DESIGN AND FABRICATION OF PNEUMATIC

PUNCHING MACHINE
An Internal Project report submitted in partial fulfilment of the requirement
For the award of the degree of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

Submitted by
T.DEEPIKA (315126520216)
P.PAVAN KUMAR (315126520166)
P.ANIL (315126520170)
P.SAHITHI (315126520175)
P.MUKESH (315126520164)

Under the Esteemed Guidance of

Mr. J.V BHANUTEJ, M.Tech (C.I.M)
Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

ANIL NEERUKONDA INSTITUTE OF TECHNOLOGY & SCIENCES(A)
(Affiliated to Andhra University, Approved by AICTE, Accredited by NBA, NAAC with “A” grade)
SANGIVALASA, VISAKHAPATNAM (District) – 531162
2019
 ANIL NEERUKONDA INSTITUTE OF TECHNOGY &

SCIENCES &TECHNOLOGY
(UGC Autonomous &Affiliated to Andhra University)
Sangivalasa, Bheemunipatnam (M), Visakhapatnam (Dt)

PRAGNAN
NAM
ANITS
BRAHMA

CERTIFICATE
This is to certify that the Project Report entitle DESIGN AND
FABRICATION OF PNEUMATIC PUNCHING MACHINE" has been carried
out by T.DEEPIKA (315126520216), P.PAVAN KUMAR (315126520166), P.ANIL
(315126520170), P.SAHITHI (315126520175), P.MUKESH (315126520164) under the
esteemed guidance of Prof J.V.BHANU TEJ, in partial fulfilment of the requirements for the
award of the Degree of Bachelor of Mechanical Engineering by Andhra University

Visakhapatnam.

APPROVED BY PROJECT GUIDE

Dr. B. NAGA RAJU Sri J.V.BHANU TEJ

Head of the department, Assistant Professor,

Dept. of Mechanical Engineering Dept. of Mechanical Engineering,

ANITS, Sangi valasa, ANITS, Sangivalasa,

Visakhapatnam. Visakhapatnam.
THIS PROJECT WORK IS APPROVED BY THE
FOLLOWING BOARD OF EXAMINERS

INTERNAL EXAMINER:
/5.919

EXTERNALEXAMINER:orb
 ACKNOWLDGEMENT

We express immensely our deep sense of gratitude to Mr. J. V BHANU TEJ,

Assistant Professor, Department of Mechanical Engineering, Anil Neerukonda Institute of
Technology & Sciences, Sangivalasa, Bheemunipatnam Mandal, Visakhapatnam district for
his valuable guidance and encouragement at every stage of the work made it a successful
fulfilment.

We are very thankful to Professor T. Subrahmanyam, Principal and Head of the

department. Dr.B.NagaRaju, Head of the Department, Mechanical Engineering, Anil
Neerukonda Institute of Technology & Sciences for their valuable suggestions.

We express our sincere thanks to the members of non-teaching staff of Mechanical

Engineering for their kind co-operation and support to carry on work.

Last but not the least, we like to convey our thanks to all who have contributed either
directly or indirectly for the completion of our work.

T.DEEPIKA (315126520216)
P.PAVANKUMAR (315126520166)
P.ANIL (315126520170)
P.SAHITHI (31512620175)
P.MUKESH(315126520164)
 CONTENTS PAGE
NO
CHAPTER-1 I NTRODUCTION 1
1.1 Introduction 1
1.2 pneumatics 2
1.2.1 Selection of pneumatics 2
1.2.2 Advantages of pneumatics 3
1.3 Punching press 4
1.4 Pneumatic control components 4
1.4.1 Pneumatic cylinder 4
1.5 Pneumatic systems 5
1.6 Main pneumatic components 6
1.6.1 compressor 6
1.6.2 Pressure regulating component 6
1.6.3 Execution component 7
1.6.4 Design of single – acting cylinder with a piston rod 9
1.6.5 Direction control valve 10
1.6.6 Control valve 13
1.7 Punch and die 14
1.7.1 Types of dies 15
1.8 Definition of the problem 17
1.9 Objective of project 17
CHAPTER-2 LITERATURE 18
2.1 Literature review 18
2.2 Summary 21
CHAPTER-3 THEORITICAL DESIGN AND CALCULATIONS 22
3.1 Theoretical Design 22
3.2 Clearance 22
3.1.2 Force Calculations 23
CHAPTER-4 MODELLING 26
4.1 Autodesk inventor 26
4.1.1 Data interoperability and exchange 27
 4.2 Part modelling 27
4.3 Assembly modelling 33
CHAPTER-5 PNEUMATIC SIMULATION 36
5.1 Introduction 36
5.2 Pneumatics equipment bar 36
5.2.1 Work surface 36
5.2.2 Air compressor 37
5.2.3 Conditioning unit 37
5.2.4 Accumulator 38
5.2.5 Direction valve , push button operator 39
5.2.6 Flow control valve 40
5.2.7 Pressure regulator 40
5.2.8 Single acting cylinder 41
5.3 Pneumatic Circuit 42
CHAPTER-6 FABRICATION
6.1 Carpentry 43
6.1.1 Dovetail joint 43
6.1.2 Half lap joint 44
6.1.3 Corner joint 45
6.2 Fabrication procedure 45
47
CHAPTER-7 FINITE ELEMENT ANALYSIS

7.1 Finite element method 47

7.2 Effect of process Parameters on Punching 47
7.2.1 The Effect of Clearance 47
7.2.2 The effect of punch fillet 48
7.2.3 The effect of sheet thickness 48
7.2.4 The effect of material of sheet 48
7.3 Experimental Procedure 48
8.1 FEA Analysis of Punching on aluminium Sheet 55
8.2 FEA Analysis of Punching on Copper Sheet 56
8.3 FEA Analysis of Punching on steel 1006 Sheet 58
9 Conclusion 61
 9.1 Conclusions 61
9.2 Future Scope 62
References 63

LIST OF TABLES
Table DESCRIPTION PAGE
No. NO.
3.1 Common materials shear Strength 23
3.2 Clearances 24
7.1 FEA Analysis on aluminium sheet for various clearances 54
7.1 FEA Analysis on copper sheet for various clearances
54
7.2 FEA Analysis on steel 1006 sheet for various clearances
54
8.4 Cost Analysis 65

LIST OF FIGURES

Figure No. Title PAGE

NO.
1.1 Punching Press 4
1.2 Air Compressor 6
1.3 Pressure regulating component 7
1.4(a) Cross Section of Single acting cylinder 7
1.4(b) Single acting cylinder 8
1.5(a) Cross Section of Double acting cylinder 8
1.5(b) Double Acting Cylinder 8
1.6 Spring Return Cylinder 9
1.7 Ram Cylinder 9
1.8 Pneumatic cylinder 9
1.9 Direction Valve 10
1.10 2/2 Direction Control valve 11
1.11 3/2 direction control Valve 12
1.12 3/2 direction control Valve 12
1.13 5/2 Direction Control Valve 12
1.14 Non Return Valve 13
1.15 Flow Control Valve 13
1.16 Shuttle Valve 14
1.17 Punch and Die 14
1.18 Inverted die 15
1.19 Compound die 16
1.20 Progressive die 16
4.1 piston 27
4.2 punch 28
4.3 die 28
4.4 Mortise and tenon joint 29
4.5 Corner joint 30
4.6 legs 30
4.8 Half lap joint 31
4.10 frame 31
4.11 assembly 34
5.1 Work surface 37
5.2 air compressor 37
5.3 conditioning unit 38
5.4 accumulator 39
5.5 Direction valve 39
5.6 Flow control valve 40
5.7 Pressure regulator 41
5.8 Single acting cylinder 41
5.9 Simulation 42
5.10 Pneumatic Circuit 42
6.1 punch 46
6.2 die 46
6.3 Final fabrication 46
7.1 Ansys Set up 49

7.2 Meshed Body 50

7.3 Meshed View 50
7.4 FEA Analysis of Punching on Aluminium sheet 51
7.5 FEA Analysis of Punching on Copper Sheet 52
7.6 FEA Analysis of Punching on Steel 1006 Sheet 53

List of Graphs:

Graph Title Page No.

No.

8.1 Clearance Vs. Total Deformation for Aluminium 55

8.2 Clearance Vs. Shear stress for Aluminium 56
8.3 Clearance Vs. Von-Mises Stress For aluminium 56
8.4 Clearance Vs. Total Deformation for Copper 57
8.5 Clearance Vs. Shear stress for Copper 57
8.6 Clearance Vs. Von-Mises Stress For Copper 57
8.7 Clearance Vs. Total Deformation for Steel 1006 58
8.8 Clearance Vs. Shear stress for Steel 1006 58
8.9 Clearance Vs. Von-Mises Stress For Steel 1006 59

Lit of Charts

Chart. Title Page No.

