SYNOPSIS

This report deals with design and fabrications of pneumatic multipurpose presses,

which is used for fixing bearings of rotors in the shaft, bendind and bend removing with

the help of a compressor.

 Initially the shaft is held between two fixtures; top of the bearing is freely located

on the step in the shaft and the other one is placed on the bottom fixture. As one of the

bearing (located on the shaft step) is compressed, both the bearings are inserted in the

shaft simultaneously as the top fixture moves down words. Similarly bending and bend

removing process also occurred.

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Chapter-2
---------------------------------------
---------------------------------------------------

INTRODUCTION
---------------------------------------------------

CHAPTER-2

INTRODUCTION

The pneumatic multipurpose press is used for fixing the bearings in the shaft by

holding the shaft between two fixtures. One of the fixtures is movable and the other is

fixed.
 The pneumatic multipurpose press is also used to remove the bend in the shaft and

bend the shaft.

The principle of operation is the same as the conventional simple press. The

difference is only in the type of drive and the type of fixtures used.

The following points reveals why we have to make use of this type of press

Pneumatic multipurpose press reduces the manual work.

This type of machine reduces working time.

By using this machine the bearings can be inserted in the various lengths of shaft

(up to 600mm).

---------------------------------
Chapter-3
---------------------------------

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SELECTION OF PNEUMATICS
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-----

CHAPTER-3

SELECTION OF PNEUMATICS
 Mechanization is broadly defined as the replacement of manual effort by

mechanical power. Pneumatics 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 both 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 advantages of an all-pneumatic system are usually economy and

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

advantages in terms of safety.

----------------------------------
Chapter-4
----------------------------------
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----------------

COMPONENTS AND
DESCRIPTIONS
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-----------------
 CHAPTER-4

PNEUMATIC COMPONENTS AND ITS DESCRIPTION

The pneumatic bearing press consists of the following components to fulfill the

requirements of complete operation of the machine.

i. Pneumatic cylinder

ii. Hand operated valve

iii. Flow control value

iv. Regulator or pressure control valve

v. Pressure gauge

vi. Connectors and

vii. Hoses

1. CYLINDER:

The cylinder is a double acting cylinder one, which means that the air pressure

operates alternatively (forward and backward). The air from the compressor is passed

through the regulator which controls the pressure to required amount by adjusting its

knob. A pressure gauge is attached to the regulator for showing the line pressure.
 Then the compressed air is passed through the directional control valve for

supplying the air alternatively to either sides of the cylinder. Two hoses take the output

of the directional Control valve and they are attached to two ends of the cylinder by

means of connectors. One of the outputs from the directional control valve is taken to the

flow control valve from taken to the cylinder.

The hose is attached to each component of pneumatic system only by connectors.

CYLINDER TECHNICAL DATA:

Barrel:

It is made of cold drawn aluminimum honed to 25mm.

Piston Rod:

M.S. hard Chrome plated

Seals:

Nitrile (Buna – N) Elastomer

End Covers:

Cast iron graded fine grained from 25mm to 300mm

Piston:

Aluminium.

Media:

Air.

Temperature Range:

0^c to 85^c

Cushions:

Adjustable standard of 400mm bore and above.

2. DIRECTIONAL CONTROL VALVE:

Technical Data:

Size : ¼”

Pressure : 0 to 10 kg / cm2

Media : Air
Working Principle:

Double acting cylinder are controlled by 2 way 5 port two position valve as shown

in the fig. This valve has one inlet port (P), two cylinder ports (A and B), and two

exhaust ports (R and S). (See solenoid valve drawings)

In this position of the valve supply is directed to cylinder port no. A, with cylinder port B

connected to exhaust port R. The air supply is connected to cylinder port B; with cylinder

port A is connected to exhaust port R.

By operating the valve in two positions the cylinder piston can get the forward

stroke to pressing operation and return stroke to retrieve the work.

3.FLOW CONTROL VALVE:

(a) Technical Data:

Size : ¼”

Pressure : 0 to 10 kg / cm2

Media : Air
( b ) Purpose:

This valve is used to speed up the piston movement and also it acts as an one – way

restriction valve which means that the air can pass through only one way and it can ’t

return back.

By using this valve the time consumption is reduced because of the faster

movement of the piston.

