Design of Pneumatic Sheet Cutting Machine

submitted
by
L. Satyannarayana (N160138), E4-ME
G. Rama Krishna (N160139), E4-ME
P. Kamal Teja (N160242), E4-ME
N. Sai Bhargav (N160066), E4-ME

Under the guidance of

Mr. G. Mohana Rao
Asst Professor

Department of Mechanical Engineering

Rajiv Gandhi University of Knowledge Technologies Nuzvid
Nuzvid – 521202, Krishna Dist.,
Andhra Pradesh
March 2022
 List of Figures
Figure Name Page No.
1. Schematic view of Shearing machine 3
2. Cross sectional view of compressor 9
3. Working of solenoid valve 11
4. Schematic controlling of machine 15
5. Upper movement of shearing blade 15
6. Cutting action of blade 16
7. Returning to initial position 16
8. Base frame and dimensions 18
9. Angle section and dimensions 18
10. Shearing plates 19
11. Base Frame Model 19
12. Shearing blades 20
13. Pneumatic cylinder and base plate model 20
14. Angle section and Connecting rod model 20
15. Assembly model 21

List of Tables

Table Name Page No.

1. Material and its properties 17

1
 List of contents
Title Page No.
Abstract 3
1. Introduction 4-7
1.1 Literature Review 5-6
1.2 Prior Concepts 6
1.3 Need for Automation 7
2. Components and Description 8-14
2.1 Principal and working of Compressor 8-10
2.2 Working of solenoid and types 10-11
2.3 Pneumatic cylinder 11-14
3. Working of Machine 15-16
4. Calculations and Designing 17-21
5. Conclusions 22
6. References 23

2
 Abstract
This Major project is intended to develop a Pneumatic Sheet Cutting Machine by using the
SolidWorks which can reduce the human efforts and power consumption compared with the
ordinary one. In simple terms this project’s motive is to designing the pneumatic sheet cutting
machine with less cost. The sheet metal cutting is the main process of the all industries and
generally it’s the hand operated one for small and medium scale industries. Automation in the
modern world is unavoidable. Any automatic machine aimed at the economical use of the
man, machine, and material et. In our project Solenoid valve is used for the automation. This
Sheet metal cutting machine works with the help of pneumatic double acting cylinder where
the piston is connected to the cutting tool which is used to cut the small size of the sheet
metal and this machine is portable in size so, easy to transportable.

Keywords: Solid works, Pneumatic, Automation, Solenoid Valve, Double acting cylinder.

Pneumatic cylinder

Supporting Frame Solenoid valve

Control unit
Movable cutter

Air Entry
Compressor
Fixed cutter

BASE

Fig.1 Schematic view of shearing Machine

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 1.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 be
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 uses air (rather than some other gas) as the fluid medium because
air is safe, low cost and readily available fluid. The main objective is achieving some goals
like reducing process time, reducing required floor space, improving working environment
for the workers, achieving cutting operation without bending, achieving good surface
finishing, and doing a full automation to reducing human involvement in cutting operation.
In shearing or cutting operation as or blade descends upon the metal, the pressure
exerted by the blade first cause the plastic deformation of the metal. Since the clearance
between the two blades is very small, the plastic deformation takes place in a localized area
and the metal adjacent to the cutting edges of the blade edges becomes highly stressed, which
causes the fracture to start on both sides of the sheet as the deformation progresses and the
sheet is sheared.
Shearing machines are classified according to the following:
1. Pneumatically Operated
2. Hydraulically Operated
3. Rack and Pinion Operated
4. Spring Operated
Brief descriptions of all the types are as follows –
• Pneumatically operated
Heart the advertisement of the header is carried out in the upward and the
downward direction using the pneumatic double acting piston and cylinder unit
arrangement along with the foot operated direction control valve. In this type of
machine high pressure air is used as the working fluid for the transfer of power and
the motion.

• Hydraulically operated
Here the lowing and rising of the header is carried over using the hydraulic
piston and cylinder arrangement. To actuate the piston and the cylinder, the oil is
allowed to enter the cylinder from front or back side of the piston but the oil is
compositely costlier and its leakage may cause so many problems.