No.
8.1 Cost Analysis pie chart 60
 ABSTRACT

Paper boxes have become a more convenient way to store daily necessities and
for packaging small quantities. The main idea of this project is to design and
fabrication of punching machine for cutting the paper for paper box using Pneumatic
System. Due to global factory’s pressing need to increase the speed of packaging
small materials and decrease operating costs, our team decided to design a machine
that would automatically punch the paper boxes and process it to folding machines.
The present work also focus on analyse the punching process for different sheet
materials, percentage of punch-die clearances. The results of computer simulations
can be used to forecast the quality of the final parts optimization.

With very few pre-existing designs for automated paper boxes/loading

devices, we essentially had come up with a design. To make our machine design as
simple as possible, we decided to make it primarily using punch and die. The need for
ever-changing process innovations is persistently fuelled by rapid technology
advancements and demands on organisations to improve their bottom line. The design
of the machine can be one in various ways , we have gone through various software’s
among which we found Autodesk Inventor as user convenient and therefore finalised
to do the design in that software. We also had a glance through the pneumatics
simulation where lab volt software has come into existence. We have performed
Finite element analysis of punching in Explicit dynamics module of ANSYS 15.0 on
various sheet metals.

The Pneumatic punching machine is successfully fabricated at very low cost.

Through FEA analysis the optimum clearance values for sheet metals of thickness
0.5mm of materials aluminium, copper and steel 1006 are determined.
 CHAPTER-1
INTRODUCTION
1.1 INTRODUCTION

The automation concept and time conservation has changed the output service
and products in factories since the industrialization time period in developing
countries. Upgrading the time usage systems in automated machines and control
systems changes the industrialisation vision. With the advance technology engineers
always try to develop, invent and improve the machines which will make the work
more efficient. In today’s practical and cost-conscious world, sheet metal parts have
already replaced many expensive cast, forged, and machined products. In most of the
sheet metal operations punching or pressing operation is the main or initial operation
in the process sequence. Automating this operation results in reduced lead time and
also can reduce human effort. Automation can be defined as the “technology
concerned with application of mechanical, electronic and computer based systems to
operate and control production”. There are many reasons for automating the process.
The reason may be to reduce manufacturing lead time, to increase labour productivity
or to improve the worker safety etc.

Punching is a metal forming process that uses a punch press to force a tool, called a
punch, through the work piece to create a hole via shearing. The punch often passes
through the work into a die. A scrap slug from the hole is deposited into the die in the
process. Depending on the material being punched this slug may be recycled and
reused or discarded. Punching is often the cheapest method for creating holes in sheet
metal in medium to high production volumes. When a specially shaped punch is used
to create multiple usable parts from a sheet of material the process is known as
blanking. In forging applications the work is often punched while hot, and this is
called hot punching.

The press includes a piston operated by the compressed air source to drive a piston
rod to operate the press. This pneumatic press is suitable for small press tool works. It
works on the principal of compressed air. A compressor plant, pipe lines control
valve, drive-members and related auxiliary application. The air is compressed in an
air compressor and for the compressor plant, the flow medium is transmitted to the

1
pneumatic system, it is of vital important that the pressure drop between generation
and consumption of compressed air is kept very low, it has been seen that pipeline
fittings and joints are mostly responsible for drop in pressure, if any in pneumatic
system.

This project title is to design and fabrication of feeder and punching mechanism for
automated paper box. The project title is more focus to create the new idea for the
paper box. The paper box has two common functions. First is the feeder mechanism
.Second mechanism is the punching mechanism. It also can use for the storing of
sweets and eatable items. The main idea for this making of paper box is automation.
This making of paper box is different from the others in the market. This is because
the design of the box is different as it includes automation.

1.2 PNEUMATICS

Pneumatics is a branch of fluid power technology, which deal with the study and
application of use of pressurized gas to affect mechanical motion. Pneumatics system
are extensively used in industry, where factories are commonly plumbed with
compressed air or other compressed inert gases. This is because a centrally-located
and electrically- powered compressed that powers cylinders and other pneumatic
devices through lever operated valves in often able to provide motive power in a
cheaper, safer, more flexible, and more reliable way than a large number of electric
motors and actuators. Pneumatic system in fixed installation such as factories use
compressed air because a sustainable supply can be made by compressing
atmospheric air. The air usually has moisture moved and a small quantity of oil added
at the compressor, to avoid corrosion of mechanical components and to lubricate
them.

1.2.1 SELECTION OF PNEUMATICS

 Pneumatics is an attractive medium for low cost mechanization particularly for

sequential and repetitive operations.

 Many factories and plant already have a compressed air system, which is
capable of providing energy requirements and control system

2
  The main advantage of pneumatics system are usually economic and
simplicity the latter reducing maintenance to a low level.

 It can have outstanding advantages in term of safety.

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 outstanding advantages in
terms of safety.

1.2.2 ADVANTAGES OF PNEUMATICS:

 SIMPLICITY OF DESIGN AND CONTROL

 Machines are easily designed using standard cylinder & other components.
RELIABILITY
 Pneumatic system tends to have long operating lives and require very little
maintenance.
 Because gas is compressible, the equipment is less likely to be damages by
shock.
 The gas in pneumatics absorbs excessive force, whereas the fluid of hydraulics
directly transfers force.
 STORAGE
 Compressed gas can be stored, allowing the use of machines when electrical
power is lost.
 SAFETY
 Very low chance of fire (Compared to hydraulic oil).
 Machines can be designed to be overload safe.

3
1.3 PUCHING PRESS
A punch press is a type of machine press used to cut holes in material. It can be small
and manually operated and hold one simple die set, or be very large, CNC operated,
with a multi-station turret and hold a much larger and complex die set.

The various punching presses are fly wheel drive, mechanical punch press, hydraulic
punch press, servo drive turret punch press etc.

Fig 1.1 Punching Press

1.4 PNEUMATIC CONTROL COMPONENTS

1.4.1 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.
(i) 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

4
single action cylinder requires only about half the air volume consumed by a double
acting for one operating cycle.

(ii) 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.
1.5 Pneumatic Systems
Fluid power is the technology that the generation, control, and transmission of power,
using pressurized fluids. Pneumatics is a branch of fluid power technology, which
deals with the study and application of the use of pressurized gas to affect mechanical
motion. Pneumatics system is extensively used in industry, where factories are
commonly plumbed with compressed air or other compressed inert gases. This is
because a centrally-located and electrically- powered compressed that powers
cylinders and other pneumatic devices through lever operated valves is often able to
provide motive power in a cheaper, safer, more flexible, and more reliable way than a
large number of electric motors and actuators. A pneumatic system in a fixed
installation such as factories uses compressed air because a sustainable supply can be
made by compressing atmospheric air. The air usually has moisture moved and a
small quantity of oil added at the compressor, to avoid corrosion of mechanical
components and to lubricate them.

A pneumatic system is a system that uses compressed air to transmit and control
energy. Pneumatic systems are used in controlling train doors, automatic production
lines, and mechanical clamps

5
1.6 Main pneumatic components

Pneumatic components can be divided into two categories:

i) Components that produce and transport compressed air.

ii) Components that consume compressed air.

All main pneumatic components can be represented by simple pneumatic symbols.

Each symbol shows only the function of the component it represents, but not its
structure. Pneumatic symbols can be combined to form pneumatic diagrams. A
pneumatic diagram describes the relations between each pneumatic component, that
is, the design of the system.

Examples of components that produce and transport compressed air include

compressors and pressure regulating components.

1.6.1 Compressor

Fig 1.2 Air Compressor

A compressor can compress air to the required pressures. It can convert the
mechanical energy from motors and engines into the potential energy in compressed
air. A single central compressor can supply various pneumatic components with
compressed air, which is transported through pipes from the cylinder to the pneumatic
components. Compressors can be divided into two classes: reciprocatory and rotary

1.6.2 Pressure regulating component

Pressure regulating components are formed by various components, each

of which has its own pneumatic symbol:

6
 i. Filter – can remove impurities from compressed air before it is fed to
the pneumatic components.
ii. Pressure regulator – to stabilize the pressure and regulate the
operation of pneumatic components.
iii. Lubricator – To provide lubrication for pneumatic components

Fig 1.3 Pressure regulating component

Examples of components that consume compressed air include execution components

(cylinders), directional control valves and assistant valves.

1.6.3 Execution component

Pneumatic execution components provide rectilinear or rotary movement. Examples

of pneumatic execution components include cylinder pistons, pneumatic motors, etc.
Rectilinear motion is produced by cylinder pistons, while pneumatic motors provide
continuous rotations. There are many kinds of cylinders, such as single acting
cylinders and double acting cylinders.

