jig design
TRANSCRIPT
i
DESIGN PROJECT REPORT
1. Design of Latch jig for Oil Seal Cap
2. Low Cost Automation in Power press
Submitted by
ABHIMANYU PANDEY (20082601)
K.C.RAKESH ROSHAN (20082639)
M.KARTHIK (20082627)
In partial fulfilment for the award of the degree
Of
BACHELOR OF ENGINEERING
IN
PRODUCTION ENGINEERING
DEPARTMENT OF PRODUCTION TECHNOLOGY MADRAS
INSTITUTE OF TECHNOLOGY CAMPUS, CHENNAI-44
ANNA UNIVERSITY CHENNAI
NOVEMBER 2011
ii
ANNA UNIVERSITY: CHENNAI 600 025
BONAFIDE CERTIFICATE
This is to certify that this project report is the bonafide work of
ABHIMANYU PANDEY (20082601)
K.C.RAKESH ROSHAN (20082639)
M.KARTHIK (20082627)
This project has been completed and submitted to The Department of
Production Technology, M.I.T, Anna University, Chennai in partial fulfilment
of the requirements for the award of the degree of BACHELOR OF
ENGINEERING in Production Engineering. Certified further that to the best of
our knowledge, the work reported herein does not form part of any thesis or
dissertation on the basis of which a degree of award was conferred on an earlier
occasion on these or any other candidates.
MR. A. JOTHILINGAM, Mr. S.GAJENDRAN,
PROFESSOR AND HEAD , ASSOCIATE PROFESSOR,
Dept. of Production Engineering, Dept. of Production Engineering,
Madras Institute of Engineering, Madras Institute of Engineering,
Anna University, Anna University,
Chennai- 600 044. Chennai- 600 044.
ii
ACKNOWLEDGEMENT
We wish to thank Prof. A. JOTHILINGAM, Professor and Head of
Department, Department of Production Technology, Madras Institute
of Technology, Anna University for granting permission and encouraging us
to carry out this project work.
It gives us immense pleasure to express our deep sense of gratitude to
our beloved guide, Mr. S. GAJENDRAN, Associate Professor, Department
of Production Technology, Madras Institute of Technology. We thank for his
act of benevolence on us.
We would like to convey our heartfelt thanks to Mr. S.
CHOODESWARAN, our project coordinator, Department of Production
Technology for his constant support throughout the course of the work.
We also thank our faculty advisor, Mr. P.GANESH, Assistant
Professor, Department of Production Technology, who has been extremely
supportive during the course of the project.
ii
ABSTRACT
The component which we selected for our design project is Oil Seal Cap. This
is used in Transfer case to prevent the Oil leak from the shafts. The
constructional aspects of this component are that it has got a circular shape with
a center hole that will fit the oil seal. The outer periphery of the oil seal cap has
got four symmetrical semi circular projections. A Hole has to be drilled in each
of the semi circular projection. These holes will become the passage for the nuts
so that this Oil Seal Cap can be fixed to the Transfer case. We are designing a
Jig for performing Drilling operation in each of the four Semi Circular
projections. The Clamp, Locators and pins used for construction of the jig are
explained below.
A Drill Jig is to be designed for the drilling of holes in semi circular projections
for inserting nuts through it. Nest locator made of Cast Iron is used for locating
the work piece. A Template made of Mild Steel is used for covering the upper
portion of the work piece. This Template has got four Renewable type drill
bushes for guiding the drill bit. Two pins are used to locate the work piece at
desired position and to provide constraint for rotation of work piece. Two
Clamping screw made of Mild Steel is used to provide adequate Clamping
force. Thus a Jig is being designed for accurate drilling of holes in Oil Seal Cap
used in Transfer Case.
INTRODUCTION
In metalworking and woodworking, a jig is a type of tool used to control the
location and/or motion of another tool. A jig's primary purpose is to
provide repeatability, accuracy, and interchange ability in the manufacturing of
products. A jig is often confused with a fixture; a fixture holds the work in a
fixed location. A device that does both functions (holding the work and guiding
a tool) is called a jig.
ii
An example of a jig is when a key is duplicated; the original is used as a jig so
the new key can have the same path as the old one. Since the advent
of automation and computer numerical controlled (CNC) machines, jigs are
often not required because the tool path is digitally programmed and stored in
memory. Jigs may be made for reforming plastics.
