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FABRICATION OF PNEUMATIC
SHEET CUTTER
Mechanical engineeringSection A, Group no. A9
26th February, 2016Guided By: Prof. D.N Thatoi
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Ansita MohantyJyoti PandaBasundhara PradhanShubhendu VermaRohit RanjanSmurtipiyush Sahoo
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Mission Statement
Use of pneumatically controlled Sheet metal cutter in an efficient way.
Fabrication of pneumatic sheet cutting machine with minimization of cost as well as size.
Making the machine automatic and user friendly so that it will be easier for operation.
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Introduction What is a Sheet metal Sheet metal is simply a metal formed
into thin and flat pieces. The thickness of sheet is called its gauge. The thickness above 6mm falls in Plate category.
There are many metals that can be made into sheet metal like Aluminum, Brass, copper, steel, tin etc. For decorative uses sheet metals of Silver, gold, platinum are also used.
Sheet metals are used in Car bodies, medical tables, roofs for buildings etc.
Use of sheet metal are now days in furniture, shelves or cupboards.
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Schematic representation
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How Sheet Metal is cut: The cutting process is done by applying Shear Force Due to application of shear Force,
the stress in the material will exceed the ultimate shear strength and the material will fail and separate at the cut location.
Shearing force is applied by 2 blades one above and one belowthe sheet.
The upper blade delivers a quick downward blow to the sheetmetal that rests on the lower blade.
The upper tool penetrates on thesheet causing the shearing andmaterial failure.
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Pneumatically Operated
Sheet cutter
Hand Operated Sheet Metal
cutter
Pictures
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CUSTOMER SURVEY FORM
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Customer Name: Rabindra PradhanAddress: Ashirvad Furniture, Laxmi Sagar
Interviewer: SmrutiDate: 15/02/2016
Questions Customer Statement Interpreted Need Importance Typical Uses
Cutting of aluminum plates
Both Industrial and general purpose should be there
Very important
Cutting of mild steelCutting of thick paper in industry
LIKES
Handy in operation No laborious worker needed, also no use of manual work which ensures safety
Very importantNo skilled user needed
Easy to usePower consumption is lessUse of pneumatic control reduces Human effort
Ease of Operation Important
Reduced cost compared to Hydraulics
Suitable for small Industries
Genuine factor for small industries
Easy maintenance compared to spring operated and rack & pinion operated
Effectiveness throughout the year
Depends on the use
DISLIKES
Lesser Sheet Thickness Limitation of Sheet type i;e sheet metal is very thin
Much needed
Less width of sheet
Not suitable for large scale production or Batch production
Comparably less use for mass production industries
Not needed
Suggested Improvement
Safety should be ensured, Operation should be easy and it should cut the sheet effortlessly
Try to make the thickness more, obtain the cutting operation comfortably.
Important
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CUSTOMER NEEDS
No. Of Occurrences (Out of 20)
Weightage
Efficient Cutting 16 0.8Reduce Human effort 14 0.7
Occupy Less space 15 0.75Low Cost 13 0.65
Less Maintenance 10 0.5Automatic Operation 11 0.55
Reduce Power Consumption 7 0.35Safety During Machining 10 0.5
Portability 15 0.75More thickness of Sheet 9 0.45
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Customer Need Statements and Importance Ranking
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SELECTED NEEDS FOR REDESIGNThe following functions were selected for redesign:
Improvisation in Cutting Operational Suitability Portability Occupying Less space
PROBLEM DEFINITION (Our Objective)
A Pneumatic sheet cutter has to be designed and developed. In order to reduce human effort in manual operated machine our machine should ensure automatic operation, finer cutting. In addition to that the product should be small in size so that it is easier to carry the product from one place to another.
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FUNCTIONAL DECOMPOSITIONThe approaches for developing functions that were followed are Fast method
Objective: To relate one sub-function to another and so to increase the product value.
Subtract Operate Procedure MethodObjective: To disassemble each component from the product
and analyze the effect in a logical way. Activity diagram and Function structure method Objective: To describe the overall process description of customer from buying the product to operating it. Also to describe the flow paths from start of machine to end of the action. Functional hierarchical decomposition Objective: To trace the flow of energy, material and signals from the bottom to the top level.