Single acting cylinder: A single acting cylinder has only one entrance that allows
compressed air to flow through. Therefore, it can only produce thrust in one
direction. The piston rod is propelled in the opposite direction by an internal spring, or
by the external force provided by mechanical movement or weight of a load

Fig 1.4(a) Cross section of a single acting cylinder

7
 Fig 1.4(b) Single acting cylinder

The thrust from the piston rod is greatly lowered because it has to overcome the force
from the spring. Therefore, in order to provide the driving force for machines, the
diameter of the cylinder should be increased. In order to match the length of the
spring, the length of the cylinder should also be increased, thus limiting the length of
the path. Single acting cylinders are used in stamping, printing, moving materials,
etc.

Double acting cylinder: In a double acting cylinder, air pressure is applied alternately
to the relative surface of the piston, producing a propelling force and a retracting
force. As the effective area of the piston is small, the thrust produced during
retraction is relatively weak. The impeccable tubes of double acting cylinders are
usually made of steel. The working surfaces are also polished and coated with
chromium to reduce friction.

Fig 1.5(a) Cross section of a double acting cylinder

Fig 1.5(b) Double acting cylinder

8
 i. Spring return cylinder: It is a cylinder in which a spring returns the
piston assembly.

Fig 1.6 Spring return cylinder

ii. Ram cylinder: It is a cylinder in which the movable element is the

piston rod

Fig 1.7 Ram cylinder

1.6.4 Design of single-acting cylinder with a piston rod

A standard pneumatic cylinder consists of five modules/parts:

Fig 1.8 Pneumatic Cylinders

 Cylinder barrel
 Bearing cap
 End cap
 Piston
 Piston rod

9
i) Cylinder barrels : Originally, these really were "just" tubes. However, nowadays
extruded profiles instead of a tube are used for most cylinders. The advantage is that a
profile can also be used for additional functions.

ii) Bearing caps: The bearing cap closes the cylinder (cylinder barrel) on one side and
at the same time forms a bearing and sealing point for the piston rod. One of the air
connections is generally located in the bearing cap.

iii) End caps: The end cap closes the cylinder (cylinder barrel) on the other side. The
second air connection is usually located in the end cap.

iv) Pistons: The piston which is in the piston rod carries out actual movement in the
cylinder. However, the piston needs to do more than just carry out a movement. It
forms a seal between the front and rear cylinder chamber. In addition, the piston has
to convert the kinetic residual energy in the end position. The bearing and end caps
also have their part to play.

v) Piston rods: The piston rod is the part which transmits the force and the movement
of the cylinder to the outside. The tip of the piston rod generally has a thread so that
other custom components can be attached to it.

1.6.5 Directional control valve: Directional control valves ensure the flow
of air between air ports by opening, closing and switching their internal connections.
Their classification is determined by the number of ports, the number of switching
positions, the normal position of the valve and its method of operation. Common
types of directional control valves include 2/2, 3/2, 5/2, etc. The first number
represents the number of ports; the second number represents the number of positions.
A directional control valve that has two ports and five positions can be represented by
the drawing in a figure as well as its own unique pneumatic symbol.

Fig 1.9 Describing (a) 5/2 directional control valve

10
i) 2/2 Directional control valve: The structure of a 2/2 directional control valve is
very simple. It uses the thrust from the spring to open and close the valve, stopping
compressed air from flowing towards working tube ‘A’ from air inlet ‘P’. When a
force is applied to the control axis, the valve will be pushed open, connecting ‘P’ with
‘A’. The force applied to the control axis has to overcome both air pressure and the
repulsive force of the spring. The control valve can be driven manually or
mechanically and restored to its original position by the spring.

(a) (b) (c)

Fig 1.10 2/2 directional control valve

(a) 2/2 control valve

(b) Cross section
(c) Pneumatic symbol of a 2/2 directional control valve

ii) 3/2 Directional control valve: A 3/2 directional control valve can be used to
control a single acting cylinder. The open valves in the middle will close until ‘P’ and
‘A’ are connected together. Then another valve will open the sealed base between
‘A’ and ‘R’ (exhaust). The valves can be driven manually, mechanically, electrically
or pneumatically. 3/2 directional control valves can further be divided into two
classes: Normally open type (N.O.) and normally closed type (N.C.)

11
 (a) (b)

Fig 1.11 3/2 directional control valve (a)3/2 control valve (b) Cross section

(a) (b)
Fig 1.12 Pneumatic symbol of 3/2 directional control valve
(a) Normally closed type
(b) Normally open type

iii) 5/2 Directional control valve: When a pressure pulse is an input into the
pressure control port ‘P', the spool will move to the left, connecting inlet ‘P' and work
passage ‘B'. Work passage ‘A' will then make a release of air through ‘R1' and ‘R2'.
The directional valves will remain in this operational position until signals of the
contrary are received. Therefore, this type of directional control valves is said to have
the function of ‘memory'.

(a) (b) (c)

Fig 1.13 5/2 directional control valve
(a) 5/2 control valve
(b) Cross section
(c) Pneumatic symbol

12
1.6.6 Control valve

A control valve is a valve that controls the flow of air. Examples include non-return
valves, flow control valves, shuttle valves, etc.

1) Non-return valve: A non-return valve allows air to flow in one direction

only. When air flows in the opposite direction, the valve will close. Another
name for non-return valve is poppet valve.

(a) (b) (c)

Fig 1.14 Non-return valve

(a) Non-return valve

(b) Cross section
(c) Pneumatic Symbol
(a) Flow control valve: A flow control valve is formed by a non-return valve
and a variable throttle

(a) (b) (c)

Fig 1.15 Flow control valve

(a) Flow control valve
(b) Cross section
(b) Pneumatic symbol

13
(b) Shuttle valve: A shuttle valve has two air inlets ‘P1’ and ‘P2’ and one air outlet
‘A’. When compressed air enters through ‘P1’, the sphere will seal and block the
other inlet ‘P2’. Air can then flow from ‘P1’ to ‘A’. When the contrary happens, the
sphere will block inlet ‘P1’, allowing air to flow from ‘P2’ to ‘A’ only

(a) (b) (c)

Fig 1.16 Shuttle valve
(a) Shuttle valve
(b) Cross section
(c) Pneumatic symbol
1.7 PUNCH AND DIE

A typical die and punch set used for blanking operation is shown below. The sheet
metal used is called strip or stock. The punch which is held in the punch holder is
bolted to the press ram while die is bolted on the press table. During the working
stroke, the punch penetrates the strip, and on the return stroke of the press ram the
strip is lifted with the punch, but it is removed from the punch by the stripper plate.
The stop pin is a gage and it sets the advance of the strip stock within the punch and
die.

Fig 1.17 Punch and die

14
CLEARANCE

In blanking operation, the die size is taken as the blank size and the punch is made
smaller giving the necessary clearance between the die and the punch.

1.7.1 TYPES OF DIES

The die set is made up of the punch holder which is fastened to the ram of the punch
press and the die shoe which is fastened to the bolster plate of the punch press.
Various types of dies are used some of the commonly used dies are as follows:

i) Inverted die is designed with the die block fastened to the punch holder and the
punch fastened to the die shoe. During the downward stroke of ram, the blank is
sheared from the strip. The blank and shedder are forced back into the die opening,
which loads a compression spring in the die opening. At the same time the punch is
forced through the scrap strip and a spring attached to the stripper is compressed and
loaded.

Fig 1.18 Inverted die

ii) Compound die combines the principles of the conventional and inverted dies in
one station. This type of die may produce a work piece which is pierced and blanked
at one station and in one operation. The piercing punch is fastened in the conventional
position to the punch holder..

15
 Fig 1.19 Compound die

iii) Progressive dies are made with two or more stations arranged in a sequence. Each
station performs an operation on the work piece, or provides an idler station, so that
the work piece is completed when the last operation has been accomplished.
Thereafter each stroke of the ram produces a finished part. Thus after the fourth stroke
of a four – station die, each successive stroke will produce a finished part

Fig 1.20 Progressive die

16
1.8 Definition of the problem:
Industries, these days always try to increase its production rate by reducing the
wastage of time, manpower, by decreasing the operating costs and by optimizing the
work to get ahead of their competition in this era. So, they often look for methods to
automate various processes in their production line. One such industry is the
packaging industry where most of the work is manually done because of the intricate
shapes of packaging and distinct requirements of several clients but requires
automation to boost its production rateThe making of paper boxes usually involved
some manual work. In this project we are trying to eliminate the manual work and
automate it which would save time and may decrease the labour cost. So, we have
decided to design a paper box using punching mechanism and automate it. Hence the
problem is identified first and is then defined and then is tried to eliminate that.