• Rack and Pinion Operated

Here the lowering and rising of the header is carried out manually using the
rack and pinion management. In this case the required pressure is applied manually
using the direct hand pressure on the rack using pinion and leaver arrangement. Since
the machine is robust and requires large pressure, hence it is not suitable.

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 • Spring Operated
The Working of springs operated machine is similar to the rack and pinion
operated machine but differs from it in construction. Here the rising and the lowering
is handled by manually and it requires too much of pressure to its operation and also
there is possibility of having damage to the workpiece if not handled carefully.

1.1 Literature Review

Manual method makes use of lever operated HSS blade to part the sheets. Sheets are
wasted if the operator makes error because of laborious process and takes more time for a
simple operation. Hydraulic cylinders are also available for sheet metal cutting.
➢ Prof. Mistry, Mr. Gopal Aravendakar, and Mr. Bhushan Bambulkarc et al.,[1]
conducted an experiment on pneumatic sheet cutting machine to overcome the
hydraulic power and human efforts. The power required for cutting the sheet metal is
higher in case of hydraulic power used.

➢ Aryan Pratihar, Adarsh Raunak, Ayog Kumar Rastogi et al.,[2] conducted an

experiment on Design and Fabrication of Pneumatic metal sheet cutting and observed
that pneumatic machines are cheaper than the hydraulic machines and their
maintenance is also as low as compared with hydraulic machines. Since two
operations are held on the same machine the production time will reduce.

➢ R Muthu Shiva, Maia James and Laxmi Shankar et al.,[3] They worked on Automatic
Sheet Metal cutting and fabricated it. The automation is achieved by using the
Arduino and which will give accurate and faster results.

➢ Asha P B, Raju B R, Prakash B, Rithwick V M et al.,[4] Developed an automatic

sheet metal cutting machine which leading to reduce the cost and human efforts and
more structured and quicker operation resulting in cleaner environment and less
maintenance.

➢ Khagendra Barman, Md. Nasar Ali, Md Raihan et al.,[5] They designed the
Pneumatic sheet cutting machine and fabricated it in order to check the working and
progress of the machine. This machine is useful for the students to do their laboratory.

➢ Madhu K Kumar, V Arun, Harsha B S et al.,[6] developed a unit for bending and
departing wide range of sheet by allowing air into cylinders which actuates the tool
and performing the both bending as well as cutting which will reducing the processing
time of manufacturing. And they observed that the bending thickness can be increased
by increase in the Compressor pressure.

➢ Ajith Kumar Singh, Dharmendra Singh and Harpreet Singh et al.,[7] are developed
the pneumatic sheet cutting machine which is working based on the solar power. The

5
 compressed air that is going into atmosphere is again used by doing some
modifications.

➢ Karan Datt et al., [8] Explained and proven experimentally how the Pneumatics are
getting engaged in industries now a days and the importance of the pneumatic power
and its applications and all.

➢ Yajun Xio, Jinling Zang and Yuming Gaun et al.,[9] They worked development and
design of pneumatic sheet cutting machine. In this experiment they used Pro-E and
Catia Software for their modelling and simulation of sheet cutting machine and finally
they concluded that the more the pressure the more the cutting efficiency.

➢ Mrs. Jyothi Katre, Palash Balapande and Kaustab Gaukart et al.,[10] They intended to
develop and fabricate the Pneumatic sheet cutting machine and They suggested these
pneumatics sheet cutting machines are best for small scale and medium scale
industries. This Machine can be made by Rack and Pinion, Lever operated and further
improved.

➢ Swapnil Laxman Gaikwad et al.,[11] Illustrated the different varieties of material and
thickness of materials that can cut by the shearing machine. By using proper
pneumatic balancing weight of parts, we can use this pneumatic shearing machine for
cut the hard material & for more thick sheets or blades.

➢ Satish G. Bahaley et al.,[12] Explained the designing and optimization of elemental

analysis of shear cutting unit through this they found that 5mm thick plates can also
easily cut. To achieve this, they developed the high strength blades.

