pneumatic bench press

Project Title

To Design and Manufacture a Semi Automatic

Pneumatic Bench Press

Project Supervisor Mr. Aftab Iqbal

Group Members

Syed Sarmad Iftikhar

Asim Dil Nawaz Khan

Adnan Sarwar

Fida Hussain

Department of Mechanical Engineering WAH ENGINEERING COLLEGE, WAH CANTT

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AKNOWLEDGEMENT

Initiating with the Name of Almighty ALLAH, the Lord of Universe,

who is the entire source of all knowledge and wisdom endowed to

mankind.

The authors wish to express their deepest thanks and gratitude to

HOD Mechanical Lt. Col (R) Hafiz Sibghat Ullah Fazil for his moral

support, guidelines, and pain taking task of reviewing this report.

Our project advisor Engr. Aftab Iqbal, Eminent Educationist &

Researcher, generously helped us in the Design and Manufacturing

of Pneumatic Bench Press and accomplishment of this report. His

valuable suggestions, and guidelines kept us abreast with latest

knowledge and Engineering practices invogue so vital for our project.

All this made it possible to maintain the timeline and complete the

project with ease otherwise it would have been a far more arduous

labor.

We would also like to place on record our appreciation for all those

who contributed by anyway in completion of this project.

Last but not the least, we are highly indebted to our parents and no

words can describe our gratitude we owe to them for their moral

support and prayers, that helped us to reach this mile stone.

Authors


ABSTRACT

This Semi Automatic Pneumatic Bench Press is Designed for

Pressure Die / Moulding of small common use components, out of

Thermosetting Plastic, like Buttons, Knobs, or window handles. The

powder is filled in the Die / Mould and then adjusted specific

pressure required for the component is exerted by the pneumatic

press on the Die / Mould, for a Specific Time. Concurrently Die

heating to melt the powder is achieved through separate electrical

heating circuit. Synchronization and system integration is so carried

out to keep the component cycle time as minimum possible for

economical production.

This Pneumatic press becomes more useful for numerous specific

applications where hydraulic Press can’t be used. For instance

Explosive powder pressing in Detonators can only be accomplished

through this kind of Pneumatic Bench Press.


TABLE OF CONTENTS

List of Topics: Page No:

CHAPTER # 1

IDENTIFICATION OF PROBLEM

1.1 Problem Identification.......................................................................................... 8

1.2 List of components ............................................................................................... 8

1.3 Project Timeline ................................................................................................... 9

CHAPTER # 2

INTRODUCTION

2.1 History of press .................................................................................................. 11

2.2 Hydraulic Press .................................................................................................. 11

2.3 Pneumatic Press ................................................................................................. 11

2.4 Applications of Pneumatic Press ........................................................................ 13

2.5 Selection Criteria................................................................................................ 13

.1 Cost ................................................................................................................. 13

.2 Size and Weight .............................................................................................. 13

.3 Type ................................................................................................................ 13

.4 Material ........................................................................................................... 13

2.6 Basic Components of Pneumatic Press .............................................................. 14

.1 Pneumatic Cylinder ........................................................................................ 14

.2 Press Body...................................................................................................... 15

.3 Mold or Die .................................................................................................... 15

.4 Control Panel.................................................................................................. 17

CHAPTER # 3

DESIGN OF PNEUMATIC PRESS

3.1 Force................................................................................................................... 20

3.2 Pneumatic Cylinder Design ............................................................................... 21

3.3. Column Design ................................................................................................. 23

3.4 Die ...................................................................................................................... 23


3.5 Design Validation .............................................................................................. 25

.1 Column Design ............................................................................................... 25

3.5.2 Die ................................................................................................................... 27

3.6 Material Procurement Chart ............................................................................. 28

CHAPTER # 4

FABRICATION AND TESTING

4.1 Pillars ................................................................................................................. 30

4.2 Steel Plates ......................................................................................................... 31

4.3 Frame ................................................................................................................. 32

4.4 Die and Its Fixture.............................................................................................. 33

4.5 Control Panel...................................................................................................... 34

4.6 Cost Analysis ..................................................................................................... 36

4.7 Project Diagram ................................................................................................. 37

4.8 Installation Procedure ....................................................................................... 38

4.9 Safety Instruction ............................................................................................... 38

4.10 Operating Procedure ........................................................................................ 39

CHAPTER # 5

CONCLUSIONS

5.1 Conclusions ........................................................................................................ 44