Jigs or templates have been known long before the industrial age. There are
many types of jigs, and each one is custom-tailored to do a specific job. Many
jigs are created because there is a necessity to do so by the tradesmen. Some are
to increase productivity, to do repetitious activities and to do a job more
precisely.
Some types of jigs are also called templates or guides. Jigs include machining
jigs, woodworking jigs (e.g. tapering jig), welders' jigs, jewelers' jigs, and many
others.
Jigs and fixtures are production-work holding devices used to manufacture
duplicate parts accurately. The correct relationship and alignment between the
cutter or other tool, and the work piece must be maintained. To do this, a jig or
fixture is designed and built to hold, support and locate every part to ensure that
each is drilled or machined within the specified limits. Jigs and fixtures are so
closely related that the terms are sometimes confused or used interchangeably.
The difference is in the way tool is guided to the work piece.
A jig is a special device that holds, supports or is placed on a part to be
machined. It is a production tool made so that it not only locates and holds the
work piece but also guides the cutting tool as the operation is performed. Jigs
are usually fitted with hardened steel bushings for guiding drills or other cutting
tools.
A drill jig is a device for ensuring a hole to be drilled, tapped or reamed, in a
work piece will be machined in proper place. Thus, instead of laying out the
ii
position of each hole on each work piece with the aid of square, straight edge,
and centre punch, the operator uses a jig to guide the drill into the proper place.
Jigs makes it possible to drill ream and tap holes at much greater speed and with
greater accuracy that holes are produced by conventional method. Another
advantage is that skilled workers are not required when the jigs are used.
Responsibility for the accuracy of hole location is taken from the
operator and given to the jig. The hole pattern should be within the
required tolerance in each part. This is the basis for the interchangeable
part concept that has made Eli Whitney’s name so prominent in the
industrial history.
The term jig should be used only for devices employed while drilling reaming
or tapping holes. It is not fastened to the machining on which it is used and may
be moved around the table of the drilling machine to bring each bushing directly
under the table. Jigs physically limit and control the path of the cutting tool.
DRILL JIG
A drill jig is a type of jig that expedites repetitive hole center location on
multiple interchangeable parts by acting as a template to guide the twist drill or
other boring device into the precise location of each intended hole center. In
metalworking practice, typically a hardened drill bushing lines each hole on the
jig plate to keep the tool from damaging the jig.
Drill jigs started falling into disuse with the invention of the jig borer.
Since the widespread penetration of the manufacturing industry by
CNC machine tools, in which servo controls are capable of moving the tool to
the correct location automatically, the need for drill jigs (and for the jobs of
the drill press operators who used them) is much less than it previously was.
Different types of Drill jigs:
ii
1. Plate jigs or channel jig.
2. Angle plate jig.
3. Box jig.
4. Leaf or latch jig.
5. Sandwich jig.
6. Trunnion jig.
7. Jig for multi spindle machines.
8. Template jig
9. Universal Jig
MAIN ACCESSORIES OF JIG
Locators,
Clamps,
Bushing.
LOCATORS
The various forces acting upon the work piece during a machining
operation necessitate its means of clamping position after it has been correctly
located. Configuration is the major factor in determining how your work piece
will be located. Examination of a typical work piece from the metal industries
shows that the configuration is determined by a combination of flat, circular,
and irregular surfaces. A flat surface is one that lies in one plane and circular
surface that is made from the segment of the circle. The inside surface of the
circle segment may be used to form a concave surface. Irregular surfaces are
not flat or circular; they may or may not be geometrical true. Each of the three
proceeding surface types may be rough of finished.