1.2 Prior Concepts

Pneumatics, from the Greek (pneumatikos, coming from the wind) is the use of
pressurized gases to do work in science and technology. Pneumatics was first documented by
Hero of Alexandria in 60 A.D., but the concept has existed before then. A pneumatic product
represents a billion-dollar industry today. Pneumatic devices are used in many industrial
applications Generally appropriate for applications involving less force than hydraulic
applications and typically less expensive than electric applications, most pneumatic devices
are designed to use clean dry air as an energy source. The actuators then convert that
compressed air into mechanical motion. The type of motion produced depends on the design
of the actuator. Pneumatic is employed in a variety of settings. In dentistry applications,
Pneumatic drills and lighters, faster and simpler than the electric drill of the same power
rating (because the prime mover, the compressor, is separate from the drill and pumped air is
capable of rotating the drill bit at extremely high rpm). Pneumatic transfer system is
employed in many industries to move powders and pellets. Pneumatic tubes can carry objects
over distances. Pneumatic devices are also used where electric motors cannot be used for
safety reasons, such as mining applications where rock drills are powdered by air motors to

6
preclude the need for electric motors depends in the mine where explosive gases may be
present.

1.3 Need for Automation

Automation can be achieved through computers, hydraulics, pneumatics, robotics, etc.,
of these sources, pneumatics forms an attractive medium for low-cost automation. The main
advantages of all pneumatic systems are economy and simplicity. Automation plays an
important role in mass production.

• Reduction of lab our and material cost

• Reduction of overall cost
• Increased production
• Increased storage capacity

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 2.COMPONENTS AND DESCRIPTION
The basic components that used in this project are as follows
1) Compressor
2) Solenoid Valve
3) Pneumatic Cylinder

2.1 Principle and working of Compressor:

An air compressor is a pneumatic device that converts power into potential
energy stored in pressurized air (i.e., compressed air). By one of several methods, an air
compressor forces more and more air into a storage tank, increasing the pressure. When the
tank's pressure reaches its engineered upper limit, the air compressor shuts off. The
compressed air, then, is held in the tank until called into use. The energy contained in the
compressed air can be used for a variety of applications, utilizing the kinetic energy of the air
as it is released and the tank depressurizes. When tank pressure reaches its lower limit, the air
compressor turns on again and re-pressurizes the tank. An air compressor must be
differentiated from a pump because it works for any gas/air, while pumps work on a liquid.
Air compressors have many uses, including: supplying high-pressure clean air to fill gas
cylinders, supplying moderate-pressure clean air to a submerged surface supplied diver,
supplying moderate-pressure clean air for driving some office and school
building pneumatic HVAC control system valves, supplying a large amount of moderate-
pressure air to power pneumatic tools, such as jackhammers, filling high pressure air tanks
(HPA), for filling tires, and to produce large volumes of moderate-pressure air for large-scale
industrial processes (such as oxidation for petroleum coking or cement plant bag house purge
systems).Air compressors are also widely used in oil and gas, mining and drilling
applications as the flushing medium, aerating muds in underbalanced drilling and in air
pigging of pipelines .Most air compressors either are reciprocating piston type, rotary vane
or rotary screw. Centrifugal compressors are common in very large applications, while rotary
screw, scroll, and reciprocating air compressors are favoured for small and medium sized
applications.
There are two basic types of air compressors:

• Positive displacement, and

• Dynamic.

Positive Displacement

In the positive displacement type, a specified quantity of air is trapped in a

compression chamber and the volume which it occupies is mechanically reduced, causing a
corresponding rise in pressure prior to discharge. Rotary screw, vane and reciprocating air
compressors are the three most common types of air positive displacement compressors
found in small and medium sized industries.