1.9 Objective of project

The main objective of the project is to fabricate a paper box maker and its
automation. The main operation performed here is the punching operation and
by using this punching operation we have to cut the paper with the required
dimensions. By using punch and die we try to punch the paper with the
required force. The present work also focus on analyse the punching process
for different sheet materials, percentage of punch-die clearances. The results
of computer simulations can be used to forecast the quality of the final parts
optimization.

17
 CHAPTER - 2
LITERATURE
Paper boxes have become a more convenient way to store daily necessities and for
packing small quantities all over the places around us, but the requirements of this
system like fixed installation, space consumption and energy consumptions limiting
its applications in some fields. In order to overcome all these problems we come up
with an idea of design and fabrication of an automated paper box maker using feeding
and punching mechanism. The following papers were referred to study the
mechanisms like feeding and punching and also design procedures of automated
paper box maker.

2.1 Literature review

Pneumatics is a branch of engineering that makes use of gas or pressurized air.

Pneumatic systems used in industry are commonly powered by compressed air or
compressed inert gases. A pneumatic system controlled through manual or
automatic solenoid valves is selected when it provides a lower cost, more flexible, or
safer alternative to electric motors and actuators.

Suraj V Bhosale1 et al [1] is carried out work on “Design and Fabrication of

Pneumatic Sheet Metal Cutting Machine “Normally the sheet metal cutting machine
is manually hand operated for medium and small scale industries. This paper gives an
insight about the automatic sheet metal cutting machine. Any automatic machine
aimed for economical use of man. In this paper, pneumatic cylinder is used for cutting
in easy way which can be use in small scale industries at lower cost. The sheet metal
cutting machine works with the help of pneumatic double acting cylinder. The piston
is connected to the moving cutting tool which is used to cut the sheet metal. The
cutting process is operated by a direction control valve by using compressor. In
manual method sheet metals goes to the scrap sometime because of wrong
dimensions, improper cutting etc. Hydraulic machines are also used for sheet metal
cutting. But this machines are used for heavy metal cutting and its cost is very high.
Hence, we are using a pneumatic system for sheet metal cutting in a easy manner. The
main advantage of pneumatic sheet metal cutting machine is to improve product
quality, repetition of work and increasing production rate.

18
A.S. Aditya Polapragada1 et al [2] has done work on “Pneumatic Auto Feed
Punching and Riveting Machine”
Press tools are used to form and cut thin metals. Press tools operation can be
simplified to a few the pneumatic systems has gained a large amount of importance in
last few decades. This importance is due to its accuracy and cost. These simple
operations involving a punch a die. There are Nemours types of presses in engineering
field, which are used to fulfil the requirements. We are interested to introduce
pneumatic system in presses. The main convenience in operating the pneumatic
system has function of pneumatic press is to form or cut thin sheet made us to design
and fabricate this unit as our metals or non-metals using pneumatic power. In this
project we have used the punching process and riveting process for simple
application.
The pneumatic press tool has an advantage of working in low pressure that is even a
pressure of General Description: 6 bars is enough for operating the unit. The
pressurized air passing through the tubes to the cylinder, forces the piston out whose
power through the linkage is transmitted to the punch. The work piece thus got is for
required dimensions and the piece can be collected through the land clearance
provided in the die. The die used in this is fixed such that the die of required shape
can be used according to the requirement. This enables us to use different type punch
dies resulting in a wide range of products. Different types of punch as requirement
can be thus got.

Ms anita v. hase et al [ 3 ] is carried out work on “Mechanically Operated

Automation System ”This Paper objective is to know the actual working of the
Automation system. A mechanism for automatically pushing up tissues which
includes a box and a pusher. The box stores a tissues in layers and has top wall with
an opening formed therein for picking up tissues their through, the pusher disposed
under the tissues in the box for pushing up tissues. In this working model, we have
made the actual working or simulation of automation system so that it is easy to
understand. Our main goal is to make a study model of punching, stamping and power
transmission in automation system. With actual working of it only placing all the
component in its proper positioning and simplifying the working of it for studying
purpose of student it is exactly similar to that of the actual automation system used in
industries.
19
Puneet Isarka et al [4] has done work on “Design and development of pneumatic
punching machine ” Pneumatic is a branch of engineering that deals which study of
air/gas characteristic and also their use in engineering appliances either in atmospheric
or above atmospheric pressure. Now a days number of application increases in
pneumatics system due to high carrying capacity, low maintenance cost and most
important not dangerous. Either compressed air or inert gas are generally used, this
paper deals with different components of punching machine (proto type) and their
assembly. .

S.p avadhani et al [5] studied on “Design and Analysis of Blanking and Piercing die
punch” The sheet metal working processes are widely used in almost all industries
like automotive, defense, medical and mechanical industries. The major advantage for
using metal working process is to improve production rate and to reduce the cost per
piece. Nowadays many people are working for developing die punches with
innovative ideas. This project is also based on new design for die punch. The project
mainly focuses on different operations done on single setup of die punch in a single
stroke, presently these operations are done on three separate setups which leading to
reduce the production rate and increasing cycle time with cost as well. The theoretical
calculations were done for calculating cutting force, tonnage required, Von-Misses
stresses, fatigue life, buckling load and total deformation. The 3D parts are modelled
in CATIA-v5 and saved in .stp file format so that it can be imported from any of the
analysis software. As per the companies requirement cad drawings are drawn in
AUTOCAD software. The various analyses like Von-Misses stress analysis, fatigue
life, are carried out on Ansys 14.0 workbench analysis software and results are
compared with theoretical results. The results are within 5% of allowable limit. Key
Words: Die punch, FEA, Ansys. Catia-V5, Autocad.

P.Goyal, et al [6] studied on “Design of pneumatically controlled small scale

punching machine”. This project work deals with the design of pneumatically
controlled small scale punching machine to carry out piercing operation on thin sheets
(1-2 mm) of different material (aluminium and plastic). Reduction in punching force
requirement being the main aim of this project work is obtained by modification in
punch tool design i.e. by provision of shear on punch face. Subsequently it results in
reduction in amount of punching force requirement. And further a CATIA model of
the machine is developed on the basis of calculations with respect to punching force

20
requirement. AMIT M. GEDAM, 2014 - In today world, due to advance
manufacturing process and advance machining process the time of production is
reduces. Thus the productivity increases which effect on mass production and batch
production. So it is essentially to products name plate parts to be the manufacture.
There are a variety of crafts for an embossing machine that allow you to create
unusual, signature pieces of artwork. Embossing machines come in several varieties.
There are multi-tasking embossers available at craft and scrapbooking stores that
allow you to embellish and cut card stock and paper pieces into a variety of different
designs in a single motion. You can also use embossing machines that feature
Custom-made thick rubber dyes secured with hand-held or desk-mounted metal
handles. These machines allow you to create personal monogrammed or logoed
designs with a raised surface, and they can be ordered through office and business
supply stores.

2.2 Summary:

Hence by considering and studying the above journals we got an idea of how to use the
different components. In this era we have got a clear idea on the manufacturing the
required component in a required way. In this chapter, our detailed research on various
research papers has been described. The inputs we took from these papers help us in
designing and fabricating the model according to our requirements. These will be
discussed in detail in subsequent chapters.

21
 CHAPTER-3
Theoretical Design and Calculations:

Design theory has been approached and interpreted in many ways, from
personal statements of design principles, through constructs of the philosophy of
design to a search for a design science. In this design we have calculated the required
punch force the clearance for the assembled punch and die. The required force
calculations are also done .In order to get the required output we need to calculate the
thrust force. The cylinder thrust force comes into picture both during the forward
stroke and during the backword stroke.

3.1 Theoretical Design

In this theoretical design we will know all the required parameter for the final
fabrication and in order to eliminate all the extra forces or unused forces. In order to
eliminate the manual work and to reduce the time consumption we have decided to do
this project.

In this project we are using the pneumatic cylinder as punching equipment.

The compressed air from the compressor is used as the force medium for this
operation. In one position, air enters to the top of the cylinder and pushes the piston so
that the punching is done. In next position, air enters to the bottom of the cylinder and
pushes the piston return back, so that the return stroke is obtained.

The key components used in this design and calculations are clearance, constant,
punching force, forward stroke, return stroke, cylinder thrust, paper.

