A Project Report on

“Design and development of pneumatic

sheet cutter”
Mechanical Engineering
Academic Year 2023-2025

Submitted the project in partial fulfilment of the requirement for the term work
of “Major Project” of Bachelor of Engineering.

Submitted to

Department of Mechanical Engineering

Pillai College of Engineering (PCE)
Dr. K. M. Vasudevan Pillai Campus
Plot No. 10, Sector 16, New Panvel,
Navi Mumbai – 410 206, Maharashtra, India

Submitted by

Name Roll No
Adittya Butte 43
Dhiraj Kadam 46
Prathamesh Mhatre 52
Yatin Raval 62

Under the Esteemed Guidance of

Professor Meeta Vedpathak
(Department of Mechanical Engineering)
 Mahatma Education Society’s
Pillai College of Engineering, New Panvel-410 206

CERTIFICATE

This is to certify that

Name Roll No
Adittya Butte 43
Dhiraj Kadam 46
Prathamesh Mhatre 52
Yatin Raval 62

Students of Mechanical Engineering have completed and submitted their “Technical

Project Report and Presentation” in partial fulfilment of the requirement for the
term work of “Major Project” during the year 2023-2024. The project work entitled
“Design and development of pneumatic sheet cutter” submitted in their 6th
semester embodies their original and sincere efforts.

Prof. Meeta Vedpathak Dr. Sandeep Joshi

(Project Guide) (Principal)
 Acknowledgement
We extend our heartfelt gratitude to Pillai College of Engineering for their unwavering
support and invaluable contributions to the success of the " Design and development of
pneumatic sheet cutter " project. The guidance provided by our Prof. Meeta Vedpathak
and institution have played a pivotal role in our journey to develop a sustainable and
innovative solution for metal cutting, they were informative and cooperative whenever we
required their technical assistance in their respective fields. We are deeply appreciative of the
encouragement, mentorship, and state-of-the-art facilities offered by Pillai College of
Engineering, which have been instrumental in our pursuit of a greener and more efficient
future in agriculture. This project stands as a testament to the power of collaboration between
educational institutions and aspiring innovators, and we are proud to acknowledge the pivotal
role played by Pillai College of Engineering in this endeavour. Finally, we would like to
appreciate our parents, siblings, and friends for their support throughout this project.
 Abstract

Metal in the form of sheets is paramount in the manufacturing industry. Its applications are
countless. But metal in the form of sheets cannot be directly used, operations like cutting, punching,
blanking, bending, trimming, etc. are needed to be carried out on the metal sheets in order to fully
utilize them. For these operations, most large scale manufacturing industries use hydraulically
operated machines. But since hydraulic machines are not cost-effective, most small and medium scale
industries use hand-operated machines for carrying out sheet metal operation. The problem with
hand-operated machines is that they are slow and cannot be automated. This is where the concept of
pneumatics will prove itself advantageous. We are developing a pneumatically operated cutting and
punching machine which will use the help of compressed air to drive a shearing blade and punch to
carry out the operations on a metallic sheet. The machine is designed to cut 1mm thick aluminium
sheets and 0.5mm thick copper sheets very easily. The main components of developed pneumatic
system are compressor, pipelines, double-acting cylinder, an actuator, and flow control valves. This
machine will thus, prove itself cost-effective and also save a lot of time in manufacturing process as
two operations can be performed on the same platform.
 Table of Contents

CHAPTER ONE 1-2

PROBLEM STATEMENT 1
1.0 INTRODUCTION 1-2

CHAPTER TWO 3
LITERATURE REVIEW 3
Chapter THREE 4-6
3.1 COMPONENT 4-5
3.2 WORKING PRINCIPAL 6

CHAPTER FOUR 8-9

4.0 DESIGN MODEL , RESULT & ANALYSIS 8
4.1 COST ANALYSIS 8-9
4.2 CAD DESIGN OF PROJRCT 8-9

CHAPTER FIVE 10
BILL OF MATERIAL10
CHAPTER SIX 11
6.1 CONCLUSION 11

6.2 FUTURE SCOPE 11

MAJOR PROJECT LOG BOOK 12

 Problem Statement Chapter ONE
The aim of this project is to design and develop a pneumatic sheet cutter tailored to the needs and
constraints of industries. The primary objective is to create a cost-effective, efficient, and user-friendly
solution that addresses the challenges faced by manufacturers when cutting various types of sheets
metals

Key Challenges:

1. Cost-effectiveness: Develop a solution that is affordable for small and medium-sized

enterprises.
2. Efficiency: Create a cutter capable of achieving high precision and cutting speed to enhance
productivity and meet tight production schedules.
3. Durability: Design a robust system capable of withstanding the rigors of continuous operation
in harsh industrial environments.
4. Versatility: Ensure the cutter can handle a variety of sheet materials commonly used in
industries, including different thicknesses and sizes.
5. Ease of Use: Simplify operation and maintenance procedures to cater to operators with varying
skill levels and minimize downtime.

