AUTOMATIC PNEUMATIC RAMMING MACHINE

CHAPTER I- INTRODUCTION

Ramming refers to the compaction of granular materials (mold materials,

but also refractory masses) using a ramming tool. In hand or floor molding (open
sand molding), bentonite-bonded or oil-bound mold sands (see Green sand mold,
O.B.B. sand, Green sand molding process) are mainly compacted by hand
ramming. The compaction by ramming should be as even as possible which is
difficult to achieve with hand molding. Depending on the mold box height,
several layers of mold sand are rammed onto each other. The following properties
of the compacted mold must be ensured:

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1. The mold must be sufficiently compacted and withstand the casting pressure, it
must not change due to casting or solidification. In particular, swelling due to
insufficient or uneven compaction needs to be avoided.

2. The mold must have sufficient gas permeability so gases generated during
casting can escape. A common method in hand molding is to create additional air
holes (venting) by piercing.

For obtaining optimum compaction, different ramming tools are available to the
molder for manual mold making. Pegging rammers and flat rammers (see Hand
rammer) are used for small molds, and pneumatic rammers are used for large
molds.

Ramming is the process of pressing the surface of sand with the help of rammer, it
is done after placing the pattern in cope box and drag box to get uniform
distribution of sand and also to get uniform strength.

Sand casting is one of the few available processes for metals with high melting
temperatures such as steels, nickel, and titanium. Because of its flexibility, heat
resistance, and relatively low cost, sand casting is the most widely used casting
process.

Castings are produced by pouring liquid metal into a mold cavity. For a casting to
be successful, the mold cavity must retain its shape until the metal has cooled and
fully solidified. Pure sand breaks apart easily, but molding sand contains bonding
material that increases its ability to resist heat and hold shape.

Green sand (an aggregate of sand, pulverized coal, bentonite clay, and water) has
traditionally been used in sand casting, however modern chemically bonded
molding systems are becoming more popular. The most widely used casting sand
is silica (SiO2).

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CHAPTER II- LITERATURE SURVEY

In Casting Sand moulding process involves the use of sand as a moulding

medium and is known as sand moulding.

Conventional Ramming Machine: The cam is actuated by a user by rotating the

handle, causing a cam to lift the weight and let it fall freely on the frame attached
to the ram head. This produces a standard compacting action to a pre-measured
amount of sand. Variety of standard specimen for Green Sand and Silicate based
(CO2) sand are prepared using a sand rammer along with accessories The sand
rammer machine can be used to measure compatibility of prepared sand by filling
the specimen tube with prepared sand so that it is level with the top of the tube.
The tube is then placed under the ram head in the shallow cup and rammed three
times. Compatibility in percentage is then calculated from the resultant height of
the sand inside the specimen tube.

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Fig 1.1 Steps in Casting Process.

The pneumatic rammer is used for ramming the sand uniformly around the
pattern. It can be used even in small scale industries. To operate this rammer an
air compressor is needed. A butt which is attached to the bottom of the piston rod
does the operation of ramming. The pressure developed inside the cylinder
reciprocates the piston and hence the butt. This rammer is handled by an operator
just by moving it over the moulding sand. The butt rams the sand at places moved
and the sand is uniformly rammed. This rammer reduces the ramming time and
labor. Due to this the cost is reduced considerably. So this machine finds
application in foundries.

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CHAPTER III- METHODOLOGY

Moulding is one of the important metals forming process in manufacturing
components for various applications in industry. Casting of any size and shape
can be made accurately. Automation in this field helps to improve the foundry
environment and accuracy of the cast parts. Efficiency of moulding is affected by
various parameters like permeability, collapsibility, adhesiveness etc. So it is a
must to avoid defects in casting. The defects occur in sand castings post a great
problem in foundry. On account of defects more than 10% castings are rejected.
Even though skilled labour is employed for ramming operation, the packing of
moulding sand will not be even throughout the moulding box. So we have
selected the idea of fabricating “PNEUMATIC RAMMER”. This rammer is
operated pneumatically. By using this rammer moulding sand will be packed
evenly throughout the box.