3.1.1 Clearance

Paper dimension-29 210 mm

Clearance = C×t×√( ÷10)

C=Constant =0.01

=shear strength of sheet=20-50

22
=30N/

C=0.01

Clearance=0.01×0.5√ ( /10)

=8.66025× mm

3.1.2 Force Calculations:

Cylinder thrust for double acting in forward stroke

F= (π/4) × ×P

D-Diameter of bore =42mm

d- Piston rod diameter=12mm

P-pressure =5Kg/

=490332.5N/

F (forward stroke) = /4) × ×490332.5N/

F=679.32N

Cylinder thrust for single acting in return stroke

F= (π/4) × ( ×P

F= (π/4) × ( ×P

=346.59N

The below are taken as a reference:

Table 1:Common Materials shear strength is as follows: unit KN/
Aluminium Brass Low Carbon steel Stainless steel

0.1724 0.2413 0.3447 0.5171

23
Table 3.2:Punch Machines die clearance
Plate thickness Mild Steel Aluminium Stainless steel

0.8-1.6 0.15-0.2 0.15-0.2 0.15-0.3

1.6-2.3 0.2-0.3 0.2-0.3 0.3-0.4

2.3-3.2 0.3-0.4 0.3-0.4 0.4-0.6

3.2-4.5 0.4-0.6 0.4-0.5 0.6-1.0

4.5-6.0 0.6-0.9 0.5-0.7

Punching Force (KN) =Perimeter (mm)*Plate thickness (mm)*shear strength

(KN/

Let the plate thickness=0.5 mm

For Aluminium

Punching Force= 774*0.5*0.1724

=66.7188 KN
For Brass

Punching force= 774*0.5*0.2413

=93.3831 KN

For Low Carbon Steel

Punching force=774*0.5*0.3447
=133.3989 KN
For Stainless Steel

Punching Force=774*0.5*0.5171
=200.11 KN

24
 Hence the required punch force the cylinder thrust during the forward and
return stroke the clearance required are calculated using certain formulas. The
dimensions are in Newton and millimetre. Hence the theoretical design is done by the
above calculations. The design is either to formulate a plan for the satisfaction of a
special need or to solve a problem. If the plan result in the creation of something
having a physical reality, then the product must be functional, safe, reliable,
competitive, usable, manufacturable and marketable.

25
 CHAPTER-4
MODELLING
In this chapter, modelling of various parts in the model can be done.
Modelling can be done in various methods such as wireframe modelling, surface
modelling, solid modelling etc. Design of a machine can be done in various ways such
as it can be done using AutoCAD, solid works, Inventor the easiest way is chosen for
design and modelling of the experimental setup. There are many packages for the
design and modelling, out of which Autodesk Inventor has been selected for its ease
of availability and as it is user friendly and is easily understandable, therefore we have
chosen the package Autodesk Inventor.

4.1 AUTODESK INVENTOR:

Autodesk Inventor is 3D CAD modelling software used to design, visualize, and test
product ideas. Inventor allows you to create product prototypes that accurately
simulate the weight, stress, friction, driving loads, and much more of products and
their components in a simulated 3D environment.

The main features of AUTODESK INVENTOR are:

 Inventor allows 2D and 3D data integration in a single environment, creating a

virtual representation of the final product that enables users to validate the
form, fit, and function of the product before it is ever built.
 Autodesk Inventor includes powerful parametric, direct edit and freeform
modelling tools as well as multi-CAD translation capabilities and in their
standard drawings.
 Inventor uses Shape Manager Autodesk's proprietary geometric modelling
kernel. Autodesk Inventor competes directly with Solid Works, Solid Edge,
and Creo.
 The automatic updating feature allows easy changes in models.
 With Inventor, prototyping can be accomplished easily by integrating 2D
AutoCAD drawings and 3D data into a digital model which will serve as a
virtual representation of the final product.
 By doing so, engineers are able to better design and simulate products without
the need to create physical prototypes.

26
  Autodesk Inventor Introduction to solid works is perfect for the new user or
for users making the switch from a completive 3D modelling application.
Autodesk Inventor sheet metal will help you get the most out of the built in
sheet metal tools found in Autodesk Inventor.

4.1.1 Data interoperability and exchange:

Inventor uses specific file formats for paths (IPT), assemblies (IAM) and drawing
views (IDW and DWG). Files can be imported or exported in DWG format. Design
Web format (DWF) is Autodesk’s preferred 2D/3D data interchange and review
format. Inventor includes a building information modelling (BIM) Exchange tool,
used to create and publish simplifies 3D representations, intelligent connections
points and additional information in native file formats for AutoCAD MEP
(mechanical, electrical and plumbing) software. This data interoperability and
exchange is used if an analysis is done.

4.2 Part Modelling:

The automatic paper box maker parts are modelled first in the Autodesk inventor.

The part modelling is done by the following steps by top down approach.

 Step 1: creating new part file with extension”.ipt”

 Step 2: creating the base part 2D sketch
 Step 3: converting 2D sketch to required 3D model by using features like
extrude, extrude cut, revolve, sweep, chamfers, fillets, holes, spiral etc.
 Step 4: Saving the file with desired part name.

Fig 4.1PISTON
27
 PUNCH
Fig 4.2

DIE
Fig 4.3
The design of various parts used in this project is as follows:

(i) Firstly we need to design a frame for the entire support of the equipment.
For this frame to be designed we need various small parts to be designed with certain
dimensions.

28
 Mortise and tenon joint
Fig 4.4

Using wood material we prepare the frame. In the above part the dovetail joint is used
to attach each other.

 For the automation to occur or to be made possible we need a base called as

frame.
 Sometimes the frame sizes may be too small or too large also, we need to use
it according to our requirement.
 Frame is often a structural system that supports other components of a
physical construction and/or steel frame that limits the constructions extent.
 This is a mortise and tenon joint.
 A mortise and tenon joint connects two pieces of wood or of other material.
 It has a butt joint and hence it is advantageous.

29
 Corner joint
Figure 4.5

 This is a dovetail joint.

 A dovetail joint is a joinery technique most commonly used in wood working.
 It is the strongest of all joints.
 It has a large gluing area, is interlocking, resists being pulled apart, looks
attractive, and would hold together even without glue.
 It has great precision and has good ease of operation.
 That is why dovetail joint is used in this type of frame which is a supporting
member.

Legs
Figure 4.6

30
 ± 0 .50
20

± 0 .50
20

Half lap joint

Figure 4.7

530
470
470

470
530
400
400

400
20
470
400 400 470
20

470
530
400
530

400

Fig 4.8 Frame

31
 L-clamp Punch

cylinder Die
support block

Frame Assembly
Assembly

Fig 4.9 various parts in the model

32
4.3 Assembly Modelling:

The assembly of the parts is done with proper constraints in the following manner to
allow the assembled model to simulate.

 Step 1: Crating new assembly file with extension “.iam”.

 Step2: Import the base part first and ground it.
 Step3: Now import all the other parts and assemble them with various
constraints to planes and features like mate, align, insert etc.
 Step 4: Give the revolutionary joint at which the motor shaft revolving
fixture assembled.
 Step5: Saving the file with desired file name.

Figure 4.10 frame assembly

The above figure is done in solid works to just get a view on the total design and how
it must be fabricated with proper and required dimensions.
The complete assembly of the paper box maker is shown in the above and below
figure here.

33
 Fig 4.11 Frame

Fig 4.12 Final Frame Assembly

The modelling of various parts is done using the software Autodesk Inventor. The
design of different joints required in the assembly of frame is done. The different
joints used in the modelling are corner joint, mortise and tenon joint; half lap joint and
reaming parts are also assembled to get the final model in the software.

34
 6 5 4 3 2 1

D D

200.00
3

225.00
6
29.80
30.00
C 7 C

410.00
PARTS LIST 1
ITEM QTY PART NUMBER
1 1 FRAME
2 1 DIE
3 1 SUPPORT BLOCK
B 4 2 L CLAMP B
5 1 CYLINDER
6 1 PISTON
297.00

500.00

7 1 PUNCH

ANIL NEERUKONDA INSTITUTE OF TECHNOLOGY & SCIENCES(A)

PART NAME: PUNCHING MACHINE ASSEMBLY

PROJECT MEMBERS PROJECT GUIDE

T.DEEPIKA (315126520216)
J V BHANUTEJ
P.PAVAN KUMAR (315126520166) Assistant Professor
P.ANIL (315126520170) Dept of Mechanical
A 210.00 P.SAHITHI (315126520175)
Engineering A
P.MUKESH (315126520164)

DRAWING NO:4.1

SCALE: 1:5
6 5 4 3 2 1
 CHAPTER-5
PNEUMATIC SIMULATION
5.1 Introduction

The lab-volt virtual laboratory (LVVL) is a three-dimensional classroom laboratory

displayed on a computer screen. Various subject such as hydraulics, pneumatics,
electromechanically systems, and digital telecommunication can be studied using this
virtual equipment.