CLAMPS
ii
The methods of clamping depend upon the type of locating device and in turn
it depends upon the original machining operation and the configuration of the
part. Once the work piece is located it is necessary to press it against the
locating surface and hold it there against the forces acting upon it. Tool
designer refer to this action as clamping and mechanism used for this action are
known as clamps. Numerous types of clamps have been developed. It is
sometimes difficult to choose between two types when designing a specific tool.
In general, the choice of clamp is largely determined by work piece and the king
of operation.
BUSHINGS
The Bushings are used to guide drills, reamers and other cutting tools into
the proper position of the work piece; they are made of tool steels or hardened
to RC 60-64, to provide a wear resisting surface. They are precision made. The
outside being ground and the inside either ground or lapped to within 0.0003
inch concentricity.
GENERAL CONSIDERATION IN THE DESIGN OF DRILL
JIGS
LOCATION
Locating surface should be as small as possible.
Sharp corners in the locating surface must be avoided.
Locating pins should be easily accessible and visible the operator.
Adjustable locators should be provided for rough surface.
CLAMPING
ii
Clamping should always be arranged directly above the points
supporting the wo
Quick acting clamps should be sued wherever possible.
Position of clamps should provide best resistance to the cutting tool.
Clamps should allow rapid loading and unloading of the components.
CLEARANCE
Adequate space in the form of channel base should be provided to
enable the metal chips to be blown clear easily.
STABILITY AND RIGIDITY
Jigs should possess high rigidity to withstand the cutting force.
A lease four legs should be provided for the jigs for the stability.
HANDLING
No sharp corners are present and provide lifting points if it is heavy.
Make the equipment as rigid as is necessary for the operation.
PARTS OF JIGS
1. Jig body
2. Location Plug
3. Locking screw
4. Latch plate
5. Drill bush
6. Clamping pad
7. Wing nut
8. Workpiece
ii
SPECIFICATION (FROM DESIGN DATA BOOK)
1. Wing nut:
A wing nut is a type of nut with two large metal "wings," one on each side, so it
can be easily tightened and loosened by hand without tools. It is sometimes
called a thumbscrew. It is used to lock the swinging plate.
d=M8
e=40
l=35
l1=20
2. Drill Bush:
A drill bushing, also known as a jig bushing, is a tool used in metalworking jigs
to guide cutting tools, most commonly drill bits. Other tools that are commonly
used in a drill bushing include counter bores, countersinks, and reamers. They
are designed to guide, position, and support the cutting tool. It is made of Oil
hardened Non Shrinking Tool steel (OHNS)
OHNS:
It is also named as high carbon or high chromium steel. This type of steel is oil
hardened from 60 to 64 RC. It contains 1% carbon, 0.5 to 2 % tungsten and 0.45
to 1% chromium. These are used for fine parts such as taps, hand reamers,
engraving cutters etc. It is also used for fine intricate shape press tools.
Type: Fixed bush
No’s: 4
ii
Material: Oil hardened Non-shrinking tool steel
d1=12
l1=20
l2=16
d2=18
d3=22
With tolerances
Inner diameter: 12F7Φ
Tolerance: +0.000 to +0.012 mm
Outer diameter: 18H6Φ
Tolerance: -0.000 to -0.018 mm
3. Locator:
Locators are used to locate the components. The locator system should facilitate
easy and quick loading of the work piece. Here location plugs with stepped
diameter are used to enable locating from the internal surfaces. As pointed out
earlier, locating a work piece from an internal diameter is the most-efficient
form of location. The locater in this case has been originally cast along with jig
body and is an integral part of it. The stepped surfaces are milled and finished to
satisfaction so that the work piece when it is seated on to it is in a balanced
state.
ii
The bigger step supports the job while it is being drilled whereas the smaller
step enters the internal cavity of the job to arrest the translation in the plane
under consideration.
Step 1 diameter: 80 mm
Step 2 diameter: 50 mm
5. Jig body
Width of jig plate= 180 mm
Length of plate= 2xTp + Lw + allowance
Where,
Tp- thickness of jig plate=10 mm
Lw-Length of work piece= 130 mm
Length of jig was calculated to be= 180 mm
Height of jig=hw+Tp+clearance
Clearance of the ductile material= 0.5 X drill diameter
Height of jig body was calculated to be=110mm
6. Clamping screw with pressure pad:
A clamp screw is an adjustable closure with a threaded cylinder and flared head.