REFRENCES ......................................................................................................... 45

APPENDIX ............................................................................................................. 46


CHAPTER # 1

IDENTIFICATION OF PROBLEM


1.1 Problem Identification

To Design and Manufacture a Semi Automatic Pneumatic Bench Press having

working / line pressure of 0.7 MPa ( 103 psi /7 bar), as available at WEC Labs , and

make it’s Dedicated use to apply Requisite adjusted pressure for a specific time to

produce small components out of Thermosetting plastic Moulding by way of

incorporating Die heating system as well. Ensure Design in built manual ease of Die

feeding and Extraction of component for economic considerations, with Emphasis on

followings: -

1. Design of:

a) Pneumatic Cylinder

b) Supporting Frame

c) Plates

d) Die / Mould

2. Design Validation

3. Design economy & optimization

4. Material selection & procurement

5. Fabrication & testing

1.2 Components that can be manufactured

Some components that can be manufactured by using pneumatic press and different

Die / Moulds are given below.

Sr. # Item Temperature Setting Time Compression

Pressure

1. Snap Button coat 165oC 1min 10 MPa

2. Knob Burner 170oC 2min 10 MPa

3. Handle window 180oC 4min 10 MPa

The Snap Button coat has been selected to make dedicated use of press and

corresponding Die / Mould Design .


1.3 Project Timeline


CHAPTER # 2

INTRODUCTION


2.1 History of Press

A machine press is a device designed to apply very specific force for specific time to

form, shape through hot or cold working, or compress solids and shearing of

materials. Machine presses range in size from very small units that are operated by

hand, to large Hydraulic or pneumatic powered industrial units used in manufacturing

and assembly line applications. For example, a simple hand-press can be used to

remove a bearing from a machine assembly, or a large press may be used to

stamp sheet metal into the curved shapes used to construct automobile bodies.

Most modern machine presses use a combination of electric motors and hydraulics to

achieve the necessary pressure. Along with the evolution of presses ,came the

evolution of Dies / Moulds Design and Metallurgy as well to achieve high volume,

qualitative & economical production .Presses are generally hydraulic or pneumatic

depending on type of work.

2.2 Hydraulic Press

Hydraulic presses are fundamentally chambers filled with some sort of liquid, usually

oil. A piston presses into the chamber, causing the oil to shift position. Since the

chamber is sealed, the oil exerts pressure on another, larger piston or base plate,

which is in turn pressed downwards.

Some types of Hydraulic Press are given as follow:

1. Shop Press: A simple frame, fabricated from steel, containing a bottle jack

or simple hydraulic cylinder. Good for general-purpose work in the auto

mechanic shop, machine shop, garage or basement shops, etc. Typically 1 to

30 tons of pressure,, depending on size and expense. Classed with engine

hoists and engine stands in many tool catalogs.

2. Forging Press: A forging press reforms the work piece into a three

dimensional objects not only changing its visible shape but also the internal

structure of the material.

3. Punch Press: A punch press is used to form holes.

4. Blanking Press: These presses are used for blanking purposes in all kind of

sheet metal.

2.3 Pneumatic Press

Pneumatic presses are controlled by the manipulation of pressurized air. The air is

forced into a tube which fills with the air and applies pressure that causes the press to

move downwards. Once the press' stroke is finished, the air is evacuated through

valves, and mechanical springs cause the pump to move upwards again.

Some types of Pneumatic Press are given as follow:


1. Stamping Press: A stamping press is a machine press used to shape or cut

metal by deforming it with a die. It generally consists of a press frame, a

bolster plate, and a ram.

2. Press Brake: A press brake is a special type of machine press that bends

sheet metal into shape. A good example of the type of work a press brake can

do is the back plate of a computer case. Other examples include brackets,

frame pieces and electronic enclosures just to name a few. Some press brakes

have CNC / PLC controls and can form parts with accuracy to a fraction of a

millimeter. Bending forces can exceed 4,000 KN (900,000 lbf).

3. Powder Compacting Press: This type of press is used along with a mould

to compact thermosetting powder.

4. Coining Press: A coining press can cut coins from a sheet metal.

The comparison between Hydraulic and Pneumatic presses is appended here under: -

Hydraulic Pneumatic

1. Uses an incompressible fluid /

hydraulic oil , as working fluid.

2. Used where High Pressure

applications are required.