4.REGULATOR (OR) PRESSURE CONTROL VALVE:

Specification:

1. Port size : ¼” BSP

2. Port size for pressure gauge : 1/8” BSP

3. Inlet pressure : 15 bar Maximum

4. Outlet pressure : 0.5 to 7 bar

5. Flow capacity : 650 NI/min*

6. Set pressure : 6 bar

7. Pressure drop : 1 bar

8. Mounting position : Vertical

* Flow capacity at 7 bar pressure

 Pressure control valves may be designed to vary the pressure to a desired level

within limits and to maintain it at certain level.

The air is passed through the throttling orifice by adjusting its knob in the desired

direction.

By adjusting the knob we can get different pressure ranges so that the load applied

by the piston can also be varied.

5. PRESSURE GAUGE:

Technical data:

Port size : 1/8” BSP

Pressure range : 0 – 10 kg/cm2

Pressure gauges are usually fitted with the regulators. So the air pressure adjusted

in the regulator is indicated by the pressure gauge and also the pressure indicated in the

pressure gauge is the line pressure of the air taken to the cylinder.

6.CONNECTORS:
 In our pneumatic system there are two types of connectors used; one is the hose

connector and the other is the reducer.

Hose connectors normally comprise an adapter (connector) hose nipple and cap

nut. These type of connectors are made up of brass or Aliminium or hardened steel.

Reducers are used to provide inter connection between two pipes or hoses of

different sizes. They may be fitted straight, tee, “V” or other configurations. These

reducers are made up of gunmetal or other materials like hardened steel etc.

7.HOSES:

Hoses used in this pneumatic system are made up of polyrethane. These hoses can

with stand at a maximums pressure level of 10 kg/cm2.

The various sizes polyurethane tubes and its specifications are shown in the table 2.

TABLE 2

Code No. Od X Id Burst Working Min. Standard Weight

(mm) Pressure Pressure Bending Length (g/m)
(kgf/cm2) (kgf/cm2) Radius (m)
(mm)
PU4025 4 X 2.5 32 < 10 10 200 9
PU4329 4.3 X 2.9 30 < 10 12 200 9
PU6040 6X4 27 < 10 16 200 18
 PU8050 8X5 32 < 10 22 100 38
PU8060 8X6 27 < 10 22 100 34
PU9565 9.5 X 6.5 28 < 10 27 100 52
PU1065 10 X 6.5 30 < 10 28 100 55
PU1080 11 X 8 27 < 10 28 100 47
PU1180 12 X 8 30 < 10 28 100 55
PU1280 12 X 8 28 < 10 37 100 78
PU1290 12 X 9 27 < 10 37 100 70
PU1296 12.6 X 9.6 30 < 10 39 100 82

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Chapter-5
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DESIGN AND DRAWINGS

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CHAPTER-5

DESIGN AND DRAWINGS

NOMENCLATURE

DESIGN NO.:1

P Total load acting at the center of the plate, kgf

L Distance between supports, mm

 E Young’s Modulus or modulus of elasticity, N/mm2

I Moment of inertia, mm4

DESIGN NO.: II

S Slenderness ratio

L Length of the pillar, cm

R Least radius of the cross section d/4 for circular cross section, cm

Pcr Critical load in buckling that would result in failure, kgf

σc Ultimate compressive strength, kgf/cm2

K Factor for end condition.

DESIGN NO.:III

d Internal diameter of the bearing, mm

D External diameter of the bearing, mm

B Thickness of the bearing, mm

I. DESIGN FOR PLATE FOR STABILITY IN DEFLECTION:

Deflection = Y = P / 48 E1

L = 300 mm
 E = 2.08 x 10^5 N/mm^2

bd^3 (400) (30)^3

= ------ = --------------- = 9 x 10^3 mm^4

12 12

Calculating the load on the plate (P):-

Maximum load acting at the --- 430kgf (from the Manufacturers

catalogue)

center of plate at 5Kg / cm^2

Maximum load acting at the center of 430 x 7

Plate at 7kg / cm^2 = -------------- = 602 kgf

Load distributed to the front half of 602

The plate = P = ----------

= 301kgf

P = 3010 N
=> Deflection of plate at maximum (3010)(300)^3(301kg)

=ν = -----------------------------------

(48) (2.08 x 1065) (9 x10^5)

ν = 9.04 x 10^3mm

This deflection is under the safe limit. So the design is safe.

II. DESIGN CALCULATIONS FOR THE PILLAR:

CALCULATION FOR STABILITY IN BUCKLING

Long and slender shafts, axially loaded, should be checked for stability in bucking.

Rankine’s formula for calculation for stability in buckling should be used if the

slenderness ratio ‘s’ is in the range of 0-100.

