Automatic Paper Cutting Machine Using Microcontroller

Paper cutting machine
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GANPAT UNIVERSITY
U. V. Patel College of Engineering
Ganpat University, Kherva-382711
Ta & Dist.: Mehsana (North Gujarat)
Ph.: 02762-286805, 286081
Fax (D): 286080
E-mail: [email protected]
Web: www.uvpce.ac.in

Automatic paper cutting machine using microcontroller
Project report

Patel Vijay (09mc04)
Chaudhari Hardik (09mc07)
Chaudhary Bhargav (09mc08)


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CERTIFICATE

Towards partial fulfillment of requirement for the award of Degree of
Bachelor of MECHATRONICS ENGINEERING of GANPAT
UNIVERSITY. This is the record of candidates own work carried out by
them under our supervision & guidance. In our opinion the work
submitted has reached a level required for being accepted for exam. The
matter embodied in this project has not been submitted to any other
university or institute.

Submitted By:
Patel Vijay. D. (09mc04)
Chaudhari Hardik .V. (09mc07)
Chaudhary Bhargav .Y. (09mc08)

GUIDE: COUNTERSIGNED:
Prof. J.K.Prajapati Prof. J. P. Patel
Professor, Head of Department,
Mechatronics Department Mechatronics Engg.
U.V. Patel College of Engineering U.V. Patel College of Engineering
Mehsana Mehsana


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Abstract

The paper-cutting machine is a recent development in the industrial world. A paper-
cutting machine is used for dividing piles of large sized sheets into smaller sized
sheets; also for squaring a pile; i.e., making all four corners rectangular; and for
trimming off irregular or incorrect edges.
The importance of the paper-cutting machine can hardly be overestimated. The
correct position of the printed matter, the widths of head, tail, and fore edge may be
destroyed by careless cutting. Friendly cooperation with every department is
necessary to produce good work. No matter how fine the printing and color work is,
if the margins are uneven and the folds mismatched, then the resulting air of
slovenliness discredits the entire work. The final touch that gives the character to a
piece of printed matter is the way it is trimmed.
The objective of this project is to cut the paper in accurate size of a4 printing paper.
This type of paper cutting is carried out by cutting an a4 size paper from roll. The
reciprocating cutter actuated by pneumatic cylinder is cut the paper when the
required length of paper has passed. Using scissoring action paper is being cut. To
make it automatic some control of paper feed and pneumatic actuation must be
there, that is carried by microcontroller.
As this is automatic paper cutting machine some easiness to user is provided by
setting different speed so that the productivity of this kind of machine can increase.
To display the no. of paper been cut 7 segment display device is also there.


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Acknowledgment

First of all I would like to thank my project guide prof. J.K.Prajapati for his
Continuous guidance and support. I would like to thanks all professor and lecturer
of me/mc department of our college u.v.patel college of engineering.
I would also like to thanks to those guys of GIDC,mahesana, those who helped us a
lot. Without them help this project might not have completed very early.
Finally I would like to thank my family and friends for putting up with my
Constant moaning about the project and supporting me through the difficult
Time.

From,
Patel Vijay. D. (09mc04)
Chaudhari Hardik .V (09mc07)
Chaudhary Bhargav Y (09mc08)


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Contents
Abstract ......................................................................................................................................................... 3
Acknowledgment .......................................................................................................................................... 4
Introduction .................................................................................................................................................. 7
History:- ..................................................................................................................................................... 7
Different Types of Paper Cutters & Trimmers:- ...................................................................................... 10
Objectives of the project:- ...................................................................................................................... 13
Parts of paper cutting machine:- ............................................................................................................ 14
Reciprocating type paper cutting machine:-........................................................................................... 15
Prerequisite for paper cutting machine: - ............................................................................................... 16
Project process layout:- .......................................................................................................................... 16
Design of mechanical parts ......................................................................................................................... 18
Its parts and function: - ........................................................................................................................... 18
Parts design: - ......................................................................................................................................... 20
Material: - ............................................................................................................................................... 29
Manufacturing details ................................................................................................................................ 30
Manufacturing processes: - .................................................................................................................... 30
Parts manufacturing processes :-............................................................................................................ 32
Pneumatic system ....................................................................................................................................... 36
Pneumatic component:- ......................................................................................................................... 36
Component function ............................................................................................................................... 36
Pneumatic circuit:- .................................................................................................................................. 38
Component design: - ............................................................................................................................... 39
Microcontroller and its programming &interfacing ................................................................................... 41
What is Microcontroller? ........................................................................................................................ 41
How microcontroller works? .................................................................................................................. 41
Project circuit diagram: - ......................................................................................................................... 42

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Circuit Description: - ............................................................................................................................... 42
Programing and its description:- ............................................................................................................. 44
Conclusion: - ................................................................................................................................................ 47
Appendix 1: - ............................................................................................................................................... 48
PROGRAM OF PROJECT FROM FLOW CHART ON PAGE NO.49: - ........................................................... 48
Bibliography: - ............................................................................................................................................. 49