The virtual equipment sets form complete training systems which are faithful three-
dimensional reproduction of actual lab-volt training systems. They have the same
physical appearance and behave in the same way as the actual training systems.

As we are using Pneumatics in our project, we deal with the Pneumatics Equipment in
the software.

5.2 Pneumatics Equipment Bar

The Pneumatics Equipment Bar is a set of buttons. Each button corresponds to
a piece of pneumatic equipment. The buttons on the Pneumatics Equipment Bar are
used to install the Work Surface and the Air Compressor in the Lab-Volt Virtual
Laboratory (LVVL), and to install a pneumatic component on the Work Surface. See
Installing Pneumatic Equipment to obtain additional information.

The buttons on the Pneumatics Equipment Bar and the name of the component
corresponding to each button are displayed below. You can click one of the following
topics to obtain a detailed description on the component related to one of the buttons
on the Pneumatics Equipment Bar.

5.2.1 Work Surface

The Work Surface provides a uniform surface on which to install pneumatic
components

36
 Fig 5.1 Work Surface

5.2.2 Air Compressor

The Air Compressor supplies air under pressure to the pneumatic system. It
consists of a compressor, a receiver, and two connection ports labeled Outlet Ports.

In order for the Air Compressor to supply air to the circuit, one of its outlet
ports has to be connected to the inlet port of the Conditioning Unit.

Fig 5.2 Air Compressor

5.2.3 Conditioning Unit

The Conditioning Unit filters regulate the system pressure and distribute
conditioned air to the pneumatic circuit. The Conditioning Unit consists of an air inlet
port, an exhaust port, the main shutoff valve, a filter, a muffler, a pressure regulator, a
pressure gauge, a 4-port manifold, 4 branch shutoff valves, and 4 outlet ports. In order
for the Conditioning Unit to supply air to the circuit, it must first be connected to the
Air Compressor.

37
 The main shutoff valve controls the air supply to the pressure regulator. The
main shutoff valve is open when its control knob is in the upper position and is closed
when its control knob is in the lower position. The position of the control knob is
changed by clicking the mouse left button on the main shutoff valve.

The pressure regulator is used to set the pressure in the circuit. Clicking the
control knob of the pressure regulator opens a dialog box that allows you to change
the pressure regulator setting.

The pressure gauge allows the monitoring of the regulated pressure. It is

possible to obtain a close-up view of the dial by clicking the mouse right button on the
Conditioning Unit and selecting Meter View in the context-sensitive menu.

The conditioned air is available through the 4 outlet ports individually

controlled by branch shutoff valves. The shutoff valves are open when their collar is
in the upper position and are closed when their collar is in the lower position. The
position of the collars is changed by clicking the mouse left button on the branch
shutoff valves.

Fig 5.3 Conditioning unit

5.2.4 Accumulator
The Accumulator is used to store pressurized air and to provide a short-term
supply of compressed air to a particular device. It has one connection port labelled
Accumulator Port.

38
 Fig 5.4 Accumulator

5.2.5 Directional Valve, Pushbutton Operated

A Directional Valve, Pushbutton Operated is used to control the direction of
air flow in a pneumatic circuit. The Directional Valve, Pushbutton Operated which is
used in the Lab-Volt Virtual Laboratory is a two-way, two-position, pushbutton
operated directional valve.

It has three connection ports that allow normally closed and normally open
configurations. Flow-path configurations are reversed by depressing the pushbutton.
To depress the pushbutton, place the mouse pointer on the pushbutton, click the
mouse left button and maintain it down. The pushbutton returns to its released
position when the mouse left button is released.

39
 Fig 5.5 Pushbutton operated directional valve

5.2.6 Flow Control Valve

The Flow Control Valve is designed to adjust the resistance to airflow in a

pneumatic circuit. It has one Inlet Port, one Outlet Port, and a Control Knob.

Fig 5.6 Flow control valve

5.2.7 Pressure Regulator

The Pressure Regulator is a valve designed to maintain a constant pressure in
pneumatic circuits. It has two connection ports, labelled Inlet and Outlet as well as an
exhaust port.

The Pressure Regulator is a normally passing valve that regulates pressure by

closing partially or completely an opening that allows fluid to flow from the Inlet port
to the Outlet port. The pressure at the Outlet port pushes (via a diaphragm) against a
spring inside the valve, to automatically adjust the valve opening so as to maintain the
desired pressure at the Outlet port.

The regulated pressure, that is the pressure at the Outlet port, is set by turning
the adjustment knob on the Pressure Regulator. Turning the adjustment knob
clockwise compresses the spring inside the valve more and more, and thereby,
increases the regulated pressure setting.

40
 Fig 5.7 Pressure Regulator

5.2.8 Single-Acting Cylinder

The Single-Acting Cylinder is a spring-return cylinder. It converts fluid

energy into linear mechanical energy which can be used to perform work in only one
direction. It has one connection port labelled Cap End Port.

When airflow is directed toward the Cap End Port of the cylinder, the pressure in the
cap end rises until enough force is generated to compress the spring, and the cylinder
rod extends. When the air pressure is released, the force of the spring makes the
cylinder rod retract. The cylinder rod can also be extended and retracted manually. To
do so, place the mouse pointer on the cylinder tip. The arrow pointer changes to a
hand pointer. Click the mouse left button and drag the rod outside or inside the
cylinder. Then release the mouse left button.

Fig 5.8 Single acting cylinder

41
5.3 Pneumatic Circuit
The pneumatic circuit is designed using all the controls in the pneumatics equipment
bar. A limit switch assembly is also used which senses the movement of the piston
and controls its movement.

Fig 5.9 Pneumatic circuit in Lab volt

The pneumatic circuit is designed using all the controls in the pneumatics equipment
bar. A limit switch assembly is also used which senses the movement of the piston
and controls its movement.

Fig 5.10 Pneumatic circuit

By using this we have learnt about what is simulation why we used that and all
the equipment used in the simulation. Simulation gave us a whole idea on how the
equipment works once if it is fabricated. The flow of the compressed air through the
hoses and its direction is observed. All this we have learnt by using Pneumatic
Simulation.
42
 CHAPTER – 6
FABRICATION
The wood fabrication is different methods to machine wood materials are
quite similar to those for metal working process. In a wood workshop there are
commonly lathes, milling centres and grinding machines. In addition there are also
sawing machines. Sawmills usually have similar equipment and machine tools , but
can handle much larger quantities and dimensions .wood ales reacts differently
depending on which direction a cut is made .Workshops specializing in wood work
have become scarce. Mostly there are small workshops which do wooden moulds,
prototypes and models for manufacturing companies, or small-scale furniture pieces.
The heavier production is usually made directly. Even if the machine tools are almost
alike, wood has completely different characteristics. Generally, wood is softer, more
brittle and more fragile compared to metals.
6.1 CARPENTARY
carpentry is a skilled trade and a craft in which the primary work for
performed is the cutting, shaping and installation of building materials during the
construction of buildings, ships, timber bridges, concrete formwork , etc. Carpenters
traditionally worked with natural wood and did the rougher work such as framing, but
today many other materials are also used and sometimes the finer trades of
cabinetmaking and furniture building are considered carpentry. Carpenters are usually
the first tradesmen on a job and the last to leave. Carpenters normally framed post-
and-beam buildings until the end of the 19th century; now this old fashioned
carpentry is called timber framing.

The types of joints used in project for the design and fabrication of the frame using
wood are
6.1.1 DOVETAIL JOINT

A dovetail or simply dovetail is a joinery technique most commonly used in

woodworking joinery (carpentry) including furniture, cabinets. Noted for its
resistance to being pulled apart (tensile strength), the dovetail joint is commonly used
to join the sides of a drawer to the front. A series of 'pins' cut to extend from the end
of one board interlock with a series of 'tails' cut into the end of another board. The

43
pins and tails have a trapezoidal shape. Once glued, a wooden dovetail joint requires
no mechanical fasteners.

Table 6.1: Types of joints in carpentary

Joint Image Description

The end of a piece of wood is butted against

another piece of wood. This is the simplest and
Butt joint weakest joint. Of those, there is the a) T-butt, b)
end-to-end butt, c) T-lap d) Miter butt and e)
edge-to-edge butt.

A form of box joint where the fingers are locked

Dovetail
together by diagonal cuts. More secure than a box
joint
joint.

A stub (the tenon) will fit tightly into a hole cut

for it (the mortise). This is a hallmark of Mission
Mortise Style furniture, and also the traditional method of
and tenon jointing frame and panel members in doors,
windows, and cabinets. This joint is a good strong
joint to use.

A joint in which the two members are joined by

Cross
removing material from each at the point of
Lap
intersection so that they overlap.

