Vimalreport

DESIGN AND FABRICATION OF FABRIC CUTTING

MACHINE

A PROJECT REPORT

Submitted By

G.SAMI DURAI (08MER092)

B.SATHISH KUMAR (08MER102)

R.VIMALANATHAN (08MER119)

in partial fulfillment of the requirements

for the award of degree

of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

SCHOOL OF BUILDING AND MECHANICAL SCIENCES

KONGU ENGINEERING COLLEGE

(Autonomous)

PERUNDURAI, ERODE – 638 052

NOVEMBER 2011

DEPARTMENT OF MECHANICAL ENGINEERING

KONGU ENGINEERING COLLEGE

(Autonomous)

PERUNDURAI ERODE – 638052

NOVEMBER-2011

BONAFIDE CERTIFICATE

This is to certify that the Project report entitled “DESIGN AND FABRICATION OF

FABRIC CUTTING MACHINE” is the bonafide record of project work done by

G.SAMI DURAI (08MER092)

B.SATHISH KUMAR (08MER102)

R.VIMALANATHAN (08MER119)

in partial fulfillment of the requirements for the award of the Degree of Bachelor of

Engineering in Mechanical Engineering in Anna University, Coimbatore during the

year 2011 - 2012.

SUPERVISOR HEAD OF THE DEPARTMENT

Date:

Submitted for the end semester viva voce examination held on ___________

INTERNAL EXAMINER EXTERNAL EXAMINER

iii

DECLARATION

We affirm that the Project Report titled “DESIGN AND FABRICATION OF

FABRIC CUTTING MACHINE” being submitted in partial fulfillment of the

requirements for the award of Bachelor of Engineering is the original work carried out

by us. It has not formed the part of any other project report or dissertation on the

basis of which a degree or award was conferred on an earlier occasion on this or any

other candidate.

Date:

G.SAMI DURAI (08MER092)

B.SATHISH KUMAR (08MER102)

R.VIMALANATHAN (08MER119)

I certify that the declaration made by the above candidates is true to the best of my

knowledge

Date: SUPERVISOR

iv

ACKNOWLEDGEMENT

We thank our beloved Correspondent Thiru. R.K.VISHWANATHAN and all

the members of Kongu Vellalar Institute of Technology Trust at this high time for

providing us with plethora of facilities to complete my project successfully.

We take privilege to express my profound thanks to our beloved Principal

Prof. S. KUPPUSWAMI who has been a bastion of moral strength and a source of

incessant encouragement to us.

We express our sincere thanks to Dr. K. KRISHNAMURTHY, Dean, School of

Building and Mechanical Sciences, for his valuable guidance and suggestions.

We express our sincere thanks to Dr. P. NAVANEETHAKRISHNAN, Head of

the Department Mechanical Engineering, for his valuable guidance and suggestion.

We take immense pleasure to express our heartfelt thanks to our beloved

project guide, Mr. M.VIJAY ANAND for his valuable suggestions, excellent guidance

and constant support provided all through the course of our project.

We thank our project coordinator Dr. V.HARIHARAN and review committee

members for their valuable suggestions for completion of the project successfully.

We also thank the teaching and non teaching staff members of Mechanical

Engineering Department and all our fellow students who stood with us to complete

our project successfully.

v

ABSTRACT

Nowadays, the textile industry is the fastest growing sector in India. For such a

sector, the productivity and the quality of the product should be enhanced. In this

project, we enhance the product quality of the textile industry. The fabrics cutting is

the major process carried out in textile industries. At present, the cutting process in

the textile industry is carried out manually by using cutting and tools, this result in

improper cutting of fabric materials. The main reason for the above problems is due to

fatigue nature of the employees and improper measuring and cutting. To overcome

these problems, an automated fabric cutting machine is designed and fabricated. In

this machine, the fabric material is fed between the rollers. The measurement of the

required length is fed in the microcontroller as an input. As soon as the desired length

is obtained, the roller will stop its rotation and the metal cuter which is placed

horizontally will cut the fabric material. The function of the cutter is attained with the

help of the pneumatic circuit. The machine is mainly designed and fabricated to avoid

the improper alignment of the fabric and increase the productivity and quality of the

product.