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Chapter 1
Introduction

History:-

The practice of cutting paper began long before the making of the book of bound
leaves, and the necessity of making a number of sheets of the same size called for
some mechanical means of cutting and trimming. The earliest cutting machine was
no doubt a sharp stone or a stick; then a piece of metal, dragged across the
parchment, with a guide to keep the cut in a straight line. The sheet was simply held
by the hand, and later the straight-edge formed a clamp also.
About the fifth century the important step of folding the vellum into leaves became
the practice. The instrument which we know to-day as scissors or shears probably
had a large part to do in these early operations. . With the invention of printing and
the multiplication of books larger and stronger means were necessary to cut the
sheets. Although the book with the untrimmed sheets was the rule of this earlier
time, and of a later time, for the smaller books and for divisions of the sheet a cutter
was necessary.
For a time the cutting of piles of paper was done by hand with a knife, a small pile
being put upon a table and a weight lay upon it. The operator leaned his weight with
one hand upon it, while he cut with the other The earliest attempt to improve this
consisted of a table, a framework of wood or metal above it, having a groove in
which the knife could be worked, and a screw clamp to hold the pile. The knife was
originally short; then longer, until it became long enough to cut through the
thickness of the book. . The hand-plough cutter was probably the first successful
machine intended to cut a number of sheets at a time.
In the Haupt Halle at the great Graphic Arts Exhibition, Leipzig, 1914, were some
illustrations showing the earliest German cutting machines and their evolution to
date. The earliest among them is the lightly constructed hand-driven vertical cutter
of 1855. This consisted of two side frames, the knife-bar guides in their slots and a
large hand wheel at the right. The next stage was a cutter of 1876, a hand-driven
wheel at the right turning gears above and outside the table. A crank and a rod

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connected to the center top of the knife-bar pulled the knife in the direction of the
two slots in the knife-bar, giving it a shearing motion.
From simply pressing with the hand to hold the sheets the hand clamp was evolved;
then the clamp was attached to a gear by which it could be held down on the sheets
with greater and steadier pressure. To quicken this operation the spring clamp was
devised, with automatic pressurefixed at first, then variable to suit varying
requirements. Perhaps the most signal advance in the art of paper-cutting
machinery that has been made is the invention of Samuel R. Brown, who devised the
fixed "throw" of the knife by means of two cranks at opposite ends of a shaft parallel
with the knife. This control of the knife enables a hair to be cut through, or half
through, or the knife edge to just touch it, with remarkable precision. The various
other mechanical connections for power-cutting machines between the pulley and
the knife, consisting of rolls, slots, guides, cams, chains, levers, etc., all require a
great number of parts between the pulley and the knife, with the consequent and
necessary "looseness" of the mechanism. This allows, after short wear, a play or
"chug" of the knife which quickly tends to destroy its best cutting abilities.
The evolution of the cutting machine has been rapid and distinctly marked in all its
essential features, from the oscillating plough to the vertical stroke, to the shear
stroke, to the double-shear stroke; from a single-rod pull-down of the knife (by a
chain, by a cam, or by a crank) to the two-rod pull-down by cams, rolls, slots, slides,
to the cranks which give a fixed dependable stroke; to the cranks which give a fixed
dependable stroke, and at the same time pull the knife endwise; from swinging-link
shear to a straight-line shear; from man-drive to power-drive; from driving by
power fixtures in front and outside the frame to fixtures located back and
underneath; from low piles to high piles; from hand clamp to power clamp, to self-
clamp, to automatic clamp, finally to friction adjustable pressure clamp; from
measuring by rule to the use of rapid automatic measuring and spacing devices.
The best paper-cutting machine is designed with a knife motion operated by cranks
which give an endwise pull to the knife; with the table of medium height; with quick
and accurate adjustments for the knife; with a foot treadle for bringing the clamp
down to the pile when desired to see exactly where the knife will strike; with an
accurate and dependable device for moving the back gage and the pile and
measuring quickly the widths to be cut; with starting handles easily reachable
without bending; with a powerful clamping pressure automatic for all height piles
and instantly adjustable for heavy or delicate work; with universal fine adjustments

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for squaring the back gage with the knife; with a simple change for the cutting stick;
with the driving shaft running at a low speed; and with a powerful main driving
clutch or friction material that will not cut or damage the parts under the heavy,
constant thrusts.


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Different Types of Paper Cutters & Trimmers:-

1. Rotary Paper Cutters
2. Stack Paper Cutters
3. Guillotine Paper Cutters
4. Hydraulic Paper Cutters
5. Corner Cutters
6. Form Cutters
1). Rotary Paper Cutter: - Rotary paper cutters use a round blade) that sits in
some sort of a cutting head. The cutting head sits on a rail and slides back and forth,
cutting paper. Rotary paper cutters are known for their extreme precision and are
very popular for cutting photos.

Fig1.1 (rotary paper cutter)
2). Stack Paper Cutters: - Stack paper cutters are beasts, designed to cut
hundreds of sheets of paper at a time. These cutters are commonly used at print
shops for cutting down prints and other material. They are also popular for cutting
down larger sheets of paper into custom-size paper. There are a variety of industrial
and commercial applications for stack cutters. These typically come in manual,
semi-auto and fully automatic variations.

Fig1.2 (stack paper cutter)

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3). Guillotine Paper Cutters: - Guillotine paper cutters, sometimes called arm or
lever cutters, are great multi-purpose machines. They typically consist of a cutting
blade and a long blade arm that can be pulled down for cutting material.
These cutters are generally very accurate and can be used to cut paper, card stock
and more.