3. Pressure ranges up to 35 – 70

MPa (5,000 to 10,000 psi).

4. Most hydraulic presses generally

consist of bigger components and

use heavy Die /mould. Hence

difficult to handle during

operation and Maintenance.

5. Hydraulic system is quite

complex to operate.

6. Any leakage in the system causes

pollution.

1. Uses compressed air as working

fluid

2. Used where Low Pressure

applications are required.

3. Pressure ranges up to 0.7 MPa

(100 psi) more or less.

4. Pneumatic applications generally

use smaller components hence

they are easy to handle.

5. Pneumatic system is easy to

operate.

6. Pneumatic system is clean and

environmental friendly.


2.4 Applications of Pneumatic Press

Pneumatic design of press suites working pressure up to 1 MPa (145 psi) whereas for

high pressure hydraulic design presses are more favorable

1. Cutting

2. Coining

3. Drawing

4. Blanking

5. Stamping

6. Detonator Filling

7. Powder metallurgy compaction techniques

2.5 Selection Criteria

The proper selection depends on following factors.

2.5.1 Type

The type of press depends upon manufacturing speed and maintenance. For example

pneumatic press move ten times faster than hydraulic press. There are also differences

as far as maintenance. Hydraulic presses require more care, and have more

components attached to them for this purpose, making them more complicated.

Pneumatic presses require less time and energy for maintenance.

2.5.2 Size and Weight

It mainly depends upon the type of application that is needed from the press. Presses

can be of small as well as large capacity.

2.5.3 Material

A variety of Steels are available from which the press can be manufactured, but

normally Mild Steel is used for making different parts of the press.

2.5.4 Cost

Budgetary limitations usually play an important role in the selection of pneumatic

press. The operation and maintenance cost of the pneumatic press are also important

consideration in assessing the overall cost.


2.6 Basic Components of Pneumatic Press

The basic components of the pneumatic press are:-

1. Pneumatic Cylinder

2. Press body

Specific usage of press depends on a type of tool/die design compatible with

press.

a. Pneumatic Cylinder

Pneumatic cylinders (also known as linear actuators) are mechanical devices which

utilize the power of compressed air to produce a force in a reciprocating linear

motion. Pneumatic cylinders use the stored potential energy of compressed air, and

convert it into kinetic energy as the air expands in an attempt to reach atmospheric

pressure. This air expansion forces a piston to move in the desired direction. The

piston is a disc or cylinder, and the piston rod transfers the force it develops to the

object to be moved. We prefer to use pneumatic cylinder because they are quieter and

cleaner.

Types

Although pneumatic cylinders will vary in appearance, size and function. Main two

types of pneumatic cylinder are:-

1. Single acting cylinder

2. Double acting cylinder

1. Single Acting Cylinder: Single acting cylinders (SAC) use the pressure

imparted by compressed air to create a driving force in one direction (usually out),

and a spring to return to the "home" position.

2. Double Acting Cylinder: Double Acting Cylinders (DAC) uses the force of air

to move in both extends and retracts strokes. They have two ports to allow air in,

one for outstroke and one for in stroke.


b. Press Body

Pneumatic cylinder, mold or die and all other accessories are mounted on the press

body. It is supported by four rods. These four rods are used to support two plates on

which pneumatic cylinder is mounted. Material used for manufacturing press body is

mild steel.

Properties of Mild Steel

Mild steel is the most common form of steel because its price is relatively low while it

provides material properties that are acceptable for many applications. Low carbon

steel contains approximately 0.05–0.15% carbon and mild steel contains 0.16–0.29%

carbon; therefore, it is neither brittle nor ductile. Mild steel has a relatively low tensile

strength, but it is cheap and malleable; surface hardness can be increased thorough

carburizing. It is often used when large quantities of steel are needed, for example as

structural steel. The density of mild steel is approximately 7.85 g/cm3 (7850 kg/m

3 or

0.284 lb/in3).