Many clamp screws have a similar appearance to a common bolt when they are
detached from the clamp assembly. Clamp screws are often tightened by hand
for fine adjustments to the tension of a clamp. The size of a clamp opening
gradually decreases as the clamp screw is twisted farther into place. Speed of
operation, operator fatigue and strategic positioning are other important
considerations for choosing a clamping system.
ii
From design data book 5.104
D1=88 mm
D2=11.2 mm
D3= 23 mm
D4= 28 mm
H= 20 mm
7. Jig Feet:
The entire body of jig should not be rest on the machine table directly.
Therefore jig feet are used at the bottom of the jig. The jig feet are either cast
with the jig body or detachable or welded to the base. They are usually
hardened and ground to have flat bottom. In this case the jig feet are cast as an
integral part of the jig body.
CALCULATION:
DETERMINATION OF AXIAL THRUST:
Axial thrust = 630 K z d s^0.85 N
where,
K = material factor
z = number of cutting edges in contact
d = diameter of drill, mm
s = feed, mm
ii
From P.S.G DESIGN DATA BOOK (page nos. 12.1, 12.2, 12.22),
K = 1.88 (for Steel)
z = 2
d = 10mm
s = 0.125mm
Axial thrust = 630 * 1.88 * 2 * 10 * (0.125^0.85) N
Axial thrust = 4044.84 N.
DETERMINATION OF POWER:
Power = (2.82 * 10^-6) * K n z (d^2) * (0.15 + 7.87s) kW
where,
n = speed, rpm
From P.S.G DESIGN DATA BOOK (page nos. 12.1, 12.2, 12.22),
n = 700 rpm
Power = (2.82 * 10^-6) * 0.55 * 2750 * 2 * (10^2) * [0.15 + (7.87 * 0.1)] kW
Power = 0.850 kW
COST ESTIMATION
SNo Name Amount (Rs)
1 Material 1500
2 Wing nut 150
ii
3 Clamp 150
4 Milling 200
5 Welding 200
Total 2200
CONCLUSION
The leaf jig is designed for an oil seal cap which is used in transfer cases of
automobiles and four holes of 10 mm diameter are drilled.
As explained, it could be seen that this is a manual jig which as well is simple.
This can very well be put into use for mass production also, if used in a proper
way. Automatic jigs or similar manual jigs with different locators and clamping
are very costly. Viability and elimination of tedious procedures are the order of
the day. Hence a cost-effective and easy-to-handle drill jig has been designed to
produce four holes on the given work piece of required dimensions.
REFERENCES
1. Jig and fixture design
-by Edward Hoffman
2. Website: nptel.iitm.ac.in
LOW COST AUTOMATION IN A POWER PRESS
ii
2.1 NEED FOR AUTOMATION
The aim of this project is to design a hydro-pneumatic power press using
low cost automation.
This project mainly emphasizes on reduction of working time and labor
cost. The working time should be reduced in order to increase the productivity
of any industry. Labor cost reduction is also very important nowadays, so that
even small scale industries can afford to go for automation.
The press that we have designed has proved to provide large tonnage
capacity in small size. It also decreases the fatigue of the operator by reducing
the consumption of human work. This device also ensures safety of the
operator’s hand as Two Hand Safety system is included in the circuit.
Pneumatic power is used in this press for all movements as air is a cheap
power source and also it is readily available. Pneumatics also ensures safer
operation and ease of fabrication of components. For Punching operation alone
hydraulic power is used in order to obtain very high pressure and to avoid
fluctuation.
2.2 HYDRO PNEUMATIC PRESS
Many Industries are using manual presses like toggle presses, fly presses,
arbor presses for blanking, piercing, riveting, bending, embossing, etc., It is also
used for forming two or more components in Manufacturing Industry.
ii
Manual operation of these presses gives fatigue to the operator, since he
has to exert physical energy. Due to this the efficiency also gets lowered down.