6.1.2 HALFLAP JOINT:

Half lap joints are among the most basic of woodworking joints, but there are
times where they are the perfect choice for connecting two pieces of stock.
A half lap joint is where two pieces of stock, which are typically the same thickness,

44
have half of the material removed so that the two boards fit together so that the joint
adds no thickness at the joint. These joints work well for right-angle connections,
especially since both boards have material removed so that they fit together seamless.

6.1.3 CORNER JOINT:

The corner joint may be regarded as a butt joint and is used to join two plates
at right angles to each other. It can be difficult to assemble and maintain correct
alignment, particularly in thin flexible sheet. The root of a single-sided weld when
loaded in tension is very weak and for the highest strength the corner joint needs to be
welded from both sides. The single-sided weld may also have a crease containing
oxides along the centre line of the penetration bead, further reducing the strength of
the weld. Pulsed AC-TIG has been found to be effective in reducing the occurrence of
this feature. The corner joint is most often found in low load- carrying applications
and in sheet metal work.

6.2 Fabrication Procedure:

(i) Using the scrap such as left parts of wood, we fabricated a frame
for the working model.
(ii) This frame involved a lot of joints for the assembly.
(iii) In order to provide proper support for the frame and for the
mobility of the working model, we attached plywood beneath the
frame.
(iv) By locating the centre of the frame we have drilled a whole in the
middle according to the diameter of the piston cylinder used.
(v) The cylinder is fitted into the hole with a certain stroke length and
for the piston to be stable it is clamped to the top part of the frame.
(vi) The punch is fixed to the piston rod of the cylinder
(vii) And to the bottom the die is fixed
(viii) These punch and die are made with the wood left as for scrap.
The die and punch are shown in figures 6.1 and 6.2 and finally assembly is shown in
6.3

45
 Fig 6.1 Punch

Fig 6.2 Die

Figure 6.3 Pneumatic Punching Machine

46
 CHAPTER-7

FINITE ELEMENT ANALYSIS

7.1 Finite-Element Method

Finite-element method (FEM) is a good choice for the analysis of sheet metal
processes since it helps in eliminating the need for time-consuming experiments to optimize
the process parameters such as sheet metal thickness, the material of the sheet, punch fillet
and percentage clearance. The FEM simulations are increasingly used for investigating and
optimizing the punching process. Computer simulations reduce the number of experiments
and can obtain accurate results. The results depend on the element type and type of mesh
considered for analysis. The main objective of the present work is to create a finite element
model to predict the shape of the cut side of a blanked product and to investigate the effect of
process parameters’ influence on the punching process. Shock waves produced because of
crash and drop test, which can be analysed using ANSYS explicit dynamics.

In high-speed dynamic problems, the time required is compared with reference to the
standard specimens and analysed. Using explicit dynamics, we can reduce the number of
steps in the analysis, thereby reducing the time for computing.

7.2 Effect of process parameters on punching

The process parameters play a significant role in determining the nature and geometry of the
material, obtained after the punching operation is done.

7.2.1 The Effect of Clearance

Clearance (C) is the space (per side) between the punch and the die tool. Proper clearance is
provided between cutting edges which enable fractures to start ideally at the cutting edge of
the punch and also at the die. The fracture will proceed toward until the cracks meet each
other and the fractured portion of the sheared edge then has a clean appearance.

With correct clearance, the angle of fractures will permit clean break below the burnish zone
(plastic deformation of the surface caused due to sliding contact with another object) because
the upper and lower fractures will extend toward one another. Burnishing generally occurs, if
the contact stresses locally exceed the yield strength of the material. Excessive clearance can

47
end in tapered cut edge as a result of any cutting operation, the alternative aspect of the fabric
that the punch enters when cutting is going to be a similar size because of the die gap.

Harder metals require large clearance and permit less penetration by the punch than ductile
materials; dull tool (punch and die) creates an effect of too small a clearance as well as burr
on the die side of the stock. Clearance is generally expressed as apercentage of the material
thickness, but some recommend absolute values.

7.2.2 The Effect of Punch Fillet

Shear angles/chamfers on the punches are used for easy stack up of the slugs. By assuming
different punch corner radii in punching, the effect of tool wear can be simulated. As
punching is a rapid process, the punch, i.e. the tool, gets easily worn out. To avoid such worn
outs and increase the punch life, punch fillets are used.

7.2.3 The Effect of Sheet Thickness

For a given material, the energy demand in punching is influenced by the sheet thickness. It's
been discovered that:

• The punching energy decreases with increasing clearance to sheet thickness magnitude
relation c/t and will increase with increasing sheet thickness.

• The proportions of different depth characteristics of the sheared profile are affected by the
thickness.

7.2.4 The Effect of Material of Sheet

The part edge quality also depends on the material being blanked. Materials with large
ductility, low yield strength and homogeneity will have better blanked edge quality,
dimensional tolerances and longer tool life.

In this project the effect of punching is studied by varying the clearance and material under
similar conditions in the ANSYS 15.0.

7.3 Experimental Procedure

Explicit dynamics module is selected in the ANSYS Workbench 15.0 to perform the
punching analysis on various geometrical models that were created in AUTODESK
INVENTOR software

48
Analysis steps:

 Initially the material is selected in materials library

 The model is imported into geometrical model
 Material is assigned to the solid bodies in Mechanical module
 Punch and die are considered as rigid and sheet as flexible
 The contact between sheet and die is considered as rough
 Mesh is auto generated. The mesh formation of Sheet is done hex dominant and
punch and die in tetrahedrons.
 Die is fixed and punch is applied with initial velocity and force. Punch degree of
freedom is arrested in all other direction except punching direction
 Analysis maximum number of cycles and end time is updated
 In the solution the total deformation, shear stress and von-Mises are studied.

The analysis is performed on the sheet metal of thickness 0.5 mm by considering different
clearance values ranging from 0.05mm to 0.25mm. The sheet metal materials considered are
Aluminium, Copper and Steel 1006. The Analysis setup of ANSYS Workbench is shown in
figure 7.1. The mesh bodies are shown in 7.2 and meshed view of sheet is shown in figure
7.3.

Fig 7.1 The Analysis setup of ANSYS Workbench

49
 Fig 7.2 The mesh bodies

Fig 7.3 meshed view of sheet

The Total deformation, Shear stress and von-Mises stress of aluminium sheet with clearance
0.2mm is shown in figures 7.4 respectively, copper in figures 7.5 respectively and Steel 1006
in figures 7.6. The other results are tabulated material wise in the tables 3(Aluminium), table
4(Copper) and table 5 (Steel 1006).

50
Fig 7.4 FEA analysis of punching on aluminium sheet

51
\

Fig 7.5 FEA analysis of punching on Copper sheet

52
Fig 7.6 FEA analysis of punching on Steel 1006 sheet

53
Table 7.1: FEA analysis of punching on aluminium sheet for various clearances
Aluminium MAXIMUM
Clearance Total Deformation Shear stress von-Mises Stress
in mm in mm in Mpa in Mpa
0.05 10.284 58.15 290
0.1 10.298 59.168 290
0.15 13.633 47.619 206.42
0.2 11.651 26.568 290
0.25 15.955 130.55 290

Table 7.2: FEA analysis of punching on copper sheet for various clearances
Copper MAXIMUM
Clearance Total Deformation Shear stress von-Mises Stress
in mm in mm in Mpa in Mpa
0.05 7.0433 166.29 450
0.1 6.7902 104.36 450
0.15 8.4034 16.959 373.03
0.2 7.3025 17.527 247.15
0.25 9.42 15.336 287.26

Table 7.3: FEA analysis of punching on steel 1006 sheet for various clearances
Steel 1006 MAXIMUM
Clearance Total Deformation Shear stress von-Mises Stress
in mm in mm in Mpa in Mpa
0.05 6.0345 44.103 435.81
0.1 6.3583 67.999 484.75
0.15 6.3666 66.625 484.07
0.2 6.4081 120.85 522.53
0.25 7.3661 107.27 621.18

54
 CHAPTER – 8
RESULTS AND DISCUSSIONS

In this chapter, a summary of our analysis and results are studied and cost
analysis of the pneumatic punching machine is discussed.

8.1 FEA analysis of punching on aluminium sheet

A detailed study of punching is carried out on aluminium sheet of thickness
0.5mm in explicit dynamics module of ANSYS 15.0 by varying clearance between
punch and die. The total deformation, shear stress and von-Mises stress are studied to
identify the optimum clearance. For aluminium sheet metal the clearance vs total
deformation, shear stress and von-Mises stress graphs are plotted in graphs 7.1, 7.2
and 7.3 respectively. The optimum clearance by comparing all results for aluminium
of 0.5 mm thick sheet metal is 0.1 mm.

