Hydraulic Sheet Cutting Report n1q6q

MORNING STAR POLYTECHNIC COLLEGE CHUNKANKADAI

HYDRAULIC SHEET CUTTING MACHINE

A Project Report In partial fulfillment of the requirement for the award of diploma In

MECHANICAL ENGINEERING Project guided by Mr. Submitted By

DIRECTORATE OF TECHNICAL EDUCATION, TAMILNADU 2013-2014

MORNING STAR POLYTECHNIC COLLEGE CHUNKANKADAI

Department Of Mechanical Engineering CERTIFICATE This is to certificate that the project entitled “HYDRAULIC SHEET CUTTING MACHINE” is a bonafide work done by……………………………….. reg.no………………………........ of final year diploma in mechanical engineering, during the year 2013-2014.

Guide Of

Head The

Department

Mr.T.KAMILLAS FRANKLIN,M.E

Mr.

Submitted For The Board Examination Held At Morning Star Polytechnic College On …………………..

Internal Examiner External Examiner Place : Chunkankadai Date :

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT I thank my God almighty who is the “SOURCE OF KNOWLEDGE” and the one who guided me in all aspects to bring out this project a successful one. My special thanks to my loving parents and my beloved friends for their help in bringing out this project successfully. I wish to express my sincere thanks to the correspondent Rev.Fr.P.PAUL RICHARD JOSEPH,M.A.,M.Phil who provide me an opportunity to do this project work in this esteemed institution. I would like to express my sincere thanks to our principal Mr.V.VINCENT JAYASEELAN,B.E.,M.Tech .,M.A.,M.Ed.,M.Phil for his encouragement while doing this project. I also express my heart full thanks to my head of the department Mr.T.KAMILLAS FRANKLIN,M.E., and my project guide -------------------------- for his keen

involvement in successful completion of my project work. I also thank for our all staff for their guidance while preparing my project work. Also I thank the entire member who helped directly and indirectly to complete my project work.

CONTENTS

CONTENTS

1 2

SYNOPSIS INTRODUCTION

3

CONSTRUCTIONAL DETAILS AND

4

DRAWING FABRICATION OF PARTS

5

WORKING PRINCIPLE

6 7

ADVANTAGES APPLICATIONS

8 9 10

COST DETAILS CONCLUSION BIBLIOGRAPHY

SYNOPSIS

SYNOPSIS The sheet metal cutting process is a main part of the all industries. Normally the sheet metal cutting machine is manually hand operated one for medium and small scale industries. The sheet metal cutting machine works with the help of hydraulic double acting cylinder. The piston is connected to the moving cutting tool. It is used to cut the small size of the sheet metal. The machine is portable in size, so easy transportable The oil from the pump is used as the force medium for this operation. There are solenoid valves, flow control valve unit is used. The 5/2 solenoid valve is used. In one position oil enters to the cylinder and pushes the piston so that the cutting stroke is obtained.

The next position oil enters to the other side of cylinder and pusses the piston return back, so that the releasing stroke is obtained. The speed of the cutting and releasing stroke is varied by the area inside the cylinder. .

INTRODUCTION

INTRODUCTION In the mechanical field sheet metal cutting process is one of the most important processes. All the small to big products need sheet metal work. In that sheet process now a days we use large size of to sheet cutting machine .and also the machine occupy large amount of space in the work shop. In that project our aim is to make simple and easy operate with less space machine. Simple in mechanism

DRAWING

DRAWING

FABRICATION OF PARTS

COMPONENTS MAJOR PARTS

 Oil pump  Direction Control Valve  Cylinder  Connecting hoses

OIL PUMP Hydraulic pumps are sources of power for many dynamic machines. Hydraulic pumps are capable of pushing large amounts of oil through hydraulic cylinders or hydraulic motors. In this fashion, the pump converts the mechanical energy of the drive (i.e. torque, speed) into hydrostatic energy (i.e. flow, pressure). Hydraulic pumps operate according to the displacement principle. This involves the existence of mechanically sealed chambers in the pump. Through these chambers, fluid is transported from the inlet (suction port) of the pump to the outlet (pressure port). The sealed chambers ensure that there is no direct connection between the two ports of the pump. As a result, these pumps are very suitable to operate at high system pressures and are ideal for hydraulics.