Young's modulus for mild steel is 210,000 MPa (30,000,000 psi).

c. Mould or Die

A die is a specialized tool used in manufacturing industries to cut or shape material

using a press. Like molds, dies are generally customized to the item they are used to

create. Forming dies are typically made by tool and die makers and put into

production after mounting into a press. The die is a metal block that is used for

forming materials like sheet metal and plastic. For the forming of sheet metal, such as

automobile body parts, two parts may be used, one, called the punch, performs the

stretching, bending, and/or blanking operation, while another part, called the die

block, securely clamps the work piece and provides similar, stretching, bending,

and/or blanking operation. The work piece may pass through several stages using

different tools or operations to obtain the final form. In the case of an automotive

component there will usually be a shearing operation after the main forming is done

and then additional crimping or rolling operations to ensure that all sharp edges are

hidden and to add rigidity to the panel. Die operations are often named after the


specific type of die that performs the operation. For example a bending operation is

performed by a bending die.

Types of Dies

Operations are not limited to one specific die as some dies may incorporate multiple

operation types. There are different types of dies; some of them will be discussed

here.

1. Compound Die: Compound dies provide multiple metal stamping features

with each stroke of the press.

2. Deep draw die: A Deep Draw Die is suitable for metal stamping parts

when the material is required to flow or stretch, as opposed to being bent or

formed

3. Form Die: Form Dies are probably the most common metal stamping dies

used in the industry.

4. Progressive die: Progressive dies provide different stations for operations

to be performed.

5. Rotary Die: A rotary die is a circular shaped die that may be used in any

manufacturing field. Two dies are used, one has cutting and creasing rules,

while the other acts as the anvil.

6. Steel Rule die: Steel-rule dies, also known as cookie-cutter dies, are used

to cut sheet metal and softer webs, such as plastics, wood, cork, felt, fabrics,

and cardboard.

Die Components

The main components of die toolset are:-

1. Die Block

This is the main part that all the other parts are attached to.

2. Guide / Back gage

These parts are all use to make sure that the material being worked on always goes

in the same position, within the die, as the last one.

3. Pilot

This is used to keep the material being worked on in position.

4. Punch plate

This part holds and supports the different punches in place.


5. Setting Block

This part is used to control the depth that the punch does into the die.

6. Stripper plate

This is used to hold the material down on the Blank/ Pierce Die and strip the

material off the punches.

d. Control Panel

Control panel consists of timer, solenoid valves, air flow regulator, thermostat and

limit switches.

1. Timer A timer is a specialized type of clock. A timer can be used to control the sequence

of an event or process. Whereas a stopwatch counts upwards from zero for

measuring elapsed time, a timer counts down from a specified time interval, like

an hourglass. Timers can be mechanical, electronic (quartz), or even software as

all modern computers include digital timers of one kind or another. When the set

period expires some timers simply indicate so (e.g., by an audible signal), while

others operate electrical switches, such as a time switch, which cuts electrical

power.

2. Solenoid valves

A solenoid valve is an electromechanical valve for use with liquid or gas. The

valve is controlled by an electric current through a solenoid in the case of a two-

port valve the flow is switched on or off; in the case of a three-port valve, the

outflow is switched between the two outlet ports. Multiple solenoid valves can be

placed together on a manifold. Solenoid valves are the most frequently used

control elements in fluids. Their tasks are to shut off, release, dose, distribute or

mix fluids. They are found in many application areas. Solenoids offer fast and safe

switching, high reliability, long service life, good medium compatibility of the

materials used, low control power and compact design.

2. Air Flow Regulator

Air flow regulators are suitable on many applications where a constant flow of air

is required. The flow regulator maintains a constant differential pressure across an

orifice to maintain a flow rate that is independent of the inlet or outlet pressure.

The orifice size is controlled with a needle valve thus providing simple adjustment

of the required flow rate.

3. Thermostat

A thermostat is the component of a control system which regulates

the temperature of a system so that the system's temperature is maintained near a

desired set point temperature. The thermostat does this by switching heating or


cooling devices on or off, or regulating the flow of a heat transfer fluid as needed,

to maintain the correct temperature.

4. Switches

A switch is an electrical component that can break an electrical circuit,

interrupting the current or diverting it from one conductor to another.


CHAPTER # 3

DESIGN OF PNEUMATIC PRESS


Statement

To find Required Force, Cylinder Bore and To Design the Columns.

Given Data:

Working Pressure = 0.7 Mpa

Before designing pneumatic press, following parameter must be calculated.

3.1 Force

The term force is related to cylinder sizing. Calculation of cylinder sizing for Thrust

and Pulling force is to be done. The Theoretical Thrust (outstroke) of a cylinder is

calculated by multiplying the effective area of the piston by the working pressure. The

effective area for thrust is the full area of the cylinder bore “D.