Considering these facts, the Hydro pneumatic press has been designed,
which will reduce the wastage of human energy and increase the production
rate.
We know that hydraulic system is applied to attain precise movement.
But in Pneumatics, due to the compressibility characteristic of the air, the air
cylinder tends to slow down on meeting an increase in load and to accelerate or
jump forward when working against a load which suddenly decreases. So,
pneumatic actuators are not suitable for the finer movement of the machine tool
movements.
These problems can be solved by combining the two fluids – air and oil.
By the use of these two media, the quick action of air and the smooth high
pressure action of oil blend ideally to provide a concept for the design of new
Hydro-Pneumatic press. It should be made clear that although the two fluids are
used in the circuit they are not to be mixed. In fact every precaution is taken to
keep them separated.
The basic laws of Hydraulic and Pneumatics are Pascal’s law, Boyle’s
law, Charles’ law, and Gay lussac’s law. These laws are obeyed by our
Hydro-Pneumatic press.
2.3 ADVANTAGES OF FLUID POWER SYSTEMS;
The fluid power drives are more compact than a mechanical dirve
because it eliminates the need for links like cams and gears.
ii
Multiplication of small forces to achieve greater forces for performing
work.
It easily provides infinite and step-less variable speed control which is
difficult to botain from other drives.
Accuracy in controlling small or large forces with instant reversal if
possible with hydraulic systems.
Constant force is possible in fluid power system regardless of spcial
motion requirements, whether the work output moves a few millimeters
or several meters per minute.
As the medium of power transmission is a fluid, it is not subjected to
any breakage of parts as in a mechanical transmission.
The parts of hydraulic system are lubricated with the hydraulic liquid
itself.
COMPARISON OF PNEUMATIC AND HYDRAULIC
SYSTEM:
For automation, most of the trade-offs favour pneumatic actuators
since pneumatic system have low weight and leakage co-effificent.
The most significant difference between hydraulic and pneumatic
system is compressibility, which usually signifies disadvantage.
Further, the stiffness or impedence of the pneumatic system can be
controlled more easily than with hydraulic counterpart.
Moreover, a pneumatic system allows easy energy storage. The
mechanical energy for automation can be stored as compressed air at a
high pressure. A regulator can expand the stored air to proper working
pressure.
ii
2.4 CONSTRUCTION OF HYDRO-PNEUMATIC PRESS:
Basically the hydro-pneumatic press consists of the following parts,
Hydro-pneumatic cylinder
Cylinder mounting plate
Supporting pillars
Base plate
Pneumatic control systems
Electrical control panel
Pneumatic pipelines
1. Hydro-pneumatic cylinder:
The main pressing operation of the press is given by this cylinder and
hence it is also known as actuating cylinder. This hydro-pneumatic cylinder is
the active component in the press and it consists of the below parts,
Cap nut
Top end plate
Top barrel
Primary stroke piston
Top partition block
Middle barrel
Secondary stroke piston
By pass rod
Bottom partition block
Bottom barrel
Power stroke piston
Bottom end plate
ii
O-rings
2. Cylinder mounting plate:
It is a mild steel block which is capable to withstand a high pressure
caused by the hydro-pneumatic cylinder. It consisting of drilled hole of
diameter 32mm at extreme ends for accommodating the supporting pillars. It
also consists of drilled hole at the centre of the plate for the reciprocation of the
power stroke piston and for fixing the cylinder to the base structure. This plate
is of 38mm thickness.
3. Supporting pillars:
The supporting pillars are made up of mild steel of diameter 32mm. the
whole weight of the cylinder and the cylinder mounting plate will act on these
shafts. Usually the raw material is of greater diameter and then it is turned to
the required diameter.
4. Base plate:
This is the plate where the job will be placed and the operation is
performed. For facilitating the clamping operation a T-slot has been provided.
This block is of thickness 40mm and cross-section 350mm x 240mm. It
consists of holes for accommodating the supporting pillars.
5. Pneumatic control systems:
This system includes various DCV’s, FRL unit, Mufflers, etc. They are
used to regulate and direct the flow of air in the respective pipelines.