vi

TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

ABSTRACT v

LIST OF TABLES viii

LIST OF FIGURES ix

LIST OF NOMENCLATURE x

1 INTRODUCTION 01

1.1 COMPONENTS USED 02

1.1.1 Power Supply 02

1.1.2 Step down Transformer 02

1.1.3 Voltage Regulator 02

1.1.4 Capacitor 03

1.1.5 Resistor 03

1.1.6 Relay 03

1.1.7 Microcontroller Interfacing with

Motor 03

1.1.8 Roller 04

1.1.9 DC Motor 04

1.1.10 Flow Control Valve 05

1.1.11 Five-Port / Two-Way

Directional Valve 05

1.1.12 Pneumatic Cylinder 05

2 LITERATURE REVIEW 07

3 PROBLEM DEFINITION 10

vii

4 DESIGN AND DEVELOPMENT 11

4.1 DESIGN PHASE 11

4.1.1 Design of Bearing 11

4.1.2 Cutting Mechanism 11

4.1.3 Clamping Mechanism 12

4.1.4 Design of Electrical Circuit 12

4.1.5 Design of Pnuematic Circuit 13

4.1.6 Design of Setup 15

4.2 OPERATIONAL FEASIBILITY 16

4.3 ECONOMIC FEASIBILITY 16

5 FABRICATION PROCESS 17

5.1 PROCESS DESCRIPTION 17

6 RESULT AND DISCUSSION 19

6.1 ADVANTAGES 20

7 CONCLUSION 21

APPENDIX 22

REFERENCES 23

viii

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

4.1 COST ESTIMATION 16

ix

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1.1 BLOCK DIAGRAM OF A REGULATED

POWER SUPPLY SYSTEM 02

1.2 INTERFACING OF

MICROCONTROLLER 04

4.1 DIMENSION OF PNEUMATIC CYLINDER 11

4.2 BLOCK DIAGRAM OF ELECTRICAL

CIRCUIT 13

4.3 SEQUENCIAL CIRCUIT DESIGN 14

4.4 MODEL OF FABRIC CUTTING

MACHINE 15

5.1 PARTS AND DIMENSION OF BASE

SETUP 18

6.1 FABRICATION PROJECT 19

x

LIST OF NOMENCLATURE

SYMBOLS NOTATIONS

A Area, cm2

D Diameter of the shaft,cm

d1 Bore diameter ,mm

d2 Piston rod diameter, mm

F Force,N

L Bearing length,cm

L1 Stroke Length of cylinder,mm

N Speed of the shaft,rpm

P Pressure,bar

DCV Direction control valve

PS Push Button

SOL Solenoid

V Voltage

1

CHAPTER 1

INTRODUCTION

In this technological and sophisticated world, automation becomes an

important factor in every field. So in every industry, automation of machines is

promoted to increase the accuracy and quality of the products. Insufficient in human

resource also leads to automation of machines in the industry. Thus for every industry

automation is a necessary one which includes textile industry. As textile industry is

the fast growing industry in India which contributes about 14% to the country's

industrial output and about 17% to export earnings. But still there is less accuracy and

man power is more in one field that is none other than textile industries.

In textile industry, fabric material is the only raw material. The cutting operation

of fabric materials is done by high cost machine in large scale industries. But in small

scale industries, the cutting operation is performed by manually i.e., by using cutting

tools. In small scale industries, the cutting operation is done manually because the

industry cannot afford huge amount for the cutting machine. This process of cutting

requires skilled person for cutting the fabric materials. Sometimes accuracy of the cut

cannot be obtained by the above stated process. This leads to wastage of fabric

materials

The major problem in these industries are improper measuring and cutting of

fabric materials, this leads to wastage of materials and reduce the productivity which

intern increases the cost of the product. . If the above problems are rectified at the

low cost, then the productivity of the products can be increased. To overcome this

problem, an Automatic Fabric Cutting Machine is designed and fabricated, which is

used to cut the fabric material for the required length accurately.

The project proceeds with fabrication of cutting machine at low cost which is an

automated one. The components used in the projects are electrical components,

pneumatic components and mechanical components. They are described in the next

section.

2

1.1 COMPONENTS USED

The components used in the project are described as follows.