The pneumatic rammer is used for ramming the sand uniformly around the
pattern. It can be used even in small scale industries. To operate this rammer an
air compressor is needed. A butt which is attached to the bottom of the piston rod
does the operation of ramming. The pressure developed inside the cylinder
reciprocates the piston and hence the butt. This rammer is handled by an operator
just by moving it over the moulding sand. The butt rams the sand at places moved
and the sand is uniformly rammed. This rammer reduces the ramming time and
labour. Due to this the cost is reduced considerably. So this machine finds
application in foundries.

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The figure below shown is the block diagram for the working of Automatic
Pneumatic Ramming Machine;

Fig 3.1 Block Diagram of Pneumatic Ramming Machine

WORKING PRINCIPLE:-

The compressed air goes to the flow control valve. The flow control valve
is used to control the flow of air. It is adjustable one. We have to adjust the lever,
so that the required pressurized air goes to the Solenoid Valve. In our project, the
solenoid valve is used as a direction control valve. This solenoid valve is
controlled by the electronic control timing unit. The ramming time is varied by
adjusting the timing (timer 555 IC) control of the electronic unit.

The compressed air goes to the pneumatic double acting cylinder. The ram is
fixed at one end of the pneumatic cylinder. The compressed air pushes the

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pneumatic cylinder, so that the piston moves downward by giving air supply in
one direction of pneumatic cylinder. The solenoid valve is changing the air flow
in the opposite direction by the small time delay. In this time the pneumatic
cylinder piston moves upward due to changing of the air flow direction. This air
flow direction is controlled by the solenoid valve.

Fig 3.2 Drawing of Ramming Machine

First we will be selecting the type of double acting cylinder for machine
based on air pressure and standard size available. Based on DA Cylinder the
frame will be designed and manufactured. A 5X2 direction control valve will be
used for actuation. Components required as follows,

i. Pneumatic cylinder
ii. MS Frame / Box
iii. Rammer
iv. Direction Control Solenoid valve
v. Pneumatic fitting

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CHAPTER IV- DETAILS OF COMPONENTS USED

1. AIR COMPRESSOR:
A compressor is a mechanical device that increases the pressure of a gas
by reducing its volume. An air compressor is a specific type of gas compressor.
Compressors are similar to pumps: both increase the pressure on a fluid and both
can transport the fluid through a pipe. As gases are compressible, the compressor
also reduces the volume of a gas. Liquids are relatively incompressible; while
some can be compressed, the main action of a pump is to pressurize and transport
liquids.

Many compressors can be staged, that is, the fluid is compressed several times in
steps or stages, to increase discharge pressure. Often, the second stage is
physically smaller than the primary stage, to accommodate the already
compressed gas without reducing its pressure. Each stage further compresses the
gas and increases its pressure and also temperature (if inter cooling between
stages is not used).

Reciprocating compressors use pistons driven by a crankshaft. They can be either

stationary or portable, can be single or multi-staged, and can be driven by electric motors
or internal combustion engines. Small reciprocating compressors from 5 to 30
horsepower (hp) are commonly seen in automotive applications and are typically for
intermittent duty. Larger reciprocating compressors well over 1,000 hp (750 kW) are
commonly found in large industrial and petroleum applications. Discharge pressures can
range from low pressure to very high pressure (>18000 psi or 180 MPa). In certain
applications, such as air compression, multi-stage double-acting compressors are said to
be the most efficient compressors available, and are typically larger, and more costly than
comparable rotary units. Another type of reciprocating compressor, usually employed in
automotive cabin air conditioning systems,[citation needed] is the swash plate or wobble
plate compressor, which uses pistons moved by a swash plate mounted on a shaft (see
axial piston pump).

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Household, home workshop, and smaller job site compressors are typically
reciprocating compressors 1½ hp or less with an attached receiver tank. A linear
compressor is a reciprocating compressor with the piston being the rotor of a linear
motor. This type of compressor can compress a wide range of gases, including
refrigerant, hydrogen, and natural gas. Because of this, it finds use in a wide range of
applications in many different industries and can be designed to a wide range of
capacities, by varying size, number of cylinders, and cylinder unloading. However, it
suffers from higher losses due to clearance volumes, resistance due to discharge and
suction valves, weighs more, is difficult to maintain due to having a large number of
moving parts, and it has inherent vibration.