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Dynamic.
Dynamic air compressors include centrifugal and axial machines, and are used in
very large manufacturing facilities.

a. Rotary Screw Compressors

Rotary screw compressors have gained popularity and market share (compared
to reciprocating compressors) since the 1980s. These units are most commonly used in sizes
ranging from about 5 to 900 HP. The most common type of rotary compressor is the helical
twin, screw compressor. Two mated rotors mesh together, trapping air, and reducing the
volume of the air along the rotors. Depending on the air purity requirements, rotary screw
compressors are available as lubricated or dry (oil free) types.
Rotor Timing Gears Seals

Oil-Free Rotate Set

Bearings Water Jacket

Fig.2. Cross-sectional view of compressor

b. Reciprocating Compressors
Reciprocating compressors have a piston that is driven through a crankshaft and by an
electric motor. Reciprocating compressors for general purpose use are commercially
obtainable in sizes from less than 1 HP to about 30 HP. Reciprocating compressors are often
used to supply air to building control and automation systems.

c. Vane Compressors
A rotary vane compressor uses an elliptical slotted rotor situated within a cylinder.
The rotor has slots along its length, each slot contains a vane. The vanes are forced outwards
by centrifugal force when the compressor is rotating, and the vanes move in and out of the
slot because the rotor is eccentric to the casing. The vanes sweep the cylinder, sucking air in

9
on one side and ejecting it on the other. In general, vane compressors are used for smaller
applications where floor space is an issue; however, they are not as efficient as rotary screw
compressors.

d. Compressor Motors
Electric motors are widely used to provide the power to drive compressors. As a
prime mover, the motor needs to supply sufficient power to start the compressor, accelerate it
to full speed, and keep the unit operating under various design conditions. Most air
compressors use standard, three phase induction motors.
Out of all these we are using the rotary compressor because of following reasons.
• It requires less lubrication and maintenance
• Rotary compressor has a smaller number of moving parts as a result vibrations are
low
• Rotary compressor uses less space than reciprocating due to its fewer moving parts.

2.2 Working of Solenoid Valve and types:

The solenoid valve is industrial equipment controlled by electromagnetism. It is an

automatic basic element to control the fluid. It belongs to the actuator, but not limits to the
hydraulic pressure and pneumatic control. In the industrial control system, the solenoid valve
is used to regulate the direction, flow rate, speed and other parameters of the medium. The
solenoid valve can coordinate with different circuits to realize the anticipated control, with
both control precision and flexibility being guaranteed. The solenoid valve is constituted by
the solenoid coil and magnetic core. It is the valve body containing one or several holes.
When the coil is got through or cut off with power, the operation of the magnetic core will
result in that the fluid passes through the valve body and is cut off, so as to reach the goal of
changing the fluid direction. The electromagnetic component of the solenoid valve is
constituted by the fixed iron core, movable iron core, coil and so on. The valve body is
constituted by the slide valve core, slide valve harness and spring base. The solenoid coil is
installed on the valve body directly while the valve body is enclosed in the seal pipe, so as to
constitute a simple and compact combination. The solenoid valve is constituted by the
solenoid coil and magnetic core. It is the valve body containing one or several holes. When
the coil is got through or cut off with power, the operation of the magnetic core will result in
that the fluid passes through the valve body and is cut off, so as to reach the goal of changing
the fluid direction. The electromagnetic component of the solenoid valve is constituted by the
fixed iron core, movable iron core, coil and so on. The valve body is constituted by the slide
valve core, slide valve harness and spring base. The solenoid coil is installed on the valve
body directly while the valve body is enclosed in the seal pipe, so as to constitute a simple
and compact combination.

How a solenoid valve works?

The solenoid valve has an enclosed chamber inside and ventilated holes in different
positions. Every hole is connected with different oil pipes. The chamber has a piston in the
middle. The two sides are two pieces of electromagnets. The electrifying magnetic coil will

10
attract the valve body to its side, so that different oil outlets will be opened or closed through
controlling the movement of the valve body. However, the oil inlet is constantly open. The
hydraulic oil will enter into different draw-off pipes. The oil pressure will be used to drive the
piston of the oil cylinder, which will drive the piston rod and then the mechanical device. In
this way, through controlling the current of the solenoid valve, the mechanical movement will
be controlled. Furthermore, let's briefly learn about the working principle of two main types
of solenoids.