1.0 Introduction

This project is study about the design and fabrication of pneumatic cutting machine which shows
capability to design more than one concept and fabricate the machine using a variety of machine.
Other than that, it is important to studies on pneumatic and cutting force analysis which are the main
topic for this project. So, at the end of this project, we will practicing on how to build and steps to
follow to complete the requirement for this project. Pneumatic systems use pressurized gases to
transmit and control power. As the name implies, pneumatic system typically use air (rather than
some other gas) as the fluid medium because air is safe, low cost and readily available fluid. The solar
pneumatically cutting machine is designed using various components. The components are pneumatic
cylinder, pressure regulator, Solenoid/direction control valve, flow control valve, compressor,
mounting table, solar panel. The solar panel charge the battery that runs the compressor. The
cylinder is used for up and down motion of the cutting blade which performs the cutting operation on
the sheet of aluminium material. The compressor provides compressed air to the cylinder, which
causes movement of the piston rod. Different pneumatic systems work efficiently at different
operating pressure. Hence selection of pressure regulator of right range is important for efficient
working of pneumatic system. Pneumatic automation components extensively use sealing material
made out of rubber compounds. For efficient and trouble free working of these seals, they need to be
oiled or lubricated to reduce friction and corrosion. Solenoid/Direction control valve is used to control

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the direction of the air.

A device which gets heated by the sun’s energy is called solar heating device. All the solar heating
devices are designed in such a way that they help in collecting as much sunlight as possible. The solar
heating devices such as solar cooker, solar water h eater and solar cells have greatly helped in solving
the energy problem, its consumption and future energy demands of our country. Solar energy also
reduces our dependence on fossil fuel .It is a device which converts solar energy directly into
electricity. Since solar energy is a light energy so we can say, “Solar cell is a device which converts
light energy into electrical energy

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 Chapter TWO

2.0 Literature Review

Madhukumar V. et al. [1] introduced a pneumatic machine capable of both cutting and bending
operations on sheet metal. Their work aimed to reduce operation costs and enhance efficiency.
Further modifications to their design could increase cutting force, indicating avenues for future
research in improving machine capabilities.

T. Z. Quazi et al. [2] explored the influence of punch-die clearance in the blanking process, identifying
an optimal clearance percentage for minimizing blanking force. This study underscores the
importance of optimizing process parameters to achieve efficient sheet metal operations.

Viraj N. Suryawanshi et al. [3] focused on reducing punching costs for metallic sheets through the
development of a pneumatic punching machine. Their work demonstrates the potential of pneumatic
systems to streamline manufacturing processes and improve cost-effectiveness.

K. K. Alaneme et al. [4] conducted a comprehensive investigation into the failure of mould dies in
punching machines. Their findings emphasized the significance of proper heat treatment in enhancing
die material toughness and fatigue resistance, essential for prolonged machine lifespan.

Neeraj Pandita et al. [5] presented a pneumatic sheet metal cutting machine offering superior
efficiency compared to manual-driven cutters. The study suggests opportunities for further
enhancement through improvements in cutting blade design.

Sudeep Kelaginamane et al. [6] introduced a PLC-controlled pneumatic punching machine,

significantly reducing production time and increasing productivity. This work highlights the potential
of automation in optimizing manufacturing processes.

A. K. Gupta et al. [7] investigated the influence of parameters such as blanking force, clearance, and
layout on sheet deformation. Their findings underscored the importance of compressor pressure in
minimizing dimensional variations, particularly for different sheet materials.

References:
[1] Madhukumar V. et al., [2] T. Z. Quazi et al., [3] Viraj N. Suryawanshi et al., [4] K. K. Alaneme et al., [5] Neeraj Pandita et al., [6]
Sudeep Kelaginamane et al., [7] A. K. Gupta et al.

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 Chapter THREE

Project Specifications

3.0 Components

1. A Double-Acting Pneumatic Cylinder :-

A double-acting pneumatic cylinder is a type of cylinder that
has two ports that control the movement of the rod. The
compressed air causes the rod to move in two directions by
extending and retracting without the assistance of a
spring. This type of pneumatic cylinder is essential for any
applications that need control of movement in two
directions. Double-acting cylinders are the most widely used
pneumatic actuators compared to single-acting cylinders given
their ability to extend and retract within a shorter time period,
thus becoming more efficient and precise.

Force Calculation

Force required to cut the Sheet = LtTmax For sheet of 0.5 mm thickness,
force required = 25×0.5×30= 375 N
This is the force required to cut the sheet metal, however the initial force required to cut
the sheet is more and it is 140-150% than we calculated,
Therefore, max force required to cut the sheet = 525 – 562.5 N
Now we have chosen 12 volt DC Air Compressor that develops a pressure of 10.34 bar
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(150psi).

Designing of a cylinder Since the max force required to cut the sheet = 562.5 N
And pressure applied by 12 volt
compressor =10.34 bar
Therefore, Force applied by the cylinder,
F = (𝜋/4) × d2×p 562.5
= (𝜋/4) × d 2×(10.34/10)
→d=26.3 mm
For safety , we have taken the cylinder of diameter 30 mm

2. 5/2 dc solenoid valve

A solenoid valve is an electromechanically operated valve. Solenoid valves differ

in the characteristics of the electric current they use, the strength of the
magnetic field they generate, the mechanism they use to regulate the fluid, and
the type and characteristics of fluid they control. The mechanism varies from
linear action, plunger-type actuators to pivoted-armature actuators and rocker
actuators. The valve can use a two-port design to regulate a flow or use a three or
more port design to switch flows between ports. Multiple solenoid valves can be
placed together on a manifold.