Thrust = F = 𝛑𝐃

𝟒

𝟐* P ................................(1)

Where

D= Cylinder Bore

P= Pressure

F= Thrust

The theoretical pull (in stroke) of a cylinder is calculated by multiplying the effective

area of the piston by the working pressure. The effective area for pull is reduced by

the cross section area of the piston rod diameter “d”.

Pull = F = 𝛑(𝐃𝟐−𝐝𝟐)

𝟒 * P ................................(2)

Where

D= Cylinder Bore

d= Piston Rod diameter

P= Pressure

F= Pull

The grade of Bakelite being used has the setting pressure of 10 MPa, and the

available working / line pressure is 7 bar. Now calculating the bore diameter of the

cylinder,

Bakelite compression Pressure = 10 MPa


Dia of Button D = 16.4 mm

Area of Button A = πD

4

2

= π∗ 16.402

4

= 211.06 mm2

Pressure P = 𝐹𝐴

Force F = P * A

As required pressure to compact Bakelite powder is 10 Mpa and

(10 MPa = 10 N/mm2)

Force F = 211.06 * 10

F = 2110.62 N

3.2 Pneumatic Cylinder Design

a. Cylinder Bore

Pressure P = 𝐹

𝐴

As available pressure is 7 bar

(7 bar = 0.7𝑁

𝑚𝑚 2 )

Area of cylinder A = 2110 .62

0.7

= 3015.17 mm2

Cylinder Area A =.πD

4

2

Cylinder Bore D = 61.96 mm

Selection of Pneumatic Cylinder

*Since pneumatic cylinders available in the market have standard Bore sizes

like 60,65,70mm,as such we procured 65mm bore Dia pneumatic cylinder by

applying 5% safety factor.


Specifications of the procured cylinder

1. External Dia= 70mm

2. Internal/Bore Dia= 65mm

3. Shaft travel= 250mm

4. Maximum Pressure = 12 bars or 1.2 N/mm2

b. Force Calculation

Thrust F = πD

4

2* P

In the formula, P is divided by 10 to convert bar to Newtons per square millimetre

(1 bar = 0.1 N/mm2)

= 𝛑∗ 𝟔𝟓𝟐 ∗𝟕

40

= 2323 N

As there are four pillars so this force will be divided on the four pillars such as

Force on each pillar =.2323

4

= 581 N

(Including the weight of plate above the pillars, this force becomes around 600N)


3.3 Column Design

The maximum air pressure at which the pneumatic cylinder can operate is 12 bars

/174 Psi so calculating force that will be produced

Force F = πD

4

2* P

= π∗65

4

2*

12

10

= 3982 N

σyield for Mild Steel is 248 MPa or 248 N/mm2.

Area A = 𝐹

𝑃

= 3982

248

= 16.06 mm2

A = πD

4

2

Diameter D = 4.52 mm

After multiplying this diameter with factor of safety i.e. 3

Diameter D = 4.52 * 3

= (13.56 mm)

Area A = 144.47 mm2

3.4 Die

For component manufacturing component die is required. So die for producing a Snap

Button was designed.

a. Material used for Manufacturing Die

A Special Purpose Grade of Tool Steel or simply referred as Die Steel is used for

manufacturing of Mould. Its properties are mentioned below:


Density (1000

kg/m3)

Elastic Modulus

(GPa)

Poisson's Ratio

Thermal Expansion

(10-6

/K)

Thermal Conductivity

(W/m-K)

Tensile Strength

(MPa)

Yield Strength

(MPa)

Hardness (Brinell 3000kg)

7.72-8.0

190-210

0.27-0.3 9.4-15.1 19.9-48.3 640-2000 380-440

210-620

Table 3.1

b. Material used for Manufacturing Items

Bakelite is a condensation polymer of phenol and formaldehyde. Bakelite is widely

used for making moulded products. It was the first thermo set plastic invented that

held its shape after being heated. Electrical insulators are made of Bakelite because of

its properties of insulation and heat resistance.

A few components that are being manufactured from this plastic by using Air

Compression Technique are:

1. Plastic Jewelry

2. Cameras, Telephone Case

3. Clocks, Radios

4. Insulating Handles for pans

5. Billiard Balls

Bakelite Grades

Sr. # Type Classification Grade Features and Applications

1

General

Type(A)

Household

(R)

PF2A1-

131

Suitable for making handles or spare parts

of daily household articles, inclusive of

Snap Buttons.