Pilot Valve Piston

De-energized

Energized

Coil
Fig.3. Working of Solenoid Valve

2.3 Pneumatic Cylinder:

Cylinder is a device which converts fluid power into liner mechanical force and
motion. These cylinders are widely used in industrial pneumatic systems. These cylinders are
also called as linear motors and reciprocating motors pneumatic cylinders are designed for a
variety of services. Pneumatic cylinders are designed for a variety of services. Pneumatic
cylinders transform the flow of pressured fluid into a push or pull of the piston rod since out
system uses double acting cylinders, we shall see some details about them. The double acting
cylinders are in one in which fluid force can be applied to the movable element in two
directories. The force exerted by the compressed air moves the piston in two directories in a
double acting cylinder. They are used particularly. The piston is required to perform work not
only on the advance movement but also on the return. In principle, the stroke length is
unlimited, although bucking and bending must be considered before we select a particular
size of piston diameter, rod length and stroke length. The main component of any pneumatic
system is the cylinder, which receivers air under pressure and the pressurized air helps to

11
move the piston to and fro. The force acting on the piston will be equal to the product of the
pressure of air and the area of the cylinder. The amount of air delivered into the cylinder into
the cylinder decides the rate of doing work. A cylinder is a hollow circular section with the
top and bottom flange provided to prevent the leakage of air. The compressed air is used to
actuate the piston. In order to move the piston to and fro, the air is supplied to the top and
bottom of the cylinder alternatively.

2.3.1 Classification of Cylinders

Cylinder is mainly classified into two types namely,

• Single acting cylinder.

• Double acting cylinder.

Single acting cylinder:

In single acting cylinder, using the spring provided around the piston rod attains the
return stroke, but it is not efficient. So, the double acting cylinder is used in which the return
stroke is attained using compressed air.

Double Acting Cylinder:

In this the force exerted by the compressed air moves the piston in two directions.
They are used partially when the piston is required to perform work not only on the advance
movement but also on the return stroke. This principle, the stroke length is unlimited,
although bucking and bending must be considered before selecting the particular size of
piston diameter, rod length and stroke length.
The different parts of double acting cylinder are:

1. Barrel

2. Piston rod

3. Top Cover

4. Bottom Cover

5. Wiper Cover

6. Retaining ring

7. Piston

8. Piston guide

9. Bearing Cap

10. 'O' ring for piston guide

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11. Hexagonal socket head screw

12. Check nut

The double acting cylinder is made up of cast aluminium. The inner and outer surface of the
cylinder should be machined accurately. The internal diameter of the cylinder should be
accurate in order to provide a smooth surface for the packing. The appearance of the outer
diameter should be good. The outer most part of the bottom and top cover contains internal
threads for inserting bolts to clamp the cylinder.

In case of double acting cylinder, a force is developed in both the directions. The
moving member inside the cylinder is nothing but a piston which is found to be moving
forward and backward due to high pressure air. The cylinder top and lower plate are flanged
together by means of bolts and nuts. The bottom of the cylinder is also flanged with end
covers for the movement of the piston in reciprocating manner. The bottom end cover has a
bore in centre whose diameter is slightly larger than piston rod diameter. The force during the
return stroke is less compared to that of the forward stroke because in the former, the piston
rod covers some area so that the air cannot concentrate in the piston rod area.

2.3.2 Parts of Pneumatic Cylinder

Piston:
The piston is a cylindrical member of certain length which reciprocates inside the
cylinder. The diameter of the piston is slightly less than that of the cylinder bore diameter and
it is fitted to the top of the piston rod. It is one of the important parts which convert the
pressure energy into mechanical power. The piston is equipped with a ring suitably
proportioned and it is relatively soft rubber which is capable of providing good sealing with
low friction at the operating pressure. The purpose of piston is to provide means of conveying
the pressure of air inside the cylinder to the piston of the oil cylinder. Generally, piston is
made up of Aluminium alloy-light and medium work and Brass or bronze or Cl-Heavy duty.