Fig1.3 (Guillotine Paper Cutters)
4). Hydraulic Paper Cutters: - Hydraulic paper cutters are probably the toughest
and most robust paper cutters available. These cutters typically come in a stack
paper cutter design and are generally used for high-volume cutting throughout the
day. These are often used in factories, print shops, paper plants and in other
businesses that handle thousands upon thousands of sheets of paper per day.

Fig 1.4(hydraulic paper cutter)

5). Corner Cutters: - Corner counters, often called corner rounder, are used for
lopping of sharp corners from paper. These useful machines can often round the

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corners of a stack of paper in excess of 100 sheets at a time. A variety of different
radius sizes are usually available.

Fig 1.5(corner cutter)
6).form cutter: - Form cutters, sometimes called paper slitters, are designed to
auto feed paper and slit it down to size. Many form cutters offer the option of
scoring and perforating along with slitting. These types of machines are great for
producing marketing material and can often make several cuts simultaneously.

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Objectives of the project:-
.
1. Objective of this project is to design, fabricate and automate the paper
cutting machine in such a way that the required length of paper of size a4
can be cut.
2. The paper cutting machines generally available in the market are
generally manual and if automatic then it is very costly. Objective is to
develop, the kind of paper cutting machine which is automatic and less
costly.


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Parts of paper cutting machine:-
Parts of paper cutting machine.
1. Die plate
2. Punch plate
3. Gripping block
4. Spring
5. Cutting blade
6. Flange
7. Guide post Fig1.8(reciprocating cutter type paper
8. Bush cutting machine)
9. Nut & bolt
10. Casing
11. Microcontroller unit
12. Pneumatic cylinder


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Reciprocating type paper cutting machine:-

A paper cutter (also referred to as paper trimmer, paper guillotine or simply a
guillotine) is a tool often found in offices and classrooms, designed to cut a large set
of paper at once with a perfectly straight edge.

Paper cutters vary in size, usually from about 30 centimeters (1 foot) in length on
each side for office work to 841 millimeters (33.1 in) (an edge of a1 paper) in design
workshops.

Paper cutting machine of reciprocating cutter type is generally used to cut the paper
of thickness from 0.2mm to 2mm. As in figure 1.6 the real paper cutting machine is
shown. As we know that the paper cutting in the scissor is due to shearing action of
paper. In scissor the shearing action on the paper is happen due to minimum
clearance between two scissor surfaces. This clearance is depends on the paper
thickness.
In reciprocating cutter type paper cutting machine same shearing action is happen.
Due to shearing action the paper is cut. Two surfaces are cutting blade edge and die
plate slit edge. In this machine paper is feed from paper roll by electrical DC drive.
Only feeding of paper is not enough, some paper gripping mechanism must be there
otherwise paper will penetrate between clearances of two mating surfaces. In order
to provide proper gripping the gripper block is there. Before paper is cut the,
gripper hold the paper so that it avoid the change of paper curl or other thing. One
question must rise in the mind is that, how this gripper block will gripe the paper?
What about the gripping force? How it will generate? The only answer is that, the
force will generate due to compression of the spring. As in the figure the spring are
compress due to the force on the punch plate. This force is generally provided by
pneumatic cylinder i.e. air operated.
As all thing mentioned above is ok then what about alignment? In order to provide
zero clearance proper alignment must be there. As in case of this is scissor this is
provided by the fulcrum and some hand force, but in case of the reciprocating cutter
type paper cutting machine this is provided by guide post.

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Summary of the above discussion is as below. When paper feed from feed roll by
electrical drive, the pneumatic force with cause the punch plate to slide down. This
will slide the gripping mechanism, it will first gripe the paper and after proper
gripping force is generated then cutter will cut the paper.

Prerequisite for paper cutting machine: -

The following are the minimum requirements for this project:
1. One must know the design of parts.
2. One must know the design software like solid works, PRO-E, etc. for simulation
purpose.
3. One must know the different manufacturing technique.
4. One must know microcontroller and how to interface microcontroller with
machine.
5. One must know the programming.
Project process layout:-

Fig1.9(process layout)
idea
design of parts
manufacturing of parts
assembly of parts
controller interface
required output

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The remaining part of the project report is as same as the process layout. The
second chapter is of the design of all parts. In this chapter we will learn how to
design of all parts. The third chapter is of manufacturing of parts. How to
manufacturing a parts &assemble them, we will discuss in this chapter. The fourth
chapter is of microcontroller. In this we will discuss how to interface electronics
circuitry with machine. In this we will also discuss about programming. In final we
will discuss by using trial & error, how to get required output.


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Chapter 2
Design of mechanical parts

Its parts and function: -

1. Die plate
2. Punch plate
3. Gripping block
4. Spring
5. Cutting blade(punch)
6. Flange
7. Guide post
8. Bush
9. Nut & bolt
10. Casing
1). Die plate: - The die plate is the female part of a complete tool for producing
work in machine. It is a block or a plate which contains a die cavity. It is also used to
provide a required mating surface for shear.
2). Punch plate: - The punch plate or punch retainer fits closely over the body of
punch and holds it in proper relative position.
3). Gripping block: - This is used for provide a gripping surface to the work
(paper). It is also provide the pad pressure.
4). spring: - The spring is force transferring element from punch plate to gripper
block. It is type of compression spring.