2 Electric

Appliance (D)

PF2A2-

131

Enhanced electric leakage resistance, can be

used to make insulating structures for low

voltage electric appliances.


3

PF2A2-

141

With better electric leakage resistance than

D131, can be used to make insulating

structures for low voltage electrical

appliances.

4

PF2A2-

151

With better electric leakage resistance than

D141, can be used to make insulating

structures for low voltage electrical

appliances.

5

Hot and

Humid (H)

PF2A4-

JS

Similar to PF2A2, but with good water

absorbency, suitable for making insulating

structure for low voltage electrical

appliances and meters in hot and humid area.

6

Special

Type

Heat-resisting

(C)

PF2C3-

431

Heat-resisting, suitable to make insulating

structure of low voltage, igniter or spark

plug of mobiles and motorcycles.

7

Electrical

Type (E)

PF2E6-

985

Low medium waste, improved absorbency,

suitable to make insulating parts for

telecommunication and radio, igniter of

mobiles and motorcycles.

8 Wear-

resisting (S)

PF2S1-

5802

High wearable property, used to make spare

parts for gas meters.

Table 3.2

Properties of selected grade PF2A1-131 ……………………… (Ref. Sr. # 1, Table 3.2)

Volumetric coefficient _ 2. 7 - 3.0

Relatively density _ 0. 60 - 1. 40

Flexueal strength MPa 70 - 140

Impact strength with gap KJ/(m2) 1. 5 - 1. 8

Impact strength without gap KJ/(m2) 4. 5 - 7. 0

Dissipation factor (1mhz) 0. 02 - 0. 08

Hot distortion temperature oC 140 - 180

Water absorbency mg 15 - 35

Contractility _ 2% - 3%

Fluidity mm 80 – 140


3.5 Design Validation

3.5.1 Column Design

σyield for Mild Steel is 248 MPa.

Allowable Stress σallow = σyield / F.O.S

= 248

3

= 82.67 Mpa

(N/mm2)

a. Buckling Load

Maximum load = (σallow x Area)

= 144.47 x 82.67

= 11.94 KN

The maximum load exceeds the force exerted by the cylinder i.e. 600 N on each pillar,

hence the design is safe.

It was more economical to buy mild steel rod of 1.25” diameter. Now calculating

maximum load that pneumatic cylinder will exert on these rods

Dia of Pillar = 1.25”

Now,

The maximum allowable stress on one pillar of the press body:-

σyield for Mild Steel is 248 MPa

σallow = σyield / F.o.S

= 248 / 5

= 49.6 Mpa

(N/mm2)


Area of Pillar

A = 791.7 mm2

Maximum Load = (σallow x Area)

= 39.3 kN

3.5.2 Die

Main aim was to Design and Manufacture working model of pneumatic press.

However, in view of economic aspect die for single Snap Button instead of multiple

Buttons was designed and manufactured.

The contraction allowance for Bakelite is 2.5% hence while designing the die; the

dimensions of the component are kept slightly bigger than the original dimensions to

compensate for the contraction that occurs when the component cools down to room

temprature.


Male Mating Part

Female Mating Part

3.6 Material Procurement Chart

Sr

#

Part name Material QTY Dimensions Cost

PKR

01 Pneumatic Cylinder - 01 - 11750

02 Sheet Metal Mild Steel 02 15” x 15” 6000

03 Angle Arm Mild Steel 01 18’ 2500

Plywood board 01 6’ x 6’ 500

04 Rods Mild Steel 04 7’ (Dia = 1.25”) 4000

Machining Charges 15000

05 Mold + Heater Die Steel 01 5” x 5”

(Thickness=1.5”)

5000

06 Panel - - 5000

07 Total 49750


CHAPTER # 4

FABRICATION AND TESTING


Fabrication process was started in 2nd

week of May.

During fabrication phase following processes were used to manufacture parts of

pneumatic press.

1. Cutting

2. Threading

3. Welding

4. Drilling

5. Grinding

6. Painting

4.1 Pillars

Mild steel rod of 6 ft length and dia 1.25” were procured. These rods were cut and

were divided into four equal parts of 16” length. Then threading on both ends of the

pillars was done and finally chrome plating was done to save them from rusting.