Different

Types

of

Hydraulic

Pumps Hydraulic pumps are manufactured depending on different functional and hydraulic system requirements, such as operating medium, required range of pressure, type of drive, etc. A large range of design principles and configurations exists behind hydraulic pumps. Consequently, not every pump can fully meet all sets of requirements to an optimum degree. Three different types of hydraulic pumps exist:

Hydraulic Gear Pumps  External gear pump  Internal gear pump  Gear ring pump  Screw spindle pump

Hydraulic Vane Pumps  Single chamber vane pump  Double chamber vane pump

Hydraulic Piston Pumps  Axial piston pump

 Radial piston pump

Directional Control Valves

Hydraulic valves:

The pneumatic cylinder is regulated and controlled by pneumatic

valves.

mechanically,

These

electrically,

valves

are

actuated

pneumatically,

and

manually, by

various

combined mode of actuation.

Need of Valves

DIRECTIONAL CONTROL VALVES To control the to and fro motion of cylinder, the fluid energy has to be regulated, controlled and reversed with a predetermined sequence in a pneumatic system.

Similarly one may have to control the quantity of pressure and flow rate to generate the desired level of force and speed of actuators.

To achieve these functions, valves are used.

Valves are fluid power elements used for controlling and regulating the working medium. The main functions of the valves are,    

Start and stop the fluid energy Control the direction of flow of compressed air Control the flow rate of the fluid Control the pressure rating of the fluid

Although various types of valves are available, they are mainly classified as below,    

Direction control valves Direction control check valves Flow control valves Pressure control valves

The main purpose of a valve in a pneumatic circuit is to control outputs. Valves can be divided into a number of groups according to what they control.

Directional control valves

Directional control valve on the receipt of some external signal, which might be mechanical, electrical or a fluid pressure pilot signal, charges the direction of or stops, or starts the flow of fluid in some part of the pneumatic/hydraulic circuit.

SOLENOID VALVE

A solenoid is an electrical mechanical device that can convert electrical power to mechanical force and motion. It consists mainly of plunger, mostly a T type plunger, wire or coil and a C-frame. The working principle is such that when an electric current is ed through a coiled wire, a magnetic field sets up around the wire. Because of coiled wire, the magnetic field would be several times stronger around and through its center. The solenoid force is directly fed to the spool of the direction control valve to shift it. This force is applied through the T-plunger that is surrounded by the coil, also called the armature. To select a proper electromagnet, the forces resisting the actuation of the magnet, i.e. the force of friction and spring force have to be kept at their minimum so that the

electromagnet can develop a force greater than the resultant of the resisting force. Mostly in the case of dc magnets, the body and the armature may be made of one piece whereas the ac magnets require both the parts to be made from thin laminated sheets to obstruct flow of eddy current and to avoid increase of the solenoid body-temperature. Whether one has to go for a dc or ac magnet, depends fully on the requirement of the control system. However in majority of pneumatic direction control valves, only dc magnets are used as the overall requirement of force and response time is quite suitable for such application.

OPERATION OF SOLENOID VALVE

With solenoid valves, a current through a solenoid is used to implement switching between positions. When a current flows through the solenoid, a magnetic field is produced which pulls the laminated steel core into the coil, the force depending on the current through the solenoid? The larger the current the greater the force exerted.

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.

Parts of a 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 es through the coil. The magnetized coil attract 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.

Working of 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.

SOLENOID VALVE (OR) CUT OFF VALVE:

The control valve is used to control the flow direction is called cut off valve or solenoid valve. This solenoid cut off valve is controlled by the electronic control unit. In our project separate solenoid valve is used for flow direction of vice cylinder. It is used to flow the air from compressor to the single acting cylinder.

1.Pressure control valves These are used to control the pressure in part of the pneumatic/hydraulic circuit.

2.Flow control valves These are used to control the rate of flow of a fluid through the valve. A directional control valve on the receipt of some, external signal, which might be mechanical, electrical or a fluid pilot signal, changes the direction of stops, or starts the flow of fluid

in some part of the pneumatic/hydraulic circuit. They can be used to carry out such functions as:

1 Controlling the direction of motion of an actuator 2 Selecting alternative flow paths for a fluid. 3 Stopping and starting the flow of fluid.

Actuators An actuator is a device that is used to apply a force to an object Fluid power actuators can be classified into two groups:

 Linear actuators are used to move an object or apply a force in a straight line.  Linear actuators can be divided into two types. They are 1. Single acting cylinders 2. Double acting cylinders A single acting cylinder is powered by fluid for the movement of the piston in one direction with it being returned

in the other direction by an internal spring or an external force, a double acting cylinder is powered by fluid in both directions.