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3. IC Timer Circuit

IC 555 timer is a well-known component in the electronic circles but what is not known

to most of the people is the internal circuitry of the IC and the function of various pins

present there in the IC. Let me tell you a fact about why 555 timer is called so, the

timer got its name from the three 5 kilo-ohm resistor in series employed in the internal

circuit of the IC.

IC 555 timer is a one of the most widely used IC in electronics and is used in various

electronic circuits for its robust and stable properties. It works as square-wave form

generator with duty cycle varying from 50% to 100%, Oscillator and can also provide

time delay in circuits. The 555 timer got its name from the three 5k ohm resistor

connected in a voltage-divider pattern which is shown in the figure below. A simplified

diagram of the internal circuit is given below for better understanding as the full internal

circuit consists of over more than 16 resistors, 20 transistors, 2 diodes, a flip-flop and

many other circuit components.

4. Solar Panel: It will convert the sun’s light rays into electrical energy and stored into battery to
reduce electricity cost. The solar panel we have used is 10 watt and 12 volts

5. Battery: It will store the electricity generated from the solar panel and will use it for
powering the system. We have used a 4 AH 12 volts Battery.
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 3.1 Working Principle

The compressed air from the compressor at the pressure of 7 to 10 bar is passed through a pipe connected to
the Solenoid valve with one input. The Solenoid Valve is actuated with Control Timing Unit. The Solenoid valve
has two outputs and one input. The air entering into the input goes out through the two outputs when the
timing control unit is actuated. Due to the high air pressure at the bottom of the piston, the air pressure below
the piston is more than the pressure above the piston. The material is placed in between the fixed and moving
cutter. When the piston is at the extreme point of the stock length, the exhaust valve is opened and the air is
exhausted through it and the pressurized air come in at the top of the piston and it pushes the piston
downwards. So the one side of the air is pulled downwards and the other side is lifted upwards. The time
duration of the succeeding cutting is adjusted with the help of control timing unit

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 Chapter FOUR
4.0 Design Model, Result & Analysis
4.1 Cost Analysis

Sr. Specification
Name of Component Cost Quantity
No (if any)

1. Wooden plank 2 Meter 400 -

2. Solar Panel 10 W 1,200 1

3. Battery 4 AH 12 volts 1450 1

4. Pneumatic Cylinder Double Acting Cylinder 1600 1

5. DC valve Solenoid 5/2 DC Valve 1500 1

6. IC Timer Circuit IC 555 Circuit 20 1

7. Cutter Hand Leaver Shearing Machine 4000 1

8. Pneumatic Air Tubing 6 MM / 20Ft 250 1

Pipe

4.2 CAD Designs of Project

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4.3 Pneumatic Circuit

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 Chapter FIVE

5.0. Bill Of Material

Sr. Standard
Item / Components Quantity Total Cost
No. Cost
1. Wooden plank 2 Meter 200/- per Meter 400

2. Solar Panel 1 pc 1200/- 1200

3. Battery 1 pcs 1450/- per 1 pc 1450

4. Pneumatic Cylinder 1 pc 1600/- per 1 pc 1600

5. DC valve 1 pc 1500/- each 1500

6. IC Timer Circuit 1 pc 20 20

6. Cutter 1 pc 4000/- each 4000

7. Pneumatic Air Tubing Pipe 1 pc 250/- 20 Ft 250

Gross Total

10. Labour Cost - -

Total Production Cost 10020 +Labour

1
0
 Chapter SIX

6.1Conclusion

After analysis and fabrication of pneumatic cutting machine using solar energy it was concluded that:
After fabrication the machine run by using the solar energy which is the unconventional source of
energy that may be used in small industries which eliminates the electricity to run the machine original
foreign-language citation.

6.2 Future scope

In this machine, compressed air is used to move the cutting tool for carrying out cutting operation
using solar energy. After the completion of the cycle the air moves out through the out port of Solenoid
valve. This air is released to the atmosphere. In future the mechanism can be developed to use this air
again for the working of cylinder

****

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 Major Project Logbook
First Evaluation: February to March 2024

Department: Mechanical Engineering

Date: 01/02/2024 to 14/03/2024

Evaluation 1

Date Operation / Task Tools & Equipment Hours Remarks

01/02/2024 We finalized the topic - -

Finalized all the

YouTube
08/02/2024 specifications of materials 3 hrs
(for reference
required.
purpose)

Finalized the design of

15/02/2024 Google 2 hrs
model

22/02/2024 We made PPT & MS Power Point & MS 12 hrs

report for our 1st Word 2022
evaluation

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 Created a CAD model
SolidWorks
29/02/2024 5 hr

07/03/2024 Created pneumatic circuit 2 hr

Festo

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