Fig 4.1 Air Compressor

A compressor is a device that increases the pressure of a substance (usually a gas)

by reducing the volume of the substance. Compressors are used in many

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applications, most of which involve increasing the pressure inside a gas storage
container, such as:

1. Compression of gases in petroleum refineries and chemical plants

2. Storage of gas in high pressure cylinders
3. Cabin pressurization in airplanes
4. Air storage for underwater activities
5. Filling tires
6. Refrigeration and air conditioners
7. Rail vehicle operation
8. Gas turbines
9. Powering pneumatic tools
10. Pipeline transport of natural gas

2. FRL Unit:-

Filter, regulator, and lubricator (FRL) compressed air systems are used to
deliver clean air, at a fixed pressure, and lubricated (if needed) to ensure proper
pneumatic component operation and increase their operation lifetime. The air
supplied by compressors is often times contaminated, over pressurized, and non-
lubricated meaning that an FRL unit is required to prevent damage to equipment.
Filters, regulators, and lubricators can be bought individually or as a package (as
seen in Figure 1) depending on what is needed to ensure the proper air
specifications are being met for downstream equipment. It is recommended to
install these devices if you:

1. Use pneumatic tools and equipment;

2. Are installing an HVAC system;
3. Require clean air to be delivered to your facility or workplace;
4. Require compliance to ISO, OSHA, ASHRA or other air quality standards;
5. Want to improve the service life, safety and reliability of your air system.

An FRL unit is comprised of a filter (F), regulator (R), and a lubricator (L). They
are often used as one unit to ensure clean air in a pneumatic system but can also

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be used individually. Having a proper FRL unit installed in a pneumatic system

provides higher reliability of the components downstream, reduced power waste
due to over pressurization, and increased component lifetime. The three
components work together to do the following:

a. Filters remove water, dirt and other harmful debris from an air system.
This is often the first step in improving the air quality.
b. Regulators adjust and control the air pressure of a system to ensure that
down-line components do not exceed their maximum operating pressures.
This is the second step in the FRL system.
c. Lubricators reduce the internal friction in tools or equipment by releasing
a controlled mist of oil into the compressed air. This is often done last
and/or right before the component needing lubrication.

Fig 4.2 FRL Unit

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3. 5X2 Lever Operated Direction Control Valve:-

A valve is a device that regulates the flow of fluid (gases, liquids, fluidized
solids, or slurries) by opening and closing or partially obstructing passage ways. A
5/2 way directional valve from the name itself has 5 ports equally spaced and 2
flow positions. It can be used to isolate and simultaneously bypass a passage way
for the fluid which for example should retract or extend a double acting cylinder.

Fig 4.3 5X2 Lever Operated Direction Control Valve

There are variety of ways to have this valve actuated. A solenoid valve is
commonly used, a lever can be manually twist or pinch to actuate the valve, an
internal or external hydraulic or pneumatic pilot to move the shaft inside,
sometimes with a spring return on the other end so it will go back to its original
position when pressure is gone, or a combination of any of the mention above.

In the figure given below, a single solenoid is used and a spring return is installed
in the other end. The inlet pressure is connected to (P) 1. (A) 2 could possibly be
connected to one end of the double acting cylinder where the piston will retract
while (B) 4 is connected to the other end that will make the piston extend.

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Fig 4.4 Symbol of 5X2 Lever Operated Direction Control Valve

The normal position when the solenoid is de-energized is that the piston rod is
blocking (B) 4 and pressure coming from (P) 1 passes through (A) 2 that will
make the cylinder normally retracted.

When the solenoid is energized, the rod blocks (A) 2 and pressure from (P) 1
passes through (B) 4 and will extend the cylinder and when the solenoid is de-
energized, the rod bounces back to its original position because of the spring
return. (E) 3 and (E) 5 is condemned or used as exhaust.

4. Double Acting Cylinder

A double-acting cylinder is a cylinder in which the working fluid acts

alternately on both sides of the piston. In order to connect the piston in a double-
acting cylinder to an external mechanism, such as a crank shaft, a hole must be
provided in one end of the cylinder for the piston rod, and this is fitted with a
gland or "stuffing box" to prevent escape of the working fluid. Double-acting
cylinders are common in steam engines but unusual in other engine types. Many
hydraulic and pneumatic cylinders use them where it is needed to produce a force
in both directions. A double-acting hydraulic cylinder has a port at each end,
supplied with hydraulic fluid for both the retraction and extension of the piston. A
double-acting cylinder is used where an external force is not available to retract
the piston or it can be used where high force is required in both directions of
travel.