Solenoid Operated Direction Control Valve:
A very common way to actuate a spool valve is by using a solenoid.
When the electric coil (solenoid) is energized it creates a magnetic force that
ii
pulls the armature in to the coil. This causes the armature to push to the push
rod to move the spool. There are no seals around the armature to wear or restrict
its movement; this allows all the power developed by the solenoid to be
transmitted to the valve spool without having to overcome seal friction. Impact
loads which frequently cause pre mature solenoid valve failure are eliminated
with construction. Thus both the DCV’s used here are solenoid operated.
WORKING:
The Working of the Hydro-Pneumatic press comprises of four stages.
Start Position
Low Force High Speed approach
High force short travel power stroke
Low force Rapid retraction
Start Position:
In this stage all the pistons are in their respective TDC positions. The air
is sent into the port 3 of the press and the air from both 1 and 2 ports are
exhausted. The oil is filled into top barrel through the bore in the primary stroke
piston rod. Simultaneously oil gets filled in the bottom barrel through the
bypass rod. In this position, the oil remains static and no pressure is exerted to
it. The punch head remains in the maximum distance from the base plate.
Low Force High Speed Approach:
When the DCV A is actuated, the compressed air flows through the port
1. This results in the extension of the Primary stroke piston. So the primary
ii
stroke piston makes the oil to exert pressure on the Power stroke piston. Thus,
the rapid extension of the punch head takes place.
High Force Short Travel Power Stroke:
When the DCV B is also actuated along with the DCV A, the compressed
air is made to enter into the port 2. This extends the secondary stroke piston.
The rod of this secondary stroke piston enters into the bore in the Power stroke
piston. The same force is exerted in the very small area which results in a very
high pressure. This very high pressure is capable of doing the punching
operation.
Low Force Rapid Retraction:
When both the solenoids are de-energized, both the DCV’s come to their
offset mode, thus exhausting the ports 1 and 2, and sending air into the port 3.
This results in the retraction of all the three pistons to their initial positions.
Two Hand Safety Operation:
Push Buttons are provided to energize the solenoids. When the first
button is pressed, Rapid extension takes place. By keeping the first button
down, if the second button is also pressed, punching operation takes place. If
both the buttons are released, then the retraction takes place. If only button 2 is
pressed, the ram goes to its initial position. Thus, to make the press working, the
worker has to use both of his hands. So, safety is ensured for the worker’s
hands.
2.6 PNEUMATIC ELEMENTS SPECIFICATIONS
Differential Pressure : 2 to 10 bar
ii
Design : Disk Seat.
Type of Reset : Spring
Standard Nominal Flow rate : 900 1/min
Weight : 280 grams
Housing : Die Cast Aluminum
Seals : Polyurethane
FRI, max supply pressure : 1Mpa/10 bar
Drain : Automatic
Regulator exhaust capacity : Less than 0.25 SCFM
Max supply pressure 10 bar
Solenoid type : 2/2 solenoid
Stainless Steel
Temperature Range 10 to 55 deg C
Power 24V DC
ii
2.8 SPECIFICATIONS
Size : 350mm x 250mm x 1000mm
Material : All steel body
Input air : 6.2 kg/cm2
Electric power : For timer 12V DC or 24V DC
For solenoid 48V AC or 220V AC
Bed to Ram Height : 150mm
Bed Size : 350mm x 240mm
Bed Plate Thickness : 40mm
Stroke Length : 72mm
2.9 CIRCUIT EXPLANATION
ii
The DCV A is two position five port solenoid operated spring offset
valve. The port 1 and 3 of the cylinder are connected in the offset position of the
valve A. The DCV B is two position three port solenoid operated spring offset
calve, which connects the opening 2 of the cylinder in the offset port condition
initially. Input source to both the valves are given in a single line. An
emergency unit is set up which consist of a solenoid actuated two position two
port DCV. The input unit includes compressor, FRL unit, and pressure
regulator. The exhaust port of each DCV is connected with muffler.