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5). Cutting blade (punch): - It is sharp edge cutting member use to cut the work
(paper). It should have sufficient sharpness for finished edge.
6). Flange: - It is member that attaches the cutting blade to the punch plate.
7). Guide post: - guiding component that ensure accurate alignment of the upper
plate with the die plate in operation. Guide post also facilitates tryout of the press
tool in a press.
8). Bush: - They are responsible for proper sliding motion between guidepost and
punch plate. They are self -lubricating in nature.
9). Nut & bolt: -They are fastening member.
10). Casing: - it is provided for safety.


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Parts design: -

The operation of paper cutting machine is similar to the press tool. The operations
that are typical performed in the press are punching, blanking, metal cutting,
trimming, perforating, etc. The paper is cut as same as the metal strip has been cut
in the press, so the design principle that uses are same as the press design. Now we
will see the design of all individual parts.
The design commonly called a axial post design or center post design. In this design
the two posts are positioned along the transverse center line of the die set. The
paper is feed from the front.

1). Die plate: - The die plate is the female part which carry the cutting edges. It
is subjected to extreme pressure and wears conditions. Hence the die plate is made
of superior quality of tool steel. The die plate may be of solid or sectional
construction depending on the size and shape of the cutting edge or die opening. If
the die opening is small and its contour is simple, a solid die plate is chosen.
Sectional dies are made up of accurately ground matching components which may
be assembled together easily.

Fig 2.1(Die plate) fig 2.2(die plate with dimension)
A).Die plate thickness: - The minimum thickness of the die plate depends upon the
strength required to resist the cutting forces, and it will depends upon the thickness
of the material being cut. The determination of the die plate thickness is usually
based on the experience and the thumb rules.
According to one right thumb rule the thickness may be obtained as follows:


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Die thickness=19mm, for blank perimeter 75mm
Die thickness=25mm, for blank perimeter =75mm to 250mm
Die thickness=31mm, for blank perimeter>250.
Here we are going to cut the paper of width 21.5 cm so we should select the
thickness is 25 mm so, it is capable of sustain the cutting force and wear and also
support the other parts.
B). Diameter of the hole: -for the average range die set the diameter of guide post is
from 2.5cm to 7.5cm.the guide post are press fitted in the die plate. In order to
provide press fit the size variation is of the up to 1mm.so the diameter of the hole is
2.4mm.
C). size of the slit: - Here we are going to cut the paper width of the 21.5cm. Some
extra size on this slit is provided for some inaccurate feed of the paper and to avoid
the interference of the cutting blade with its surface. This extra size is of up to 4cm.
So, the length of the slit is the 25.5cm. The width of the slit is of 3cm if we are cut it
by gas welding.
D). distance of hole from the edge: - The distance of the hole from the edge is also
depends on the thickness of the plate. It is at least equal to the 2 times the thickness.
So the distance of the hole from edge is we are taking 2.5times thickness then equal
to the 5cm.
E). distance between the hole and slit: - In order to avoid the tearing of the plate
during press fit the distance between the hole and slit should at least 2 times of the
thickness of the plate . And it should be of 4cm.
F). Length of the die plate: - From the above data the length of the die plate is finding
as follow: -

Length=Distance of the hole from edge*2+diameter of the hole*2+distance
between the hole and slit*2+length of the slit.+ Extra length to accommodate
stripper block dimension
Length= 2.5*2*T+2.4*2+2*2*T+21.5+4+10
Length= 62.8 cm
Dimension of stripper we will see in next section.

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G). Width of the die plate: - for proper gripping surface it should be taken as 15 cm.

2). Punch plate: - This plate support the cutting blade. The force generate during
the cutting operation is transfer from cutter to punch plate so it should be capable to
sustain this force.

Fig 2.3(punch plate with dimension)
A). Thickness of the punch plate: - thickness of the punch plate is found as below
It should be 0.5 times the die thickness for guided punches.
It should be 0.75 times the die thickness for unguided punches.
So, the thickness of the punch plate is 0.5*2.5=1.75cm
Not much amount of load is generated we can take it as 1.5cm.
B). Length of the punch plate: -
Length= 2*distance of the hole from the edge+2*diameter of the major
hole+2*distance between the minor & major hole+2*diameter of the
minor hole+ distance between the two inner (minor) hole
Length= 2*2.5*1.5+2*3.5+2*2*1.5+2*2.9+31.5
Length= 57.8cm
C). Width: - it should be same as the die plate i.e. 15 cm

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3). Paper stripper mechanism: -

Fig 2.4(stripper mechanism)

Paper stripping mechanism having three component
A. Stripper block
B. Spring
C. Small guide rod.
A).Stripper block: -

Fig 2.5(stripper block)


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There no any relation so the dimension of this block is found. But, one can find the
length and width of the block using the relation, which is the distance of the hole
from the edge as function of the thickness.
Thickness of the lower plate is 2cm and height of other section above it is 2cm.
The diameter of the hole is 2cm
The distance of the hole from edge is 3.9cm

B). spring: -
Here,
d = wire diameter of spring (mm)
D = mean coil diameter (mm)
C = D/d
=maximum load
n= no. of spring turns
G=modulus of rigidity
K= Wahls factor
=maximum deflection of the spring.