A pneumatic cylinder is a mechanical device that converts compressed air

energy into a reciprocating linear motion. A double-acting cylinder uses
compressed air to move a piston in and out, while a single-acting cylinder uses

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compressed air for one-way movement and a return spring for the other. They
have numerous accessories, like sensors to detect the position of the piston and
different mounting accessories to mount the cylinder or add components to the
end of the piston. A wide range of industries requiring linear motion use
pneumatic cylinders since they are simple to use and are a cost-efficient solution.
They are also referred to as air cylinders

Pneumatic cylinder parts

Figure 4.5 shows the main components of a double-acting pneumatic cylinder.

They are cap-end port (A), tie rod (B), rod-end port (C), piston (D), barrel (E), and
piston rod (F). A single-acting cylinder will only have either a cap-end port (A) or
a rod-end port (C) and utilize a mechanical spring for the secondary motion. The
pneumatic cylinder barrel (E) is sealed on both ends with a head cap and end cap.
The compressed air (or spring) moves the piston (D) and subsequently the piston
rod (F). The stroke length of a pneumatic cylinder is how far the piston rod can
extend.

Fig 4.5 Pneumatic Double Acting Cylinder

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Double-acting pneumatic cylinder

Double-acting pneumatic cylinders are the most common type since they give the
user complete control of the piston movement. Figure 3 shows how the piston and
piston rod move when compressed air enters the cap-end port and the rod-end
port. A negative position is when the piston rod is retracted, and a positive
position is when the piston rod is extended.

When compressed air enters the cap-end port, it pushes the piston forward
(positively), extending the piston rod (shown in Figure 4.6 A). Air is forced out of
the rod-end port. To retract the piston rod, compressed air enters the rod-end port,
forcing air out of the cap-end port, and forcing the piston to retract to the negative
position (shown in Figure 4.6 B).

Fig 4.6 Double Acting Cylinder

Double-acting pneumatic cylinders allow the user full control, longer

piston stroke length, and a constant output force through the entire stroke. They
can also operate at higher cycling rates. However, a double-acting cylinder should
not be used if the application requires a base position during fail-safe scenarios
encase there is a loss in compressed air. Since they use compressed air for both
directions, they also use more energy.

A double-acting pneumatic cylinder uses compressed air to move a piston

in and out, while a single-acting pneumatic cylinder uses compressed air for one-

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way movement and a return spring for the other. The stroke is the total distance
that the piston rod is capable of moving in one direction

Selection Criteria

1. Cylinder Diameter: The diameter of the pneumatic cylinder is directly

proportional to the amount of force it can generate from an input air
pressure. For single-acting pneumatic cylinders, the opposing spring force
should also be taken into consideration.

F = (P x A) - f

Where,

F: Cylinder’s Force (N)

P: Air Pressure (MPa)

A: Piston Area (mm2)

f: Friction Drag (N)

2. Stroke Length: Ensure that the piston rod can extend or retract the required
length. It is also important to note that longer piston rods puts higher stress
on the rod and requires a longer pneumatic cylinder.
3. Mounting Style
4. Position Feedback
5. Cushioning
6. Operating pressure
7. Connection size

Fig 4.7 ISO symbols for pneumatic cylinders

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5. Polyurethane Tube:-

Polyurethane tubes or Pu tubes are extra flexible and soft and are
especially suitable in applications where short bending radii for the tubing are
indispensable.

Polyurethane combines the best properties of both plastic and rubber. It

offers abrasion and tear resistance, high tensile and elongation values, and low
compression set. Polyurethane is naturally flexible and exhibits virtually unlimited
flexural abilities.

Combining good chemical resistance with excellent weathering

characteristics sets polyurethane apart from most other thermoplastics. It has
exceptional resistance to most gasolines, oils, kerosene, and other petroleum-
based chemicals, making PU tubing and hose, also known as PUR tubing and
hose, an ideal choice for fuel lines.