Clearance vsTotal Deformation

18
16
total deformation in mm

14
12
10
8
6
4
2
0
Clearan
ce 0.05 0.1 0.15 0.2
in mm
Total Deformation
10.284 10.298 13.633 11.651 15.955
in mm

Graph 8.1 Aluminium sheet of 0.5 mm thickness, clearance vs Total deformation

55
 140 Clearance vs Shear stress
120
100

Shear stress
in Mpa
80
60
40
20
0
Clearance
0.05 0.1 0.15 0.2
in mm
Shear stress
58.15 59.168 47.619 26.568 130.55
in Mpa

Graph 8.2 Aluminium sheet of 0.5 mm thickness, clearance vs Shear stress

Clearance vs von-Mises Stress

350
300
von-Mises Stress

250
in Mpa

200
150
100
50
0
Clearance
0.05 0.1 0.15 0.2
in mm
von-Mises Stress
290 290 206.42 290 290
in Mpa

Graph 8.3 Aluminium sheet of 0.5 mm thickness, clearance vs von-Mises stress

8.2 FEA analysis of punching on Copper sheet

A detailed study of punching is carried out on Copper sheet of thickness
0.5mm in explicit dynamics module of ANSYS 15.0 by varying clearance between
punch and die. The total deformation, shear stress and von-Mises stress are studied to
identify the optimum clearance. For copper sheet metal the clearance vs total
deformation, shear stress and von-Mises stress graphs are plotted in graphs 7.4, 7.5
and 7.6 respectively. The optimum clearance by comparing all results for Copper of
0.5 mm thick sheet metal is 0.05 mm.

56
 Clearance vs Total Deformation
10
8

Total Deformation
6
4

in mm
2
0
Clearanc
e 0.05 0.1 0.15 0.2
in mm
Total Deformation
7.0433 6.7902 8.4034 7.3025 9.42
in mm

Graph 8.4 Copper sheet of 0.5 mm thickness, clearance vs Total deformation

Clearance vs Shear stress

200
Shear stress

150
in Mpa

100
50
0
Clearance
0.05 0.1 0.15 0.2
in mm
Shear stress
166.29 104.36 16.959 17.527 15.336
in Mpa

Graph 8.5 Copper sheet of 0.5 mm thickness, clearance vs Shear stress

Clearance vs von-Mises Stress

500
von-Mises Stress

400
300
in Mpa

200
100
0
Clearanc
e 0.05 0.1 0.15 0.2
in mm
von-Mises Stress
450 450 373.03 247.15 287.26
in Mpa

Graph 8.6 Copper sheet of 0.5 mm thickness, clearance vs. Von-Mises stress

57
8.3 FEA analysis of punching on Steel 1006 sheet
A detailed study of punching is carried out on Steel 1006 sheet of thickness
0.5mm in explicit dynamics module of ANSYS 15.0 by varying clearance between
punch and die. The total deformation, shear stress and von-Mises stress are studied to
identify the optimum clearance. For Steel 1006 sheet metal the clearance vs total
deformation, shear stress and von-Mises stress graphs are plotted in graphs 7.7, 7.8
and 7.9 respectively. The optimum clearance by comparing all results for Steel 1006
of 0.5 mm thick sheet metal is 0.15 mm.

Clearance vs Total Deformation

8
Total Deformation

7
6
5
in mm

4
3
2
1
0
Clearan
ce 0.05 0.1 0.15 0.2
in mm
Total Deformation
6.0345 6.3583 6.3666 6.4081 7.3661
in mm

Graph 8.7 Steel 1006 sheet of 0.5 mm thickness, clearance vs Total deformation

Clearance vs Shear stress

140
120
Shear stress

100
in Mpa

80
60
40
20
0
Clearanc
e 0.05 0.1 0.15 0.2
in mm
Shear stress
44.103 67.999 66.625 120.85 107.27
in Mpa

Graph 8.8 Steel 1006 sheet of 0.5 mm thickness, clearance vs Shear stress

58
 Clearance vs von-Mises Stress
700
600
von-Mises Stress 500
in Mpa 400
300
200
100
0
Clearanc
e 0.05 0.1 0.15 0.2
in mm
von-Mises Stress
435.81 484.75 484.07 522.53 621.18
in Mpa

Graph 8.9 Steel 1006 sheet of 0.5 mm thickness, clearance vs von-Mises stress

8.4 Cost Analysis

Table 6 : Cost analysis

S.No Name of the Component Cost in Rs.

1 Pneumatic Cylinder 800

2 Wood 1500
3 Plywood 240
4 Bolts nuts and nails 40
5 Hoses 90
6 Connectors 100
7 Pneumatic Ports 150

8 5/2 mechanical lever valve 1300

9 Pressure regulator 700

10 Labour cost for carpentry and drilling 1000

Total Cost: Rs.5920/-

59
 Cost Analysis
1 Pneumatic Cylinder
2 Wood
3 Plywood
4 Bolts nuts and nails
5 Hoses
6 Connectors
7 Pneumatic Ports
8 5/2 mechanical lever valve
9 Pressure regulator
10 Labor cost for carpentry and drilling

17% 13%

12%
25%

22%
4%
1%
3% 2% 1%

Chart 8.1 Cost analysis

The cost analysis of the total setup is done and tabulated in table 8.1 and pie chart is
shown in chart. 8.1. The total cost comes to Rs. 5,920/-. And maximum portion is
spent on pneumatic system

60
 CHAPTER-9
CONCLUSIONS
We have fabricated the machine using pneumatic systems and it is tested in
punching the paper. It can be used in manufacturing industry for punching the paper
and if proper allowances are given the paper gets cut. We have performed Finite
element analysis of punching on various sheet metals and determined the optimum
clearance values for sheet metals of thickness 0.5mm of materials aluminium, copper
and steel 1006.
The project carried out by us made an impressing task in the field of small
scale industries to reduce manual work. It is very usefully for the workers to do the
work as fast as possible. This project has also reduced the cost involved in the
concern. Project has been designed to perform the entire requirement task which has
also been provided.
9.1 Conclusions
We conclude that for the manufacturing of one or two boxes, there exists only a
small difference between manual and automated operations. But, in order to
manufacture large amounts of boxes, a lot of time will be consumed by the manual
operation but in our experimentation we have come to know that if the proper
allowance is given the paper gets cut in four ends according to the required
dimensions.
 The arrangement of the entire equipment is done, i.e the 3D model of the box
punching machine is developed according to the formulated design and its
mechanism status is successfully studied by pneumatic simulation.
 The box punching machine is fabricated with minor changes due to
manufacturing feasibility.
 The total cost is spent to fabricate the machine is Rs 5,920/-
 Hence in order for the paper to get cut the allowances must be given correctly
so that at once when the punch falls with a force the paper should get cut with
the required place with the required dimensions.
 The optimum clearance for aluminium of 0.5 mm thick sheet metal is 0.1 mm.
 The optimum clearance for Copper of 0.5 mm thick sheet metal is 0.05 mm.
 The optimum clearance for Steel 1006 of 0.5 mm thick sheet metal is 0.15
mm.

61
9.2 Future Scope
The modelling and fabrication of the model is already done but there is lot of
scope for improvement for this machine.

 FEA analysis can be done on frame and other joints to determine the optimum
dimensions.
 PLC or microcontroller can be used to automate the whole process which will
reduce the time, which is widely used in industries.
 Hydraulic systems can be used and the same model can be used for metal
sheets.
 The feeding mechanism can also be used to feed the paper or sheet to
machine.

62
REFERENCES

[1] Suraj V Bhosalel, “Design and Fabrication of Pneumatic Sheet Metal Cutting
Machine”, International Journal of Magazine of Engineering, Technology,Volume 7,
Issue 8-7, Pg 177-289.

[2] A.S. Aditya Polapragadal, “Pneumatic Auto Feed Punching and Riveting Machine
Journal of Pneumatic punching and technology, Volume 1, Issue 7, 2012, Pg 6-10.

[3] Ms anita v. hase “Mechanically Operated Automation System”, Journal of

automatically Operated system and its Technology, Volume 5 2015,Issue 5, Pg 69-
75.

[4] Puneet Isarka “Design and development of pneumatic punching machine”, Journal
of Pneumatic systems, Volume 4,Issue 11,2017,Pg 25-36.

[5] S.p avadhani “Design and Analysis of Blanking and Piercing of die punch”,
International Journal for blanking and Piercing technology, Volume 4 ,2017,Issue 05,
pg 56-65

[6] P.Goyal, studied on “Design of pneumatically controlled small scale punching

machine”, Journal of Pneumatics Science and Technology, Volume 4, 2015 Pg 199-
208

63