Generally the design of the spring is find by make some assumption .The assumed
data is as below
o No. of turns n=18
o Maximum deflection(max)=70mm
o Major diameter(D)=2.5cm
o Maximum load=100N
o Material modulus of rigidity(G)=80kN/
2

1). Wire diameter: -The wire diameter is found using the equation as below

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1008[
18
8010
=70mm

=388
The wire diameter is d=2.5mm, but the standard wire diameter is
2.33mm.
2). Wahls factor: -

41
44
+
0.615
=K

4101
4104
+
0.615
10
=K

The value of the Wahls factor is 1.14

3). spring stiffness: -

The stiffness of the spring is 1.42 N/mm.
4). Stress produce in the spring: -

8

.
2.337

The maximum stress produce in the spring is 514 N/
2

According to this the material is carbon steel.


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No table of figures entries found.5).The free length: -
Free length =n*d+
+0.15

=18*2.337+70+0.15*70
=12.25cm
6). Pitch: -
Now we are using the ground ended spring
So, pitch=

.

=
12.25
18

0.7mm

C).Small Guide post: - The smaller guide post is uses for proper alignment of the
stripper plate on the paper. This guide post is also press fitted on the stripper plate.
The dimension of the rod is as below
diameter=2cm
length=16cm
nut type=M20

Fig 2.6(nut for smaller guide rod) Fig 2.7(smaller stripper rod)

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The nut is provides on the punch plate size of the rod so, the guide rod cannot
comes out from the punch plate during reverse motion of the punch plate.

4).Cutting blade: -

Fig 2.8(cutting blade)

The knife is most important. It must be kept sharp. It must be of the proper shape
and thickness and bevel and temper and free from any burrs or lumps on its back
edge. Modern, high speed, labor saving binding and printing machine require special
tools to keep production running at full capacity. The use of the proper grade and
hardness of cutting sticks is important to the performance of high tech knives. A
stick that is too soft will not provide a quality cut on the last sheet of paper and a
stick that is too hard can damage the knife edge.

They vary in thickness, straightness, concave, bevel, flatness, temper, and quality of
steel; and also in the character of their sharpening and honing, which varies with
the fineness or coarseness of the grinding wheel and stone. These variations need
only be a few thousandths of an inch to cause trouble. Knives bought from the
maker of paper-cutting machines are apt to give the best results because they
receive two inspections: one by the knife maker, and another by the machine
maker, who is careful to see that only perfect knives are supplied.


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5). Flange (angle plate): - angle plate is use to attach the cutting blade with the
punch plate.

Fig 2.9(flange or angle plate)
The distance of the hole drilled on the plate is depends on the thickness. It should at
least equal to the thickness of the angle plate. Here we are taking thickness of the
plate is 8mm, and the distance of the hole from the edge is more than 1cm.
Now here we are supporting the plate of the 22cm so we are using the plate of the
length of 20cm. The distance of the hole from the other edge is 40mm that also
follow the above condition.

6). Nut & bolt: - The dimension of the nut and bolt for flange is depends on the
spacing between them. It is 10% of the distance between the holes. In the flange the
distance between two holes is 12cm. so the nut &bolt for the flange is M12.

7) Bush: - The punch plate is slide over the guide post. To provide smooth slide the
bushes are press fitted in the punch plate. The bushes used are having a self-
lubricating property. Now according to design date book.
The fit provide for slip fit is H6p6.
The diameter for the smaller guide rod is 2.0cm
So the dimension of the bush is 3.0cm
For the guide rod it should be 3.6cm

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Fig 2.10(bush)
Material: -

PARTS NAME MATERIAL
Die plate Mild steel
Punch plate Aluminum
Guide rod Mild steel
Cutting blade Mild steel
Flange Aluminum
Spring Carbon steel
Stripper block Wood or plastic

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Chapter 3
Manufacturing details

Manufacturing processes: -

manufacturing
processes
shaping joining finishing
Adhesive
Gas metal arc
welding
Gas tungsten
arc welding
Shielded
metal arc
welding
Resistance
Spot Welding
Rivetting
Screw and
Nut
Assembly
Casting
Rolling
Forging
Drawing
Sintering
Electro
Forming
Machining
Polishing
Electro
plating
Enameling
Printing
Heat
Treatment

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Metal shaping (forming):- Metal forming is a general term, for a large group, that
includes a wide variety of manufacturing processes. Metal forming processes are
characteristic in that the metal being processed is plastically deformed in order to
shape it into a desired geometry.
Metal joining: - Almost all products are assemblies of a large number of
components. Some of the components or sub-assemblies can move with respect to
each other, others are physically fixed together, with no relative motion possible.
Welding, mechanical fastening, soldering brazing are various metal joining process.
Material finishing:- After metal shaping and joining process object being made is
not having much quality. Quality means not aesthetic good. To make it very
aesthetic surface finish of the object is key thing. Surface finish of any object is done
by removing small amount of material from surface of object. Various metal
finishing processes are grinding, polishing, buffing, etc.