4.2 Steel Plates

Two steel plates of dimension 12” x 12” and 1” thick were procured. Then grinding of

these plates was done to make their surface smooth. Four holes were drilled in upper

plate to support the pillars and 5 holes to hold the pneumatic cylinder. Four holes

were drilled in lower plate to support pillars and one hole to fasten the die and then

the plates were painted.

These plates were coated with red oxide layer to protect these plates from corrosion;


These plates were finally painted with green colour.

4.3 Frame

The angle arm was cut in to the designed length and then welded together to form the

supporting frame. Holes were drilled for supporting the plates, pillars and panel. Then

grinding of inner and outer surface was done and finally paint was applied.


4.4 Die and Its Fixture

The mold was made from steel by a Die Maker. Then a fixture for the mold was cut

and grinded. Two holes were drilled ant a nut was welded in the center to attach it

with the shaft of the pneumatic cylinder.

*The fixture guides the male part of die on the pillars in order to keep it aligned

towards the female die part.


4.5 Control Panel

Then control panel was made having circuitry that would turn the press on/off and

control the actuating valves of the pneumatic cylinder.


Circuit Diagram

Pneumatic Line Diagram Compressor

Filter

Air Flow

Regulator Guage

Solenoid

Valve 1

Solenoid

Valve 2

Solenoid

Valve 3

Relay


4.6 Cost Analysis

Sr.

#

Item Material Source Estimated

Cost

Actual Cost

1 Pneumatic

Cylinder

Local Rs. 12,000/- Rs. 11,750/-

2 Frame (Raw

Material +

Machining)

Mild Steel Local Rs. 15,000/- Rs. 12,500/-

3 Mold Stainless

Steel

Local Rs. 8,000/- Rs. 4,000/-

4 Control Panel Local Rs. 4,000/- Rs. 5,000/-

5 Transportation Rs. 10,000/-

(Appx.)

Rs. 43,250 /-


4.7 Project Diagram

1 Pneumatic Cylinder 5 Control Panel

2 Columns 6 Ejector

3 Die 7 Air Filter

4 Frame 8 Pressure Guage

1

5

2

4

6

7

3


4.8 Installation Procedure

The pneumatic press should be positioned and leveled on a flat surface like a

workbench. Operate able air pressure required from compressor is 100 psi or 650 kPa.

Lubricate the guide way of the die so that it can move smoothly.

4.9 Safety Instructions

Instructions should be read before operating equipment.

1. Ensure that the machine is operated just in a safe and functional way.

2. Before working on pneumatic parts for check up or repair, disconnect the

Pneumatic Press from the air line.

3. Keep work area clean.

4. Cluttered areas and benches invite accidents.

5. Keep work area well lighted.

6. Keep children away.

7. All visitors should be kept at a safe distance from work area. Do not force equipment.

8. It will do the job better and safer at the rate for which it was designed.

9. Wear proper apparel.

10. Do not wear loose clothing, gloves, neckties, rings, bracelets or other jewelry

to get caught in moving parts.

11. Always use safety glasses. Everyday eyeglasses only have impact resistant

lenses, they are not safety glasses.


4.10 Operating Procedure

Following procedure should be followed to operate this pneumatic press:

a. Air Inlet

Connect the air supply with the air compressor unit and make sure it is fasten tightly

and pressure gage is indicating the required pressure (100 psi).


b. Preheating

Set the thermostat at 200oC, the timer at 5 minutes and push the start button.

c. Feeding

Before the feeding process lubricate the die then pour the measured quantity of

Bakelite powder into the female part of the die and set the temperature to 170oC.


d. Pressure Application

Set the timer to 1.5 minutes and push the start button.


e. Extraction

When the stroke is completed, push the ejector lever and extract the component.


CHAPTER # 5

CONCLUSION


5.1 Conclusion

The press can be used for various applications like Stamping, Blanking,

Cutting, etc.. The Press body is capable of supporting a Pneumatic

Cylinder of a bigger capacity. Further on the feeding system can also be

made automatic instead of manual.


References

1. Britannica.com: Pneumatic Press

2. Buzzle.com: Mild Steel

3. Degarmo, Black & Kohser 2003, pp. 430–431

4. eHow home: Pneumatic Press vs. Hydraulic Press

5. Jimtrade.com: Hydraulic Press vs. Pneumatic Press

6. Newworldencyclopedia.org: Bakelite

7. Wikipedia: Die_(manufacturing)

8. Wikipedia: Pneumatic Cylinder


Appendix

pneumatic bench press

Documents