1.1.1 Power Supply

A power supply is a device that supplies electrical energy to one or more

electric loads. The term is most commonly applied to devices that convert one form of

electrical energy to another, though it may also refer to devices that convert another

form of energy to electrical energy. A regulated power supply is one that controls the

output voltage or current to a specific value; the controlled value is held nearly

constant despite variations in either load current or the voltage supplied by the power

supply's energy source. The Figure 1.1 shows the block diagram of a regulated power

supply system.

Figure 1.1 Block Diagram of a Regulated Power Supply System

1.1.2 Step down Transformer

Step down transformers convert electrical voltage from one level or phase

configuration usually down to a lower level. The transformer takes in the high voltage

at a low current and puts out a low voltage at a high current. In this project 220 V AC

is converted to 5-12 V DC.

1.1.3 Voltage Regulator

A voltage regulator is an electrical regulator designed to automatically maintain

a constant voltage level. A simple voltage regulator can be made from a resistor in

series with a diode. The power supply of most PCs generates power at 5 volts but

most microprocessors require a voltage below 3.5 volts. The voltage regulator's job is

to reduce the 5 volt signal to the lower voltage required by the microprocessor.

Typically, voltage regulators are surrounded by heat sinks because they generate

significant heat.

3

1.1.4 Capacitor

A capacitor is a passive two-terminal electrical component used to store

energy in an electric field. It is used in this circuit to help keep the voltage regulator’s

output voltage constant over time. The rate of change of the voltage across a

capacitor is proportional to the current flowing out of it divided by the capacitance.

Therefore, the larger the capacitor, the small changes in voltage at the output of the

regulator over time for a fixed current drain.

1.1.5 Resistor

A linear resistor is a linear, passive two-terminal electrical component that

implements electrical resistance as a circuit element. The current through a resistor is

in direct proportion to the voltage across the resistor's terminals. Thus, the ratio of the

voltage applied across a resistor's terminals to the intensity of current through the

circuit is called resistance.

1.1.6 Relay

A relay is an electrically operated switch. Many relays use an Electromagnet to

operate a switching mechanism mechanically, but other operating principles are also

used. Relays are used where it is necessary to control a circuit by a low-power signal,

or where several circuits must be controlled by one signal. The first relays were used

in long distance telegraph circuits, repeating the signal coming in from one circuit and

re-transmitting it to another. Relays were used extensively in telephone exchanges

and early computers to perform logical operations.

1.1.7 Microcontroller Interfacing With Motor

The AT89C51 is a low power, high performance C-MOS 8-bit microcomputer

with 4k bytes of flash programmable and erasable read only memory (PEROM). The

device is manufactured using Atmel’s high-density nonvolatile memory technology

and is compatible with the industry standard MCS-51 instruction set and pinout. The

on-chip flash allows the program memory to be reprogrammed in-system or by a

4

conventional nonvolatile memory programmer. By combining a versatile 8-bit CPU

with flash on the monolithic chip, the AT89C51 is a powerful microcomputer, which

provides a flexible and cost-effective solution to many embedded control applications.

Figure 1.2 shows the microcontroller interfacing with motor.

Figure 1.2 Interfacing of Microcontroller

1.1.8 Roller

Roller is made up of sheet metal. In this sheet is rolled and wielded by using

electric arc wielding. The ends of rolled sheets are closed by using sheet plates

machined to proper dimensions and the shaft is provided at centre of roller. The

material of plate and shaft is MS steel. Thus desired roller is obtained. The

dimensions are specified below. The specifications of roller are as follows:

Outer diameter = 76 mm

Length of the roller = 305 mm

1.1.9 DC Motor

A DC Motor is high quality low cost DC geared motor. It has steel gears and

pinions to ensure longer life and better wear and tear properties. Stall Torque is the

torque which is produced by a motor when the output rotational speed is zero, it may

also mean the torque load that causes the output rotational speed of a motor to

become zero - i.e. to cause stalling. The motor is used to rotate the roller at constant

speed.

5

The specifications of the motor are described as follows

Input voltage = 12 V

Type = DC motor

Speed = 30 RPM

Shaft Diameter = 8 mm

Motor weight = 1 ½ Kg

Load withstanding capacity = 75 Kg

1.1.10 Flow Control Valve

Flow control valves, also known as volume control valves, are used to regulate

the volumetric flow of the compressed air to different parts of a pneumatic system. In

this project, two flow control valves are used for two pneumatic cylinders. By using

this, the flow can be controlled during the operation of ejecting, holding and cutting

operation.