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SMOOTH OPERATION
TRANSMITMECHANICAL
ENERGY
PRODUCE CUTTING FORCE
PISTON CYLINDER
COMPRESS IT PNEUMATICALLY
LUBRICATIONDAMP
VIBRATIONS
TRANSMIT FORCE TO
CUTTING BLADE
ALIGNMENT OF WORK PIECE
LOCOMOTION OF CUTTING BLADE
OVER SHEET METAL
CUT THE SHEET
PROVIDE AIR
GENERATE NOISE
HOW? WHY?
REDUCE NOISE
ELIMINATELEAKAGE
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PORTABILITY LINEAR SMOOTH OPERATION
FAST Method
AIR COMPRESSOR FRL CONTROL UNIT PNEUMATIC CYLINDER
CUTTER BLADE ASSEMBLY
Compressed Air can’t be Generated
Compressed air flow can’t be regulated
Pressurized air can’t be expanded
No up-down motion of blade for cutting
Main source of energy i;e Compressed air Pressure can’t be given to Cylinder
The FRL (Filtration- Regulation- Lubrication) process can’t be performed
As expansion wont take place, piston movement can’t occur
Moving blade can’t be pushed down
Energy can’t be stored in the Cylinder to perform mechanical work
Connecting rod can’t Reciprocate
Shearing operation can’t take place
The Rod can’t push the Upper blade
Also no support arms to hold and secure the sheet
SUBTRACT AND OPERATE APPLIED TO THE PNEUMATIC SHEET CUTTER
Cut The Metal Sheet
Input Metal Sheet
Input Air Pressure Hold
Reciprocate Connecting
Rod
Permit Finer Cut
Fix the Metal Under Cutter
Provide Indication for Cutting
Accept it through FRL Control Unit
Transmit Pressure to Connecting
Rod
Support the Pneumatic
Cylinder
Convert Compressed
Air Pressure to Mechanical
work
Reciprocation of Cylinder
Rod
Movement of the Blade
Fix The Pneumatic Cylinder On
the Machine
SOP Diagram
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Purchase Transport in Package
Unpackaged
Main Frame for Support
StorePrepare to Cut the Sheet
Flow of compressed
air to the Cylinder
Motion of connecting
rod
Cutting of Sheet metal
Throw away Debris
Process descriptions as Activity Diagrams for Sheet cutter product
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Open System
Close System
Support Cutting blades
Execute Cutting
Store the split sheet Raw Metal sheet
Pressure force
AirSheet uncut
Cutting force
Release air
Sheared metal sheet
Provide elect. to compressor
Generation of compressed
air
Stores compressed
air
Flow of air to FRL unit
Compression & storage
Release into pneumatic
cylinderCut the sheet
FRL UnitExpansion of
air inside cylinder
Motion of connecting
rod to movement of
blade
Shearing over the sheet
Electrical energy
Compressed air pressure
Air
Uncut Sheet
Sheared metal
K.E of blade
Cutting of metal as required
Desired cut
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Cut the metal sheet
Supply power
Use electricity
Supplyelectricity
Generate compressed
air
Automatic work
Use different sheets
Accept sheets Hold sheets
Movement of upper
blade
Feel easier operation
Use regulating
switch
Convert elet. To
compressed air
Apply K.E to blade
Reciprocate connecting
rod
Convert air Pr. to K.E Expansion of
compressed air in cylinder
Regulate air flow
Withstand air flow
Motion of connecting
rod
Use FRL control unit
Use tubes to allow air
flow
Provide compressed air
Hierarchical Decomposition
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Conclusion Thus our concept is complying to the demands of the
customer whose use the products as well as those who are new.
The latent needs of customers, which they were not able to reciprocate properly is estimated successfully.
The individual functions were studied thoroughly and were evaluated by each group member.
Further study will involve more analysis about the product and comparison of similar products available in the market.
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References Ajit Kumar Singh, Harpreet Singh and 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: Vol. 4 Issue 03, March-2015
A.S. Aditya Polapragada & K. Sri Varsha , “Pneumatic Auto Feed Punching, cutting and Riveting Machine “, International Journal of Engineering Research & Technology (IJERT) Vol. 1 Issue 7, September - 2012 ISSN: 2278-0181.
P.M.Pradhan, “Experimental Investigation and Fabrication of Pneumatic Cutting tool”, International Journal of Innovative Research in Science, Engineering and Technology, Vol. 2, Issue 6, June 2013.
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