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Parts manufacturing processes :-
1) shaping process:-
Shaping machines are machine tools which by way of chip removal give work pieces
the desired shape, dimension and surface finish. They produce mainly flat surfaces,
shoulders, grooves and similar shape
In the paper cutting machine the die plate and cutting blade is most important parts.
The thickness of the mild steel plate is 2.5 cm, which is made from mild steel. To
make smooth the surface of the plate, material from its surface should remove.
Material is removed by the shaper machine.
Machine in the figure 3.1 is shaper machine. The die plate is fitted in the wise.
Material from the surface of the plate is removed by the reciprocating motion of
tool. Reciprocating motion of the tool is due to crank and slotted link mechanism. In
this mechanism the working stroke is slow and the idle stroke is fast. The wise is
mounting on the table, which have a horizontal as well as vertical motion. Due to
this facility whole plate can be made of appropriate size.

Advantages of shaping machine:-
1. A shaping machine is used to machine surfaces. It can cut curves,
angles and many other shapes.
2. A rack can be machined for a rack and pinion gear system.

2) Turning :-
The guide post and smaller guide rod is made from the mild steel. To make it
appropriate size the material is removed from the surface of the rod. As shown in
the figure 3.3 the rod of the guide post is fit in to the chuck. The guide post surface
is highly finished, for that first material should remove from the surface of the rod
by turning & after that polishing on the lathe using the polishing paper.

3). Polishing: -

The guide post, smaller guide rod is of smooth surface. During
Turning process the surface we get is not smooth enough so we can use it for direct
use. At that time there is lot of option to improve the surface of rod.

33

One of them is polishing on the lathe. Work piece we want to finish is held on the
chuck. The high grade polishing paper is wound round the rod and held tight. After
this turn the work piece. That will smooth the surface of rod.

4). threading:-
One easy way to make a thread on the any circular bar is using lathe. For that the
tool post and cross slide is attach with the lead screw using lock nut. Require pitch
will set using various speed of work piece and tool post.
Other simple way to thread is using tap set. Tap set is generally use for internal
thread.
On the small guide rod the thread is made with the same method. The required
thread is of size M20 specification. The speed of the work piece and lead screw is set
so that required pitch corresponds to M20 thread.
5) . Surface grinding:-
The cutting blade made from the mild steel which is one of the magnetic materials
so magnetic chuck is used to hold the blade. The table will reciprocate and it will
smooth the surface of the blade. After the surface grinding has done the blade is sent
for make sharp edge.
6). honing process:-
Every knife, when coming direct from the grinding machine, has a wire edge which
should be honed off before the knife is adjusted to the knife-bar. The knife should be
laid on a bench or table, flat side down, with the edge of the knife protruding about
one-eighth of an inch beyond the edge of the table. The hone should be held flat on
the bevel, and the motion should be a circular or rotary movement as well as up and
down, and the honing should be done from one end to the other without lifting the
hone from the knife.
When a fine wire edge appears on the flat side, lay the hone on lightly with no
pressure and absolutely flat, and draw from one end to the other. After honing the
knife for a short time (four or five minutes) the wire edge will disappear or get so
thin that a small piece of white pine or other soft wood, if drawn along the cutting
edge, will eliminate this thin wire edge.

34

NOTE:- . Never hone the flat side of the knife.
Never hone a knife while in the machine.
7). Drilling :-
A drilling machine, called a drill press, is used to cut holes into or through metal,
wood, or other materials. Drilling machines use a drilling tool that has cutting edges
at its point.
Drill press operators must know how to set up the work, set speed and feed, and
provide for coolant to get an acceptable finished product.
The parts like punch plate, die plate, the blade, and flange, holes are made by drilling
use of different size of drill. The commonly standard size of drill tool is of 30, 35, 28,
and 08.
8). gas cutting:-
The common methods used in cutting metal are oxygen gas flame cutting, air
carbon-arc cutting, and plasma-arc cutting . To cut mild-carbon steel for producing
the slit with the oxy gas cutting torch, you should adjust the preheating flames to
neutral.
The die plate having a slit has been cut by using gas cutting. How it is cut the
procedure is as below.
Hold the torch perpendicular to the work, Hold the torch in this position until the
spot you are heating is a bright red. Open the cutting oxygen valve slowly but
steadily by pressing down on the cutting valve lever. When the cut is started
correctly, a shower of sparks will fall from the opposite side of the work, indicating
that the flame has pierced the metal. Move the cutting torch forward along the line
just fast enough for the flame to continue to penetrate the work completely. If you
have made the cut properly, you will get a clean, narrow cut that looks almost like it
was made by a saw.


35

9).hydraulic press fitting:-
The guide posts are press fitted in to the die plate so that proper alignment is
happen. For that hydraulic press is used. In hydraulic press a fluid, such as oil, is
displaced when either piston is pushed inward. The distance the large piston will
move is the distance that the small piston is moved divided by the ratio of the areas
of the heads of the pistons.
The guide rod is hold in the drilled hole of the die plate then using hydraulic press it
will fit. In figure show the die plate and guide rod are hold on the base plate and
then the above rigid part force the rod to fit in to the die plate.


36

Chapter 4
Pneumatic system

Pneumatic component:-
Examples of components that produce and transport compressed air
1. Compressor
2. FRL unit
3. Execution component
1. Cylinder
2. Direction control valve
3. Control valve
Component function
1. Compressor:- To provide a compressed air compressor is use .compressed
air is passing to component by pipe.
2. FRL unit: -
FRL unit is used for filtering of air. With regulating pressure, with
lubrication.