 We are know that,

Slenderness ratio ‘s’ = L/R

Where,

L = 90cm

D 4.2

R = -------- = -------------- 1.05cm

4 4

90

=> S = ---------- = 85.71

1.05

As the slenderness ratio for the pillar is with in the range of 20 to 100, Rankine ’s

formula should be used for calculating the stability for buckling.

Rankine’ s formulas for bucking:

 Π d^2 σ c/4

Pcr = -------------------------

[L +k (L/R) ^2]

(Refer page 171: machine tool design hand book)

Where

“K” depends upon the material and condition.

For steel k = 1/25000 for both ends of column fixed.

D = 4.2cm

σ c = 22090 kgf/cm^2

L = 90cm

R = 1.05cm

Π (4.2) ^2 x (2200/4)

Pcr = --------------------------------

90 + 1/25000(90/10.5) ^2

30479.723
 Pcr = ---------------

90.29

Pcr = 337.58 kgf.

For the pillar based on its material and dimensions, the critical load for bucking that

would result in failure is calculated to be 337.58 kgf.

But as only a maximum load of 150.5 kgf is applied on each pillar while working,

the design is safe.

III. MINIMUM CLEARANCE CALCULATION FOR INSERTING BEARINGS:

Selecting a PSG 3hp T.E.F.C motor, the bearing and shaft sizes at driving and non-

driving ends are detailed below:

DRIVING END:

(SKF) Bearing:

Brg. No. = 6306

 d = 30mm

D = 72mm (refer page 4.14 D.D)

B = 19MM

Tolerance = -10 microns

Shaft:

Size = 30j6 (From component drg.)

= 30+0.009

NON DRIVING END

Bearing:

Brg. No. = 6305

d = 25mm

D = 62mm

B = 17mm
 (Refer page :4.14 D.D)

Shaft:

Size = 25j6

= 25+0.009

To get the minimum clearance between the shaft and bearing, the shaft and bearing

should be of their maximum and minimum sizes respectively.

DRIVING END:

Minimum size of bearing = 30.000-0.01

= 29.99mm

Maximum size of shaft = 30.000+0.009

= 30.009mm

=> Clearance between shaft and

Bearing = 30.009 (-)

 29.990

-----------------

00.019mm

-----------------

Minimum clearance = 0.019mm

NON – DRIVING END

Minimum size of bearing = 25.000-0.01

= 24.99mm

Maximum size of shaft = 25.0000.0009

= 25.009mm

Clearance between shaft and

Bearing = 25.009

24.990

--------

00.019

--------

Minimum clearance = 0.019mm

Clearance of driving end + clearance of non driving end

Mean clearance = ----------------------------------------------------------------------

 2

0.019 + 0.019

= ---------------------------------

Mean clearance = 0.019mm

For the maximum size of the shaft and bearing for which the machine is designed

the minimum mean clearance (between the shaft and the bearing) is calculated to be

0.019 mm or 19 micros. Even though the fit is a clearance one, the bearing cannot be

mounted on the shaft by hand force and also hammering would result in reduced life of

the bearing. So, a constant force should be applied for which the machine is designed to

perform.

1. Double acting pneumatic cylinder

Technical Data

Stroke length : Cylinder stoker length 160 mm = 0.16 m

Piston rod : 18 mm = 18 x 10ˉ³ m

Quantity : 2

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. 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

3. Connectors

Technical data

Max working pressure : 10 x 10 ⁵ N/m²

Temperature : 0-100 º C

Fluid media : Air

Material : Brass
4. 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

 -----------------------------------
Chapter-6
------------------------------------

---------------------------------------------------------------------------------
PRINCIPLE OF OPERATION
---------------------------------------------------------------------------------

CHAPTER-6

PRINCIPLE OF OPERATION

The pneumatic multipurpose press is used for fixing bearings in the shaft up to a length of 600mm. In the

pneumatic multipurpose press the main thing being the pressure developed is done with the help of a compressor.

The air in that compressor is passed to the double acting cylinder through the control valves. There are two

control valves used in this press. One is pressure control valve or regulator and another one is the flow control valve.
 When the compressed air is passed to the pressure control valve, the required pressure is obtained by adjusting

its knob. When the air is passed to the flow control valve, the speed of movement of piston is controlled by adjusting the

knob. The cylinder piston rod is connected to the top fixture.

A bottom fixture is fixed on the bottom plate by using ‘T’ bolts or hexagonal bolts and nuts.

