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MY UNDERGRADUATE PROJECT CARRIED OUT AT KLESCET, BELGAUM
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VEERESHGOUDA S NARAGUNDADVANCED MATERIALS TECHNOLOGY
U.V.C.E. BANGALORE
INTUITIIONINTRODUCTIONLITRATURE SURVEYEXISTING MACHINESOUR MACHINETHE DESIGNTHE ENGINEERINGPARTS DRAFTING AND ASSEMBLYTHE FABRICATIONADVANTAGES AND APPLICATIONSCONCLUSION AND SCOPE FOR IMPROVEMENTCOSTINGREFERENCES
AREA: HYDRAULICS
MANUAL OR MOTOR
NEED FOR SMALL EFFICIENT PAPER CUTTING AND PUNCHING MACHINE FOR THE XEROX SHOP AROUND COLLEGE AREA
The conventional machines used for binding works occupy more than half a room and are more costly. And are difficult for transportation and even consume more power.This hydraulic paper cutting and punching machine will overcome these disadvantages effectively. This also reduces cost, power and working space.This project is an integration of both cutting and punching operations. And hence meet the requirement of both small and large capacity binding operation based on hydraulic system design.
Definition: Hydraulics is a branch of engineering concerned mainly with moving liquids. The term is applied commonly to the study of the mechanical properties of water, other liquids, and even gases when the effects of compressibility are small. Hydraulics can be divided into two areas, hydrostatics and hydrokinetics.
“Pascal’s law states that when a confined fluid is placed under pressure, the pressure is transmitted equally in all directions and directed normal on all faces of the container.”
1. A reservoir to hold the fluid.
2. A pump to force the fluid through the system.
3. Valves to control the flow.
4. An actuator to convert the fluid energy into mechanical force to do the work.
Contd..
Manual pump
Hoses
Pressure gauge
Ram
Cutting and punching tool
Our machine Other machine
Less floor area required
Integration of cutting and punching operations
Ease of repair as it has removable tools
Low initial and maintenance cost
Can be used in small shops
No need of skilled operators
Large floor space is requiredDifficult for women operatorsHigh initial and maintenance cost Highly skilled operators(programmers)Not affordable for small shopsMany machines are not integrated to perform cutting and punching operations
Cylinder design:Cylinder specificationsCapacity=100 bar
Diameter of piston=40mm
Stroke=75mmA=πD2/4=1256.6mm2
100*(105) =F/(1256.6*10^6F =12.566KN
Formula from design data hand book
Where, C=D/di
D= (Outside dia. + Inside dia.)/2= (22+25)/2
D=23.5mm, l=60mmdi =22mm
C= =1.068Now,
K =12.60 N/mm
Where,F=K*x
F=12.60*25F=300N
For two springs,F=600N
Then,Total force on each punch=
(12566-600)/7 =1708.37 N/punch
(Square and ground end spring is used).
Contd..
Specifications and Materials4037 Alloy steel
303-316 Stainless steelDiameter of punch, D=6mmLength of punch, l=60mm
Surface hardness, RC-60minimumCore hardness, RC-47minimum
Yield strength, σ0 =758MPaShear stress in one paper, τ = shear
force/shear area= s
f/3.142*d*t=700*10-
3/(3.14*6*.137)
=0.271066 N/mm2
Shear stress for 15 papers = 15*0.271066
= 4.066N/mm2
Shear yield strength of Punch = σ0/ 2=758 / 2
= 379 N/mm2 > shear strength for 15 papers
Hence design is safe.
Punch design: The thickness of paper is which is typically given in thousandths
of an inch.[10] Paper may be between 0.07 millimetres (0.0028 in) and 0.18
millimetres (0.0071 in) thick. The density of paper ranges from 250 kg/m3 (16 lb/cu ft) for tissue
paper to 1,500 kg/m3 (94 lb/cu ft) for some speciality paper. Printing paper is
about 800 kg/m3 (50 lb/cu ft)
Contd..
Use of standard hydraulic power pack
(ϕ 40 mm * 75 mm stroke)
Use of polished ms supporting plates
(50 mm width*16mm thickness*280 mm length)
Use of standard diameter punches (ϕ6mm*60mm length)
Use of springs (di=22mm*60 mm length)
Use of standard guide rods (ϕ20mm*150mm length)
Use of en8 cutting tool material (80mm w*10 mm t*280mm l).
Punch drawing
Supporting plate drawing
Die plate drawing
Guide rod drawing.
Spring drawing
Tool assemblies drawing
Drilling on supporting plates for guide rods (ϕ20.5mm)
Drilling on punch plate (ϕ6 mm)
Thread cutting on guide rod and tapping on die plate (M16)
Counter sinking on punch plate for brazing operation (45° *2mm)
Brazing operations
Advantages
Less floor area required
Integration of cutting and punching operations
Ease of repair as it has removable tools
Low initial and maintenance cost
Can be used in small shops
No need of skilled operators
Applications of our machine
The machine can be used by binders and Xerox shops.
Any other hydraulic press operations as it have removable tooling.
It can perform cutting and punching operations at once.
It can also be used as simple hydraulic clamping device.
Conclusion of the project
The hydraulic paper cutting and punching machine with removable tooling, which can be removed and repaired easily.
Simple design using hydraulic press makes it economical and efficient.
SCOPE FOR IMPROVEMENT
The hydraulic system used is of small capacity and uses manual pump so this can be further improved by using large capacity power pack and automatic pump so that even large pressing operations can be performed.
Even three side cutting and one side punching operations can be performed by further improvements.
Design analysis and optimization using any FEA Package
Process simulation of cutting and punching using simulation software.
Total cost of the project
=Material cost + process cost
=13,200+850
= Rs. 14,050
Closer tolerance in punch and die hole.
Stephen Timoshenko, strength of materials, 3rd edition,cbs publishers and distributors pvt.ltd.2002.K.Mahadevan and K.Balaveera reddy, Design data handbook, 3rd edition,cbs publishers and distributors pvt.ltd.2010.Esposite Anthony, fluid power with applications, PHI publications 4th edition 2004.R.S.khurmi and J.K.gupta, a text book of machine design, Eurasia publications.
Thank you