The piston is double acting type. The piston moves forward when the high-pressure
air is turned from the right side of cylinder. The piston moves backward when high pressure
acts on the piston from the left side of the cylinder. The piston should be as strong and rigid
as possible. The efficiency and economy of the machine primarily depends on the working of
the piston. It must operate in the cylinder with a minimum of friction and should be able to
withstand the high compressor force developed in the cylinder and also the shock load during
operation.

The piston should have the following qualities.

a. The movement of the piston not creates much noise.

b. It should be frictionless.

c. It should withstand high pressure.

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Piston Rod:
The piston rod is circular in cross section. It connects piston with piston of another
cylinder. The piston rod is made of mild steel ground and polished. A high finish is essential
on the outer rod surface to minimize wear on the rod seals. The piston rod is connected to the
piston by mechanical fastening. The piston and the piston rod can be separated if necessary.
One end of the piston rod is connected to the bottom of the piston. The other end of the piston
rod is connected to the other piston rod by means of coupling. The piston transmits the
working force to the oil cylinder through the piston rod. The piston rod is designed to
withstand the high compressive force. It should avoid bending and withstand shock loads
caused by the cutting force. The piston moves inside the rod seal fixed in the bottom cover
plate of the cylinder. The sealing arrangements prevent the leakage of air from the bottom of
the cylinder while the rod reciprocates through it.

Cylinder Cover Plates:

The cylinder should be enclosed to get the applied pressure from the compressor and
act on the pinion. The cylinder is thus closed by the cover plates on both the ends such that
there is no leakage of air. An inlet port is provided on the top cover plate and an outlet port
on the bottom cover plate. There is also a hole drilled for the movement of the piston. The
cylinder cover plate protects the cylinder from dust and other particle and maintains the same
pressure that is taken from the compressor. The flange has to hold the piston in both of its
extreme positions. The piston hits the top plat during the return stroke and hits the bottom
plate during end of forward stroke. So, the cover plates must be strong enough to withstand
the load.

Cylinder Mounting Plates:

It is attached to the cylinder cover plates and also to the carriage with the help of 'L'
bends and bolts.

Control Valve:
Various types of control valves are used to regulate, control and monitor the air
energy for control of direction pressure, flow, etc. Pneumatic energy is regulated and
controlled by pneumatic valves. Functionally valves are divided into four major groups.

Direction Control
Flow Control

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 3.WORKING OF MACHINE
The following figure shows the general layout for the machine.

Fig.4. Schematic controlling of Machine

Initially the air-compressor is started and allowed the receiver tank air pressure to
reach up to 8 bar. The supply air is then passed to the manifold through FRL unit to condition
the air and eligible to industrial use. From the manifold a separate supply for the machine is
taken out and given to ON-OFF switch, so as to operate the machine at will without
interrupting the running of compressor. Then the pipe carries compressed air first to
machine's Direction Control Valve. At position 'A' shows the non-actuated circuit diagrams.

Connecting link

Upper blade

Lower
blade

Machine at position A
Position A
Fig.5. Raising of the Shearing blade

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At position 'B', the DC valve is at left hand position as shown in figure. The cap end port &
pressure port get connected to each other and the rod end port gets connected to the exhaust
port. The compressed air comes in the cap end of the cylinder and pushes the pistons
outwards. The air already present in the rod end side is pushed out of the cylinder
When the piston moves outwards, the force is transmitted through the connecting link and the
upper blade moves downwards. Before the actuating DC valve, the sheet is inserted in
between the upper & lower blades. As upper blade moves downwards, the stress is generated
in the sheet metal and goes beyond ultimate shear stress of sheet metal. And thus, the
shearing action takes place.

Position B Fig.6. Cutting Action of blade

Now the DC valve is operated to come at position 'C', as shown in figure. The rod end
port & pressure port get connected to each other and the cap end port gets connected to the
exhaust port. The compressed air comes in the rod end of the cylinder and pushes the pistons
inwards. The air already present in the cap end side is pushed out of the cylinder The sheet
metal is either again inserted for further cutting in case of large pieces; the small cut pieces
are removed and the next sheet is inserted to cut.