Bearing inserting procedure:

First one of the bearings is placed on the bottom fixture. Then the shaft is taken and the other bearing is kept ion

the step in the shaft. When the shaft is kept vertically on the bottom fixture some portion of the shaft goes inside the

bottom fixture.

At the same time the compressor is loaded to get the pressure required and the hand operated valve is manually

actuated from the neutral position to the input position to move the piston. The top fixture in the piston had inserted to

its required position rod pushes the bearing which is placed on the shaft.

When the bearing had inserted to its required position, there will not be any further down ward movement; at the

same time the entire shaft will move downward so that the another bearing placed on the bottom fixture also gets
inserted. Then the valve is brought to the output position in which the air moves the piston upward and the shaft is

removed.

Bearing Removing procedure:

The shaft is kept vertically between the bottom fixture and top fixture. The bearing which is removed is in the top of

the fixture. The remaining portion of the shaft touches the bottom fixture.

At the same time the compressor is loaded to get the pressure required and the hand operated valve is manually

actuated from the neutral position to the input position to move the piston. The top fixture in the piston had inserted to

its required position rod pushes the bearing which is placed on the shaft. When the bearing had removed to its required

position, there will not be any further down ward movement. Then the valve is brought to the output position in which

the air moves the piston upward and the shaft is removed
 --------------------------------

Chapter-7
---------------------------------

------------------------------------

AIR LEAKS
------------------------------------

CHAPTER-7
AIR LEAKS

Air leaks are not hazardous, but they can be extremely waste full of power. In a typical system as much as 10% of

the power requirements at any period can be made up of air leaking to waste.

Air loss and power wastage by air leaks

* Two stage compression

 ---------------------------------

Chapter-8
---------------------------------
-----------------------------------------------------

PROCESS SHEET
------------------------------------------------------

Sheet No. : 1
Part Name : BOTTOM & TOP PLATE Total Time : 1080 min.
Material : C15 Quantity : 1
Seq. Operation Machin Settin Speed Feed No. of Machi Tools Gauges Remark
No. details e g (rpm) Mm/re cots ning
Time v Time
(min) (min)
1 Chucking Lathe 16 - - - - Chuckkey Surface -
gauge
2 Facing Lathe 20 120 0.5 4 45 Facing tool Vernier -
3 Turning Lathe 12 120 0.5 4 30 R.H. tool Meter Scale -
4 Reversing The Lathe 30 Chuckkey Surface -
job & chucking gauge
 - - - -
5 Facing Lathe 20 120 0.5 4 45 Facing tool Vernier -
6 Turning Lathe 12 120 0.5 4 30 R.H. tool Meter -

Scale
7 Changing the job 40 Chuckkey

to another M/C - - - - - - -
8 Fixing on the Milling 10 - - - - Spanner ‘T’ - -

table M/C bolt & Nut

9 Milling Milling 10 125 1 3 90 Plain Meter Scale -

M/C milling

cutter
10 Reversing Milling 15

The job & fixing M/C - - - - Spanner - -

11 Milling Milling 10 125 1 3 90 End mill Meter -

M/C Cutter Scale

12 ‘T’ slot Milling 20 80 0.5 4 295 ‘T’ slot - -

M/C cutter
13 Changing the job Drilling 30

to another M/C & M/C

fixing - - - - Spanner ‘1’ - -

 bolt & nut
14 Drilling Dia. Drilling 40 Drill bit

43mm M/C 100 0.5 1 100 - -

15 Drilling Dia. Drilling 20 100 0.5 1 50 Drill bit

30mm M/C - -

Sheet No. :2

Part Name : NUT Total Time : 180 min/Nut.

Material : C15 Quantity : 16

Seq. Operation Machine Setting Speed Feed No. Machining Tools Gauges Remarks

No. details time (rpm) mm/rev of time (min)

(min) cuts
1 chucking Lathe 3 - - - - chuckkey Surface -

gauge
2 facing lathe 2 500 2 3 10 Facing tool vernier -
3 turning lathe 2 500 2 4 5 R.H. tool Vernier -
4 Reversing lathe 5 - - - - chuckkey Surface -

the job & gauge

 chucking
5 facing lathe 2 500 2 3 10 Facing tool vernier -
6 turning lathe 2 500 2 4 5 R.H. tool vernier -
7 threading lathe 10 120 4.5 5 34 Threading Thread pitch -

tool guage
8 Changing Milling 10 - - - - Chuckkey, - -

the job to m/c mandrel

another

m/c &

fixing
9 slotting Milling 20 250 10 3 60 End milling - -

m/c cutter

Sheet No. :3

Part Name : BOTTOM FIXTURE Total Time : 180 min.