Polyurethane tubes are used for transmission of pneumatic fluid i.e.

compressed air. Polyurethane combines the best properties of both plastic and
rubber. It offers abrasion and tear resistance, high tensile and elongation values,
and low compression set.

Fig 4.8 Polyurethane Tube

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Uses of Pneumatic Tubes:

Pneumatic tubes are used for controlling the lubricating oil system and also for
several air tools. These coil tubes are rough in performance and vigorous in
design. Pneumatic tubes are more flexible than nylon tubes and have high
resistance to cold temperatures.

These tubes are light in weight and are available in various sizes (OD and ID) to
meet your specific requirements.

Features of pneumatic tubes:

1. High Flexibility
2. Ambient Temp: (-) 35 to 60 0C
3. Working Pressure: (-) 0.95 to 10 Bar
4. Small Bending Radius

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CHAPTER V- DESIGN AND CALCULATION

A. Material Selection

To prepare any machine part, the type of material should be properly

selected, considering design, safety .The selection of material for engineering
application is given by the following factors:-

1) Availability of materials

2) Suitability of the material for the required components.

3) Cost of the materials.

The machine is basically made up of mild steel. The reasons for the
selection are Mild steel is readily available in market .It is economical to use and
is available in standard sizes. It has good mechanical properties i.e. it is easily
machinable .It has moderate factor of safety, because factor of safety results in
unnecessary wastage of material and heavy selection. Low factor of safety results
in unnecessary risk of failure. It has high tensile strength. Low coefficient of
thermal expansion.

Bed and Frame

Frame is the structure used for supporting pneumatic cylinder and Bed is
the structure used for handling the material to be rammed. Frame and bed is made
from the Mild Steel bar of 1inch i.e. 25mm respectively of the given following
dimensions mentioned in the table no 5.1 given below;

Body Material Length Width Height

(mm) (mm) (mm)
Frame 25 mm M S Bar 300 200 400
Box 3 mm M S Sheet 125 125 125
Table 5.1 Size of Machine

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Below attached is photograph of frame in fig 5.1 along with box attached
for ramming purpose.

Fig 5.1 Construction of Frame and Box

B. PNEUMATIC CYLINDER

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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 transforms 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.

Pressure available from the compressor = 1000000Pa (10 bar)

Diameter of the piston = 32mm

π 2
Cross sectional Area of the cylinder = ×d = 804.352 mm2
4

Force = Area X Pressure

The piston is machined to the specified to the specified dimension in a

lathe and piston rod is mated (tight fit) in the bore of the piston and then turned in
a lathe. Surface grinding is done on piston and piston rod. The nature of fit
between cylinder and piston is clearance fit – running fit.

Tolerance = 32± 0.02

Total stroke length = 135 mm

Working stroke length = 65mm

The diameter of the piston = 32mm

The piston force F = P X A = 10 X 105 X 804.352 X 10-6

F = 804.352 N

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Fig 5.2 Double Acting Cylinder 32mm X 150mm

DIRECTION CONTROL VALVE:

The solenoid valve is responsible for reciprocating motion of the Ram. It is

electrically powered. The trip dogs actuate the solenoid valve.

Technical Data:

Size: ¼”

Pressure: 0 to 10 kg / cm2

Media: Air

Working Principle:

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Double acting cylinder are controlled by 2 way 5 port two position valve as shown
in the fig. This valve has one inlet port (P), two cylinder ports (A and B), and two
exhaust ports (R and S).

Fig 5.3 5X2 Direction Control Valv

DESIGN PROCEDURE OF FRAME & BED

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Tools Tools Instrument Minutes

s
1. Cutting Of M/C Cutting Axe Measuring 15 Min
Stand Vice M/C Saw Tape, Steel
(Supports) Rule.
2. Filling Of Bench Grinding - - 10 Min
Stand Vice M/C
(Supports)
3. Welding Of M/C Welding - Tri Square, 45 Min
Stand Vice M/C Measuring
(Supports) Tape.