1.1.11 Five-Port / Two-Way Directional Valve

Two-way valves are also available with five external ports, one pressure port,

two actuator ports, and two exhaust ports. Such valves provide the same basic

control of flow paths as the four-ported version, but have individual exhaust ports. In

the fluid power field this is referred to as a "five-ported, two-way valve." This type of

valve brings all flow paths to individual external ports. The pressure port is connected

to system pressure after a regulator. Actuator ports are connected to inlet and outlet

ports of a cylinder or motor. Each exhaust port serves an actuator port.

1.1.12 Pneumatic Cylinder

Pneumatic cylinders are the devices used for converting the pressure energy

of air (also called pneumatic energy) into linear mechanical force and motion to

perform useful work. Pneumatic cylinder mainly consists of a piston, a cylinder, and

valves or ports. Mainly pneumatic cylinder is classified into single acting and double

acting cylinder. Pneumatic cylinders employ a smooth-bore cylinder with a piston

6

affixed to a piston rod, with several seals between the piston and cylinder. They most

often consist of metal components, although many composites are used for special

applications. They are available with a variety of end fittings and pneumatic piping

and tubing connections. In double-acting cylinders, air pressure can be applied to

either side of the piston, therefore producing pneumatic force in both directions. They

perform work in both directions of movement. These cylinders do not require a return

whenever the device is not powered. In this project, two double-acting cylinders are

used. The dimension of the pneumatic cylinders are specified below,

Cylinder diameter = 140 mm

Bore diameter = 100 mm

Stroke length = 100 mm

Piston rod diameter = 50 mm

7

CHAPTER 2

LITERATURE REVIEW

Borelli et al (2002) convey about the hot cutting fabric by using infrared images

to cut. In the hot cutting of fabric, one of the variables of great importance in the

control of the process is the contact temperature between the tool and the fabric. This

work presents a technique for the measurement of the temperature based on the

processing of infrared images. The cutting mechanism used in this was thermal

degradation.

Thilagavathi et al (2010) about Fiber structures, yarn structures, and

mechanical properties of fibers namely tensile modulus, tenacity, and elongation, are

the key performance indicators of fabric cut resistance. P-aramid and UHDPE (Ultra

High Density Polyethylene) based high performance fibers are most commonly used

for protection against mechanical risks. Specially engineered composite yarns and

fabrics enhance cut resistance. This paper discusses the influence of textile structure

configuration on the performance of cut resistant textiles. A three tier laminate

composite was made using knitted Kevlar fabric, as the outer surface, polyurethane

foam in the middle and a knitted nylon fabric as the skin contact layer. This specially

engineered laminate showed a 20% increase in cut resistance when compared with

the Kevlar fabric used for lamination. The combination of breathable PU foam and

knitted fabric yielded high stretch with improved breathability and dexterity.

Kothari et al (2006) reports about the cutting behavior of textile fabrics have

been developed. It has been tried to identify the forces involved in cutting a material

with a reciprocating knife and also to derive an expression for the sliding distance,

which is a measure of the cut resistance of the material. The cut resistance increase

with the increase in inch of the fabric.

ASTM committee (2002) reports that the hydraulic bursting strength of textile

fabrics. This deal with the strength of the fabrics can be determined by pressure

applied on the fabrics. The various methods used to determine the strength clamping,

8

hydraulic pressure system and gauges. The different types of fabrics material are

taken for the determination of strength.

Zheng et al (2008) report about a new creditable and effective multiaxial

circular tensile tester (MACTT) with 16 load sensors installed around a circumference

has been developed. The new tester could be used to measure tensile properties in

various directions with one sample simultaneously under the same initial conditions.

As a result, not only an error could be reduced, but also the experiment samples and

time could be saved. The experimental results showed good agreement with the

theoretical approximate values calculated based on Hooke’s Law. For general fabrics,

the anisotropic tensile properties could be measured easily with the new tester,

although it was difficult to understand their structures and mechanical characteristics

systematically. Therefore, the new tester showed more important results.