Circuit performance:
When DCV A is energized, hence it shifts to position of the valve. Thus
the pressurized air supply is given to opening 1 of the cylinder and the air
exhaust from the opening 3 of the cylinder. When DCV B is energized and
hence supply is given to opening 2 of the cylinder. When both the DCV’s are in
de-energized condition, the supply is given only to opening 3 and hence it helps
in retraction of the piston. When the emergency valve is energized the supply
to the entire unit is stopped immediately.
Relay diagram:
The electrical diagram is called the relay diagram. PB1 (NO) is a push
button when pressed, SOL A gets actuated and hence extension takes place.
When PB2 (NO) is pressed, SOL B gets actuated and hence power stroke takes
place, when stop button is NC condition. When it is pushed, the 1-CR gets de-
energized, this breaks 1-CR and de-energizes it, and hence SOL C is de-
activated.
ii
2.12 CALCULATION OF TONNAGE:
Material Factor:
For Mild Steel : 0.95
For Aluminium : 0.5
ii
For High Carbon Steel : 1.4
Shear Factor:
For Flat Bottom Dies : 1
For Concave Surface Dies : 0.6 to 0.9
Perimeter:
According to the geometry of the surface to be punched
Eg : For Circular Hole =3.14 x diameter
Tonnage =Material Factor x Shear Factor x Perimeter x Thickness x 0.102
=0.95 x 1 x 3.14 x
SALIENT FEATURES:
Fast Action
Compact, Light Weight and vibration free pneumatic valves
Force and speed infinitely adjustable
Energy efficient: 50% to 70% raising over equivalent hydraulic and
pneumatic systems
Low cost up to 60% cheaper than equivalent hydraulic press
Safety: true non tie down, interlocked two handed safety operation.
Optimally adapted to individual requirements due to its modular
design
High flexibility and economic efficiency due to short changeover
times
ii
Easy and accurate positioning of tools due to the precise alignment
between ram bore and the ground press table
The force output pre selector allows reducing the pressure for the
power stroke to 1 bar / 15.4 ps i. This reduces the nominal press force
to 1/6 of the maximum force.
No mechanical compression spring in the cylinder of the hydro-
pneumatic system, providing a long service life
Low maintenance resulting in high productivity
Long service life and precision due to maintenance-free guides
Tool protection due to smooth switchover from rapid approach stroke
to power stroke
Additional safety when using heavy tools due to the optional ram drift
lock device for retention of ram in home position.
Low noise level (< 75 dBA)
APPLICATIONS:
Assembling, riveting, staking, swaging, crimping, marking, numbering,
deforming, stamping, dismantling
High force over a short distance
2.13 COST ESTIMATION:
Cylinder expenses :
Solenoid operated DCVs :
FRL Unit
Air Compressor
ii
Other expenses
Total Cost
2.14 CONCLUSION:
All Basic expectations of today’s industry such as automation increased production, low cost, and appreciable quality are met by this Hydro-Pneumatic press. Low cost is proves by using Pneumatic source and getting the same tonnage capacity of Hydraulic press.
A single compressor is enough to run two or more Hydro-Pneumatic presses. The safety of the worker is also ensured by employing the Two Hand Safety System in the fluid circuit.
This press is also portable and reliable as it has very small machine structures and can give the large tonnage. So this press is expected to meet today’s Industrial Manufacturing scenario.
REFERENCES
1. “Fluid power with applications” by “Anthony Esposito” , Pearson education, Inc. 2000
2. “A text book of production technology” by “D. O.P.Khanna”, Dhanpat Rai publications, 2005
3. “PSG Design Data Book” by “Faculty of Mechanical Engineers”, Kalaikathir publications, 2005
4. “Hydraulic and pneumatic controls” by “Srinivasan R”, Vijay Nicole Private Ltd.
5. “A textbook of Machine Design” by “Khurmi R S, Gupta J K”, S. Chand & company Ltd, 2005.
6. “Press tool Design and Construction” by “Prakah H.Joshi”, Wheeler Publishing, 1996.
7. “Pneumatic Technical Data”, Trade and Technical Press Ltd, England.