Position c
Fig.7. Returning to its initial position
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 4.CALCULATIONS AND DESIGNING
Let’s see the different calculations for the main parts of the assembly. First of all, we
need to calculate how much force is required to cut the sheet metal. The following are the
different sheet metals that are using widely in industrial applications.

Table.1 Material and its properties

Material Length of Thickness of sheet Shear strength (Mpa)
cut(mm) metal(mm)
Aluminium 25 0.5 30
Copper 25 0.5 86
Galvanized steel 25 0.5 11.31
Cast Iron 25 0.5 130-690
Here we considering the highest shear strength material for our calculations.
i.e., For Cast iron
The force required to cut the sheet (Frequired ) = L x t x Tmax
= 25x0.5x130=1625N
It is the force required to cut sheet.
But the initial force required to cut the sheet is more and it’s 140-150% of we calculated.
So, Fmax = 2275 to 2437.5 N
Shear Blade area (Ablade) = 300X15 = 4500 mm2
• Prequired = Fmax/ Ablade = 2437.5/4500 = 0.542Mpa = 5.42bar
to overcome any loses consider Pmax= 1.5 x 5.42 = 8.13bar

Calculation For the Diameter of Pneumatic Cylinder:

Fmax = (pi/4) xd2 x Pmax
From this d can be calculated as 58.2mm ~ 60mm
Hence, the required diameter is 60mm.
By using these dimensions let’s make the parts of the machine.

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2d Drawings of the Machine parts:

Base Frame: Front View Scale: 1:10

Top View Scale: 1:10 Left View Scale: 1:10

Fig.8. Base frame and its dimensions

which is used for giving the support for the all the parts like shearing blades, angle section
and pneumatic cylinder etc.

Angle Section:
Angle section is designed to withstand for the vibrations as well as to achieve the
cutting by fixing the one of the shearing blades on it.

Front View Scale: 1:2 Left View Scale: 1:2

Fig.9. Angle section and its Dimensions

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Shearing Blades: Front View Scale: 1:3 Left View Scale: 1:10

Top View Scale: 1:3

Fig.10. Shearing blades and Dimensions

Shearing blades are designed in such a way that to achieve the shearing of the plate. to
achieve this shearing of plate there is a clearance of 2-10% is provided and an offset of 5-
10% is provided for the upper movable shearing blade.

3D CAD Model design:

CAD means Computer Aided Design these models are needed to get a real time
experience of the material or machine we are developing.
Based on the 2d drawings developed the 3D models in solid works.

Fig.11. Base Frame

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 Fig.12. Shearing Blades

Fig.13. Pneumatic Cylinder and Base plate

Fig.14. Angle section and connecting rod

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Assembly of all the components we developed.
Which gives a brief idea about how the machine looks like.

Fig.15. Assembly of Components

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 5.CONCLUSION
It can be concluded that Pneumatic shearing machine is more economical as compared to
hydraulic one. Higher pressure compressor can be employed for increasing the range of
cutting thickness. As far as small sheet metal cutting units are concerned, this device founds
to be of greater benefit as it reduces the dependency on the expensive hydraulic shearing
machine.

Merits:
✓ Fast cutting actions are carried out and cutting without bending is achieved.
✓ Simple in construction and quick response.
✓ Operation cost is quite less Because, the medium used to operate is air.
✓ Continuous operation is possible

Demerits:
✓ Sheet more than 2mm thickness is cannot cut easily.
✓ Compressed air is must So, there is a need of silencer.

✓ High torque cannot be obtained.

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 6.REFERENCES
➢ Ajit kumar singh, Harpreet singh, Dharmendra sharma,” Design and Fabrication of
Pneumatic Auto Sheet Metal Cutting Machine Using Solar Energy “International
Journal of Engineering Research & Technology (IJERT) ISSN: 2278-0181
IJERTV4IS030877 www.ijert.org (This work is licensed under a Creative Commons
Attribution 4.0 International License.) Vol. 4 Issue 03, March-2015.
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And some of the video references also taken to understand the working of components
Links
https://youtu.be/-MLGr1_Fw0c
https://youtu.be/hmz1h5fk2bI

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