Hace et al (2002) convey about the working of water jet cutting machine that

has been built for cutting of leather or synthetic textile in shoe industry. The main

parts of the machine are the transport system, the XY system with the cutting head,

and the high-pressure (HP) pump. The transport system feeds material into the

cutting section and holds it during the cutting period. It consists of three sections. In

the input section the material is laid down on a transport table. The table then

transports material toward the cutting section. When cutting, the gripper holds down

the material and the transport system is stopped. Afterward, the cut pieces are

transported to the output section. Electrical motors and pneumatic cylinders power

the transport system.

Chiang, L.E (1994) describes the design and construction of a low power laser

cutting machine with three degrees of freedom for applications such as wood, textile

fabrics and the like. An available 10 Watt laser gun is used to provide the cutting

mechanism. The results show that such a machine is feasible at a reasonable cost for

applications where speed and repeatability are more important than high precision

and power.

CO2 laser cutting machine uses focus lens to make CO2 laser beam focus on

material surface to melt materials, at the same time uses compressed gas which is

9

coaxial with the laser beam to blow melting materials, and laser beam and materials

are in relative motion along certain tracks, thus forming cutting slotting in a definite

shape. Since 1970s, with the unceasing development and perfection CO2 laser and

numerical control technology, CO2 laser cutting machine has become an advanced

processing device for plates cutting in industry. In 1950s &1960s the main methods

for plates cutting are as follows: cutting medium thickness plate, adopting method is

oxyacetylene flame cutting method; for thin plate, forming by shearing mass complex

components by stamping, sheet by adopting the vibration shears. All cutting methods

have their flaws, but still have their applications in specific fields.

The hydraulic cutting machine is specifically designed to cut Emery Cloth,

Rubber and Leather with precision and speed. The salient features of the hydraulic

cutting machines are

The accuracy of the programme is 0.01 mm 0.001 inches. Conversion from mm

to inch fraction is also possible.

The worm gear drive has ground worm and needs less power than any other

conventional drive. The gears are running in oil bath.

It has a new drive mechanism for clamping. The special features of this

machine are double clamping pressure and gentle setting of the clamp on the

materials to be cut. The clamping pressure is adjustable with a knob positioned

under the table at a convenient place.

The knife can be changed easily by lift system and safely by a single operator.

A set of infra red light beams are projected in front of the cutting zone just

above the table to avoid an accident.

2.1 Summary

From the above study there are different types of cutting mechanism used in

fabric. In that cost of cutting in each machine is higher and manual work operation is

maximum in cutting a fabric. This project deals with the reduction in cost and to

reduce manual work. In this various kinds of fabric material are used for cutting with

required force mentioned in the above study tension of the fabric is determined.

10

CHAPTER-3

PROBLEM DEFINITION

In textile shop all the fabric materials are measured and cut manually with the

help of cutting tools and measuring tools. In this process of cutting is not obtained

accurately and time taken for cutting is also quite high. If the measurement is not

accurate, wastage of materials will be more and then the quality will also be reduced.

Nowadays quality is the main aspect of customer. Mostly the length of the cutting will

vary according to the type of the fabric material.

In those machines, bulk orders of fabrics and same size of cutting is only

possible. The size cannot be changed immediately for cutting a fabric. It has large

procedure and that should be followed for changing the size.

This project deals with above the defined problems and rectifies them in order

to reduce manual work and also the continuous process of cutting is obtained.

Adjusting the size can be made easily in this machine. Cost is much less compared to

the large machine used in textile industries.

11

CHAPTER 4

DESIGN AND DEVELOPMENT

The design and development section deals with the designing of various

components that are used in the project. The design can be carried out for various

components are bearing design, clamping and cutting mechanism, design of electrical

circuit, design of pneumatic circuit and design of model.

4.1 DESIGN PHASE

The designing of various parts of the model is described as below

4.1.1 Design of Bearing

Diameter of the shaft, D = 20mm

Speed of the shaft, N = 42.8 rpm

Assumed allowable bearing pressure is 0.016 N per sq.mm

Area, A = L × D

Area, A = 20 × L sq.mm

Pressure, P =Load

Area

= 58.8620×L

(20×L)×0.016 = 58.86

L = 183.93mm

For this bearing length and shaft diameter p204 bearing is selected.

4.1.2 Cutting Mechanism

Figure 4.1 shows the dimensions of the pneumatic cylinder.