4. Filling Of Bench Grinding - - 20 Min

Stand After Vice M/C
Welding

Table 5.1 DESIGN PROCEDURE OF FRAME & BED

COST ANALYSIS
BILL OF MATERIAL
SR Total
DESCRIPITION OF PARTS QUANTITY
NO. Amount
1. AIR TANK OR RESERVIOR 01 N.A

2. FRL Unit 01 N.A

3. 5 X 2 Lever Operated Direction Control 01 950

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Valve
4. Double Acting Pneumatic Cylinder 01 2750

5. HOSES & OTHER CONNECTIONS 07 300

6. Construction of Bed & Frame 01 4000

7. Powder Coating & Finishing 01 1500

8. Total 9,500

TABLE 5.2 BILL OF MATERIAL

SELECTION OF COMPRESSOR
 Compressor selection procedure is based on pressure required of air to
apply brakes.
 Normally pressure required is 6 to 8 bar. So compressor required should be
of 8 to 10 bar capacity.
 If compressor capacity is more than required control air pressure with flow
control valve & pressure generating in compressor should be minimized.
SELECTION OF AIR TANK
 Normally pressure required is 6 to 8 bar. So air tank should be capable of
holding more than 6 to 8 bar air pressure.

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CHAPTER VI- RESULT AND DISSCUSSION

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The compressed air goes to the flow control valve. The flow control valve
is used to control the flow of air. It is adjustable one. We have to adjust the lever,
so that the required pressurized air goes to the D C Valve. In our project, the D C
valve is used as a direction control valve. This valve is controlled by the hand
operated lever.

The compressed air goes to the pneumatic double acting cylinder. The ram
is fixed at one end of the pneumatic cylinder. The compressed air pushes the
pneumatic cylinder, so that the piston moves downward by giving air supply in
one direction of pneumatic cylinder. The valve is changing the air flow in the
opposite direction by the small time delay. In this time the pneumatic cylinder
piston moves upward due to changing of the air flow direction. This air flow
direction is controlled by the D C valve. Below attached figure 6.1 and 6.2 is the
actual photograph
of automatic ramming
machine with all
attached components.

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Fig 6.1
Automatic
Ramming
Machine (Stationary
Position)

Fig 6.2 Automatic Ramming Machine (Actuated Position)

The rammer can be handled by an operator without feeling uneasiness. No

separate skill is required to operate this rammer. The operation is quick and hence
it is a time saving one. The operation is easy and consumes less cost. Due to the
above reasons it finds its extensive application in manufacturing industries. It has
an extensive application in both large scale and small scale industries because of
its economy and easy handling. Strength uniform ramming of sand is obtained by
this rammer. The time consumption for ramming is reduced greatly. It has
following advantages;

1. Skilled labour is not required.

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2. Easy operation
3. It can be transported easily from one place to another
4. Since dismantling and assembling is simple.
5. It reduces more labour for ramming operation.
6. Maintenance is easy.

CHAPTER VII- CONCULSION AND FUTURE SCOPE

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Uniform ramming of sand is obtained by this rammer. The time

consumption for ramming is reduced considerably. It eliminates more labour for
ramming operation and hence the labour cost is reduced. Skilled labour is not
required to operate this machine. Transportation of this machine is easy.
Maintenance is also easy, the reduction of production time and elimination of
more labour for ramming operation reduce production cost, and thereby the
economy is greatly achieved.

ADVANTAGES

a. The pneumatic is more efficient in the technical field.

b. Quick response is achieved
c. Simple in construction
d. Easy maintenance and repair
e. Cost of unit is very less
f. No fire hazard problem due to overloading
g. Continuous operation is possible without stopping

DISADVANTAGES

a. Silencer must be used while compressing the air

b. High torque cannot be obtained
c. Load carrying capacity is low

APPLICATIONS

a. This machine is very useful for small scale industries

b. These machines can be used to Garbage Pressing, paper industries also.

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c. All industrial application

CHAPTER VIII- REFERENCES

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1. Design data book- P.S.G. Tech.

2. Pneumatic hand book- R.H.Warrning, Machine tool design hand book –
Central machine tool Institute, Bangalore.
3. Strength of materials- R.S.Kurmi
4. Manufacturing Technology- M.Haslehurst
5. AUTOMATIC PNEUMATIC RAMMING MACHINE, CHINMAY
ANEGUNDI et. all, International Journal of Mechanical And Production
Engineering, ISSN: 2320-2092, Volume- 2, Issue-9, Sept.-2014

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