CYLINDERS Cylinders are the one, which offers the rectilinear motion to mechanical elements. Cylinders are classified as light, medium, and heavy duty with respect to their application. In our project we use double acting cylinder.

Double acting cylinder The force exerted by the compressed air moves the piston in two directions in a double acting cylinder. They are used particularly when the piston is required to perform work not only on the advance movement but also on the return. In principle, the stroke length is unlimited, although buckling and bending must be considered before we select a particular size of piston diameter, rod length and stroke length.

We use cylinders that are double acting type (i.e.) the compressed air can be ed to either end of the cylinder. These cylinders are made up of cast iron.

Oil Seal Air seal is used to prevent the leakage of air pressure from the cylinder. Normally it is made up of neoprene rubber. If there are any air leakages in the system, it will reduce the efficiency.

Wiper Seal: Wiper seal is provided at the entrance of the cylinder to avoid dust materials from the environment. It is made up of neoprene rubber.

Circlip Circlip is used to protect the out coming of air seal and wiper seal from the cylinder. It is made up of steel.

“O” Ring The “O” rings are fitted into the grooves of piston to maintain perfect seal between the piston and the cylinder wall. They are mostly made up of neoprene rubber.

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) Elastomerhieced by the electronic circuit.

End Covers: Cast iron graded fine grained from 25mm to 300mm

Piston: Aluminium.

Media: Oil Temperature Range: 0°c to 85°c

CUTTING EDGE

• The cutting edge used is of two metal plates are pivoted at the one end like the scissor • The other end has a pivot point for the piston rod • The cutter cuts the sheet metal by using shear force

WORKING PRINCIPLE

WORKING PRINCIPLE

The oil pump is rotated by an electric motor. The pump pressurizes the oil into the main gallery from where the oil is supplied to the direction control valves for the operation of the cylinder. The sheet metal to be cut is placed between the cutting edges. The upper cutting edge is in pivot to the end of the piston rod. When pressure is applied to the cylinder the piston forces the cutter to cut the metal. Oil from the pump is used as the force medium for this operation. There are direction control valves, flow control valve unit is used. The 5/2 dc valve is used. In one position oil enters to the cylinder and pushes the piston so that the cutting stroke is obtained. The next position oil enters to the other side of cylinder and pusses the piston return back, so that the releasing stroke is obtained. The speed of the cutting and releasing stroke is varied by the area inside the cylinder.The sheet metal is placed between the two cutting edges and the cutting is obtained.

ADVANTAGES

ADVANTAGES

         

Hydraulic power is more efficient in the technical field Quick response is achieved Simple in construction Easy to maintain and repair Cost of the unit is less when compared to other robotics The operation is very easy Manual effort is less Operation time is less Low investing cost The machine is simple

APPLICATIONS

APPLICATIONS

• It is used in sheet metal industries • It can be used labs in colleges • It can be used in sheet metal shops

COST DETAILS

COST DETAILS MATERIAL COST

=1500

COST OF CYLINDER

=1500

COST OF DC VALVE

=1000

COST OF OIL PUMP

=1500

TOTAL COST

=5500

Total cost for this project = 5,500.00

CONCLUSION

CONCLUSION Thus the sheet cutting machine provides an easy way to cut the material and it can also be used in the sheet metal shops and the industries for the easy cutting of the sheet metal

BIBLIOGRAPHY

BIBLIOGRAPHY  Anthony Esposito (2012) “ Fluid Power” Pearson, ISBN 978-81-775-8580-3  Dr.R.K.Bansal (2010) “Fluid Mechanics and Hydraulic Machines” Laxmi Publications, ISBN 978-81-318-0815-3  Er.R.K.Rajput (2006) “ Strength of Materials” S.Chand, ISBN 81-219-2594-0  PSG College of Technology “PSG Design Data Book”(2012)  T.J.Prabhu (2011) “ Design of Transmission Element”  V.B.Bhandari (2012) “ Design of Machine Elements” Mc Graw Hill, ISBN 978-0-07-068179-8

 Vanalkar.A.V., Mechanism Synthesis for Stirrup Making Machine, Proceeding, 4th International Conference on Mechanical 

Engineering,

ICME-

2001,

BANGLADESH, pp. 271, December-2001 www.sciencedirect .com

BUET,

Dhaka,