Figure 4.1 Dimensions of Pneumatic Cylinder

12

Bore diameter d1= 100 mm

Piston rod diameter d2= 50 mm

Stroke length L = 100 mm

Pressure p = 6 bar

Force needed for cutting fabrics is less compared to clamping force,

F = π

4 [p × (d1

2 - d22)]

F = π

4 × [6 × e5× (0.12 -0.052)]

F = 3.534 KN

4.1.3 Clamping Mechanism

Bore diameter d1= 100 mm

Piston rod diameter d2= 50 mm

Stroke length L = 100 mm

Pressure p = 8 bar

Force needed for cutting fabrics is less compared to clamping force,

F = π

4 [p × (d1

2 - d22)]

F = π

4 × [8 × e5× (0.12 -0.052)]

F = 4.71 KN

4.1.4 Design of Electrical Circuit

The entire circuit consists of three major blocks power supply unit, data

processing unit and controller unit. In this circuit, it requires 5V DC supply which is

step down from a 230V AC supply using 15-0-15 step down transformer. This 15V AC

supply is converted into 15V DC using rectifier circuit. The rectified DC supply is

filtered using 1000 µF capacitor and finally 5V DC supply is acquired using 7805

13

regulator. This 5V DC supply is given to the DC motor, Variable Resistor and

Microcontroller.

The input to the Microcontroller is given in the form of Keypad which acts as a

controller unit. Based on the signal given, corresponding signal will be generated in

the Microcontroller unit. The generated signal is given to the DC Motor, which makes

the motor to run. The motor speed can be varied using a variable resistor through

which the motor runs at a desired speed. Figure 4.2 shows the circuit design of

electrical components.

Figure 4.2 Block Diagram of Electrical Circuit

4.1.5 Design of Pnuematic Circuit

The operating sequence of the cylinders is A+B+B-A-. The cylinder A is used

to clamp the fabrics and cylinder B is used to cut the fabrics. This operation is done

as follows. When PS A is in normally close condition ,the SOL A is actuated and the

cylinder A extracts.Then the clamping of fabrics occurs. When PS B is in normally

close condition ,the SOL B is actuated and the cylinder A extracts.Then the cutting of

fabrics occurs. Figure 4.3 shows the sequential circuit design of the pneumatic circuit.

14

SOL A = Solenoid A SOL B = Solenoid B

PS A = Push button A PS B = Push button B

Figure 4.3 Sequential Circuit Design

When PS B is in normally open condition ,the spring pulls the piston in 5/2

DCV. This forces air in opposite direction and the cylinder B retracts.Thus the knife

retracts. When PS A is in normally open condition ,the spring pulls the piston in 5/2

DCV. This forces air in opposite direction and the cylinder A retracts.Thus the

clamping of fabrics releases.

15

4.1.6 Design of Setup

By using PRO-ENGINEER WILDFIRE 4.0, the first prototype is designed. This

model is assembled by different parts. The part diagram is designed with the help of

different icon in Pro/E. Some of the icons used to create this model are line,

rectangle, pattern, extrude, trim etc. The parts we designed by using PRO-E are

roller, cylinder, base table, knife and motor. After designing the various parts of the

model with the help of PRO-E, the assembly section of the model begins. To

assemble these parts we changed the module as assembly and then the base table is

opened by using open icon. The base table is fixed by choosing default in the

placement tab. After fixing the base table, the roller part is opened by using open

icon. Then the alignment of roller is done by using align and mate icon in the

placement tab. Thus the roller is fitted on the base table. Similarly same size of roller

is fitted on the other side of the base table. Figure 4.4 shows the assembly diagram of

the fabric cutting machine.

Figure 4.4 Model of Fabric Cutting Machine

A stand like arrangement is made to hold the cutting mechanism i.e., two

cylinders. Then the cylinder part is opened and fitted to the stand arrangement. This

16

is done by using mate and fix icon. After fixing the cylinders, knife and clamp are

assembled at the end of piston rod of the cylinders.

The motor is fixed at the one end of the roller which is used to roll the fabrics.

The shaft in the roller is used to couple with the motor. Thus the complete assembly

of this model is done with the help of Pro/E WILDFIRE 4.0.

