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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
PDFaid.com#1 pdf solutions
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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
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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.
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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
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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
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CHAPTER # 1
IDENTIFICATION OF PROBLEM
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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 .
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1.3 Project Timeline
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CHAPTER # 2
INTRODUCTION
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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:
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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.
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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.
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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.
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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
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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.
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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
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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.
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CHAPTER # 3
DESIGN OF PNEUMATIC PRESS
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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
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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.
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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)
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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:
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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.
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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
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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)
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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.
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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
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CHAPTER # 4
FABRICATION AND TESTING
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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.
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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;
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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.
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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.
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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.
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Circuit Diagram
Pneumatic Line Diagram Compressor
Filter
Air Flow
Regulator Guage
Solenoid
Valve 1
Solenoid
Valve 2
Solenoid
Valve 3
Relay
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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 /-
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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
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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.
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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).
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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.
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d. Pressure Application
Set the timer to 1.5 minutes and push the start button.
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e. Extraction
When the stroke is completed, push the ejector lever and extract the component.
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CHAPTER # 5
CONCLUSION
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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.
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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
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Appendix
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