Material : C15 Quantity :1

Seq. Operation Machine Setting Speed Feed No. of Machining Tools Gauges Remark

No. details time(min) (rpm) (mm/rev) cuts time(min)

1 Chucking Lathe 10 - - - - Chuckk Surface -

ey gauge
2 Facing Lathe 5 500 2 3 10 Facing - -

tool
3 Turning Lathe 5 500 2 5 20 R.H. - -

tool
4 Reversing the Lathe 10 - - - - Chuckk Surface -

job & chucking ey gauge

5 Facing Lathe 5 500 2 3 10 Facing Meter -

tool scale
6 Turning Lathe 5 500 2 5 20 R.H. Vernier -

tool
7 Changing the Lathe 10 - - - - Chuckk - -

job to another ey

m/c
8 Fixing on the Drilling 15 - - - - ‘T’ bolt - -

table m/c Nut &

spanner
9 Drilling dia. Drilling 5 560 0.4 2 10 Drill bit Vernier -
 27mm m/c
10 Drilling dia. Drilling 10 560 0.5 4 20 Drill bit - -

11mm m/c
 ----------------------------------

Chapter-9
------------------------------------

---------------------------------------------------------------------------------

MERITS AND DEMERITS

---------------------------------------------------------------------------------

CHAPTER-9
MERITS AND DEMERITS

Merits:

1. It reduces the manual work

2. It reduces the production time

3. Uniform application of the load gives perfect fitting of the bearing.

4. Damages to the bearing due to the hammering is prevented

5. It occupies less floor space

6. Less skilled operator is sufficient

Demerits:

1. Initial cost is high

2. Cylinder stroke length is constant

3. Need a separate compressor

 ------------------------------------------

Chapter-10
------------------------------------------

-----------------------------------------------------------------------

LIST OF MATERIALS
------------------------------------------------------------------------

CHAPTER-10

LIST OF MATERIALS

PART MATERIAL QUANTITY

Pneumatic cylinder Cast iron 1

DC Valve Aluminium 1

Flow control valve Aluminium 1

Top plate Mild steel 1

Bottom plate Mild steel 1

Square rod En8 4

punch En8 1

die En8 1

Hexagonal nut En8 16

Hose Polyurethane 3m
Pneumatic connecter Brass 8
 ---------------------------------------------

Chapter-11
----------------------------------------------

--------------------------------------------------------------

COST ESTIMATION
--------------------------------------------------------------

CHAPTER-11
COST ESTIMATION

1. MATERIAL COST:
PART MATERIAL QUANTITY AMOUNT(Rs)
Pneumatic cylinder Cast iron 1 700

DC Valve Aluminium 1 50

Flow control valve Aluminium 1 100

Top plate Mild steel 1 300

Bottom plate Mild steel 1 400

Square rod En8 4 500

punch En8 1 100

die En8 1 200

Hexagonal nut En8 16 70

Hose Polyurethane 3m 300

Pneumatic connecter Brass 8 200

TOTAL :

2. LABOUR COST

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

Cost = Rs.1000.

3. OVERHEAD CHARGES

The overhead charges are arrived by “Manufacturing cost”

Manufacturing Cost = Material Cost + Labour cost

= 2920 + 1000
= Rs.3920.

Overhead Charges = 20% of the manufacturing cost

= Rs.784.

TOTAL COST
Total cost = Material Cost + Labour cost + Overhead Charges
= 2920 + 1000 + 784
= Rs.4704.

Total cost for this project = Rs.4704

 ----------------------------------

Chapter-12
----------------------------------
-----------------------------------------

CONCLUSION
-----------------------------------------

CHAPTER-12
CONCLUSION

This multipurpose press is used for pressing stampings, bearing of rotors, removing

bend in a shaft etc. So this machine very useful in all industries.

The design of this machine can be improved to reduce further manual work by

incorporating the following ideas and attachments.

By incorporating FRL (Filter, Regulator, and Lubrication) unit, the functioning of

the machine can be improved.

The hand operated valves can be replaced by solenoid valves

Limit switches can also be used to get the variable strokes.

 ----------------------------------------------------

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

BIBLIOGRAPHY

1. Design data book - P.S.G. Tech.

2. Pneumatic hand book - R.H.Warrning

3. Machine tool design hand book - Central machine tool Institute,

Bangalore.

4. Strength of materials - R.S.Kurmi

5. Manufacturing Technology - M.Haslehurst.