Fig4.1 (FRL symbol)

3. Execution component: -execution component are pneumatic double acting
cylinder and 5/2 solenoid direction control valve.

37

1. Double acting pneumatic cylinder:-

Fig 4.2 (symbol of DAC)

2. Direction control valve: -
5/2 Directional control valve :-

Fig 4.3 (symbol of 5/2 DCV)
3. 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.
Flow control valve: -

Fig 4.4 (symbol of FCV)


38

Pneumatic circuit:-
In paper cutting machine the stroke to the cutting blade is provide by the double
acting pneumatic cylinder. Now we will see how this pneumatic cylinder will work.

Fig 4.5 (circuit of DAC with 5/2 DCV)

In this pneumatic circuit compressed air passed through FRL unit to direction
control valve. The direction control valve is 5 port and 2 way spring return solenoid
valve. This valve having coil attach to one side. When voltage is applied to coil it will
energize and produce magnetic field .That will attract the metal spool and valve
change the position. This will cause cylinder to actuate and blade attach to cylinder
end will cut the paper.


39

Component design: -

1. Pneumatic cylinder:-

Fig 4.6(DAC)

A) .Stroke length: -
L=5 cm clearance between the die plate and stripper block at
retracted position+3 cm cutter travel to cut the paper+1cm for
cut total width of the paper+1cm clearance between the punch
plate and cylinder supporting plate.
L=5+3+1+1
L=10cm

B).cylinder bore: -
At initially we assume that the maximum load acting on the
spring is 100N. If two springs are use in parallel then the force should
divide on two springs such that on individual it will 100N. Then force
acting on both should be 200N. This force is provided by pneumatic
cylinder.
If we assume that the cylinder will operate at 2bar pressure. The
necessary diameter of bore to generate 200N force if find as below.


40

210
10
4

2
=200N

4

2
=1000N
d=3.5cm
If we assume that the cylinder will operate at 3bar pressure. The necessary
diameter of bore to generate 200N force is

310
10
4

2
=200N

4

2
=
2000
3
N
d =2.9cm
now the standard bore diameter is 3.2cm is available.so the cylinder is operate
between 2 & 3 bar pressure.
2. Solenoid valve: -

Fig 4.7(5/2 DCV)
The solenoid valve is operates at 12V DC. It is 5/2 single side solenoid valve. It is
suitable for double acting cylinder because both pressure rating are same. When
supply of 12V DC is applied to coil, coil will energize and produce magnetic field.
This magnetic field will attract the metallic spool so valve will change its position.


41

Chapter 5
Microcontroller and its programming &interfacing

What is Microcontroller?

Microcontrollers have only been with us for a few decades but their impact (direct
or indirect) on our lives is profound. Usually these are supposed to be just data
processors performing exhaustive numeric operations.
A microcontroller (sometimes abbreviated C, uC or MCU) is a small computer on a
single integrated circuit containing a processor core, memory, and programmable
input/output peripherals. Microcontrollers are designed for embedded applications,
in contrast to the microprocessors used in personal computers or other general
purpose applications.
Microcontrollers are used in automatically controlled products and devices, such as
automobile engine control systems, implantable medical devices, remote controls,
office machines, appliances, power tools, toys and other embedded systems.
How microcontroller works?

Microcontroller has a memory in which the program is stored in form of machine
language (i.e. 1 and 0). Each location contain group of the 1and 0. Each pattern has
some meaning. When power is on the execution from first location is start, first
location data is fetch. The data is travel from memory location to data decoder by
data bus (wire). After understanding the meaning of the bit pattern the operation is
performed. The pattern from next location is fetch and same process is continued.


42

Project circuit diagram: -

Fig 5.1(project circuit)
Circuit Description: -
The microcontroller uses in paper cutting machine serve three task
1. Automatic feed of paper role
2. Automatic actuation of the pneumatic cylinder
3. To count and display no of paper has been cut.
Circuit diagram in fig 5.1 shows connection of electrical drives, solenoid valve, and
7- segment LED to the microcontroller. We know that in microcontroller all port can
use as I/O port. So we can connect device to any port. Here 2, 7-segment LED are
connected to port 0 & 2. 7-segment is of common cathode type so cathode of both is
connected to ground pin.

43

Four switches for different speed are connected to port 3. Two motor and one
solenoid is connected to port 1 through transistor circuit. Reason for using
transistor is that, microcontroller provide 5 volt signal and motor, valve are
operates at 12 volts.
The solenoid valve can connect to microcontroller using relay. Relay cannot directly
connect to microcontroller because relay required current of 10mA, while controller
provides current of 1mA. So we are connecting relay to microcontroller through
transistor circuit. Another way to interface relay with microcontroller is by current
buffer IC i.e. uln2003 or uln2803.
The 7-segment connect to port 0 is through pull up register. Because port o pins are
with open drain. Not all time 7-segments are connected port through current buffer
IC.


44

Programing and its description:-

how to program?
In implementation of microcontroller in paper cutting machine is to synchronize all
operation. The role is feed using motor. For some length of paper, motor should
continue for some time. After motor stop, delay should generate and then cylinder will
get signal to actuate. At that time paper will cut and 7-segment will increment by one,
again motor will start. Same process is continuing.
In above discussion time delay is key thing. Now we will see how delay is generate in
8051.
8051 has two 16 bit timer register. Both timers operate in 4 modes. Maximum time
delay using timer is generate of 0.07s.
Time delay of 0.05s: -
Here crystal of frequency 11.0592MHz is used. So time for one clock pulse is 0.09042 s.
one machine cycle is having 12 clock pulses. So time for one machine cycle is 1.085s.
To produce time delay of 0.05 second no. of machine cycle require is

0.05
1.085
=46082.946083
Now, the value that should load in timer register is finding as below.
65536-46083=19453(decimal)
Value load in timer register is in form of hex is 4BFDh


45

Flow chart: -


46

DISCRIPTION: -
Starting of the flow chart we write value to all port as per its requirement. Here we are
using port 0, 1, and2. Now take K, L both as zero. Then send value of K and L to port 2
and 0 respectively. Start motor M1 for n1 seconds. After required length of paper is feed
stop it. When motor will stop give signal to solenoid valve for n2 seconds. Within this
time period paper will cut. After that remove signal from solenoid so cylinder will go in
retract position. After that start motor M2 for n3 second so cutting paper will send
outside .Then increment value of K by one ,than check it whether it is less than 9 or not,
if it is less than 9 then no need of increment the value of l by one . Then send value of K
and L to port 2, 0 respectively. And continue the process. when value of will reach to 9
then increment the value of L by one so It will increment no to tenth place no display to
seven segment.


47

Conclusion: -

Automatic paper cutting machine using microcontroller is combination of
electronics and mechanical. This combination is one step of automation. In manual
paper cutting machine the force require to cutting the paper, and feed of paper is
manual while in automatic this thing is handle by electrical, pneumatic drives. If
there is something that will force this component work synchronizes then it will
bring automation in to it. This controlling is carried out by microcontroller 8051. So
with combination of electronics and mechanical project is working like this,
electrical drives will feed the paper role and pneumatic force will cut the paper. All
operation is controlled by the microcontroller.
At the starting of the project when title is given to us, we scare because for us title
was much tough then our capability. When time has passed we come to know how
to make design and it working then it brought courage in us and we started our
work quickly. During manufacturing of parts it was good experience. During this
period we came to know how to manufacture a parts and what type of instrument
are current in use. While during programming and electronics circuit it was very
good because it provide lots of information to us.
In this project what we have done is not enough. There are still lot of improvement
can be possible. If one wants to improve then it will be create something new.
Working with this project is bringing lots of knowledge in to us. We came to know
how industrial people are works. It was pleasure for us to working with industrial
people.


48

Appendix 1: -
Program of delay using timer 0 in mode 1: -
mov 89h,#01h
mov 8ch,#4ch
mov 8ah,#0bh
setb 8ch
here: jnb 8dh,here
clr 8ch
clr 8dh

PROGRAM OF PROJECT FROM FLOW CHART ON PAGE NO.49: -

mov 0a0h,a
clr a
inc dptr
djnz r2,label3
mov 82h,r3
movc a,@a+dptr
mov 80h,a
clr a
mov r2,#0ah
inc r3
mov dptr,#0100h
ljmp label3
org 0100h
db 60h
db 5bh
db 79h
db 65h
db 3dh
db 3fh
db 70h
db 7fh
db 7dh
db 7eh

end

setb 90h
mov r0,#64h
label: acall delay
djnz r0,label
clr 90h
mov r1,#14h
label2: acall delay
djnz r1,label2
setb 92h
mov 37h,#28h
label6: acall delay
djnz 37h,label6
clr 92h
ljmp label1
label3: djnz r4,label7
here: jmp here
delay: mov 89h,#01h
mov 8ch,#4ch
mov 8ah,#0bh
setb 8ch
here2: jnb 8dh,here2
clr 8ch
clr 8dh
ret
label1: movc a,@a+dptr
org 0000h
mov 0b0h,#00h
mov 90h,#00h
mov 80h,#00h
mov 0a0h,#00h
here3: jnb 0b0h,here3
mov r3,#00h
mov r4,#63h
mov r2,#0ah
clr a
mov dptr,#0100h
mov 0a0h,#7eh
mov 80h,#7eh
label7: setb 91h
mov 35h,#28h
label4: acall delay
djnz 35h,label4
clr 91h
mov 36h,#14h
label5: acall delay
djnz 36h,label5


49

Bibliography: -

1. Niel Gray, Paper-Cutting Machines, The committee on education
united typothetae of America, 1918.
2. P.C.Sharma and D.K.Aggarwal,machine design, kataria and sons,1999
3. Floyd, electronics device, Pearson publication,
4. David calcutt, fred cowan , 8051 microcontroller and application based
introduction, Elsevier, a division of reed Elsevier india orivate limited, 2006
5. richmond k. kumordzi, design and implementation of dc motor speed control
using pulse width modulation technique.
6. by Ivana suchy, Hand book of die design, McGraw-Hill books,1998
7. M.mahajan, textbook of metrology ,dhanpat rai.

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Paper cutting machine

=maximum deflection of the spring.

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