4.2 OPERATIONAL FEASIBILITY

The motor is operated by means of the microcontroller when input is given. Its

operation is fully based on the microcontroller. After the length is measured it moves

to second process automatically with the help of microcontroller. When the clamping

process is over it moves to the cutting automatically. Its operation is based on

microcontroller only thing is input should be entered after that all the process are

carried out. It does not require any skilled labor to operate the machine.

4.3 ECONOMIC FEASIBILITY

The cost of the pneumatic components is only higher but for accuracy and

automation we have to choose pneumatic components. Table 4.1 shows the cost of

the fabricated model and it is economical one.

Table 4.1 Cost Estimation

S.NO List of Components QUANTITY COST in

Rs.

1 30rpm DC motor 1 800.00

2 Pneumatic cylinders 2 1000.00

3 5/2 DCV 2 1600.00

4 Flow control valve 2 400.00

5 Hoses 5 m 150.00

6 Distributors 4 150.00

7 Electrical circuit 1 1250.00

8 Rollers 2 550.00

9 Electrical wire 4 m 70.00

10 Switches 2 30.00

11 Stand for rollers & cylinders 625.00

Total 6625.00

17

CHAPTER 5

FABRICATION PROCESS

In this chapter, the electrical and pneumatic circuits of the fabric cutting

machine are discussed. The working principle and the process description of the

fabric cutting machines are discussed below.

5.1 PROCESS DESCRIPTION

In this method, cutting and clamping of fabrics is done by automatically. Two

rollers are used for obtaining the desired length of the fabric. First, two rollers are

mounted on the roller stand. One is act as a driver and another one is driven. First

roller is driven by a 30 rpm DC motor and second roller is driven by first roller.

Normally, fabric is rolled on the first roller and another end of the fabric is attached to

the driven roller. The motor is operated by means of microcontroller when the input is

given. The operation is fully based on the microcontroller. The entire circuit consists

of three major blocks Power Supply unit, Data Processing unit and Controller unit. In

this circuit, it requires a 5V DC supply which is step down from a 230V AC supply

using 15-0-15 step down transformer. This 15V AC supply is converted into 15V DC

using rectifier circuit. The rectified DC supply is filtered using 1000 µF capacitor and

finally 5V DC supply is acquired by using 7805 regulator. This 5V DC supply is given

to the DC motor, Variable Resistor and Microcontroller.

The input to the Microcontroller is given through the Keypad which acts as a

controller unit. Based on the signal given, corresponding signal will be generated in

the Microcontroller unit. The generated signal is given to the DC Motor, which makes

the motor to run. The time required to rotate the rollers is fed to the microcontroller as

the input through the keypad. The power supplied to various electronic components

by using a variable resistor.

Based on the input given the corresponding signal will be sent to the

microcontroller, which controls the rotation of the roller by enabling the dc motor. So,

the desired length of the fabric is obtained by this electrical circuit. If the given input to

18

the controller unit is 30 sec means, then the motor runs for 30 sec and the

corresponding length of the fabric is obtained. If the desired length is obtained then

the clamping and cutting operations are done by actuated the pneumatic cylinders.

These double acting pneumatic cylinders are actuated by using 5/2 direction

control valves controlled by the solenoid and flow control valves. The operating

cylinder sequence is A+B+B-A-. When the air supplied to the pneumatic circuits, the

power supply is also given to the solenoid A which operates direction control valve.

Thus the pneumatic cylinders extraction and retraction is done by pressing the push

buttons. When the pneumatic cylinder A extracts, then the clamping is carried out and

then the cylinder B extracts to carry out cutting operation. Then the fabric is cut by

using sharp knife and the cylinder B retracts so that the knife arrangement returns

back to original place. When the push button A is in off state, then the cylinder A

retracts releasing the clamp. Thus the required length of the fabric is obtained by

using electrical and pneumatic circuit. Figure 5.1 shows the working procedure of the

fabric cutting machine.

Figure 5.1 Parts and Dimensions of Base Setup

19

CHAPTER 6

RESULT AND DISCUSSION

This project is fabricated with the help of electrical and pneumatic components.

The model is fabricated mainly to reduce the manual cutting of fabrics. The required

length of the fabric was obtained by using the micro controller. Then the clamping and

cutting operation is done by using pneumatic circuit design. Because of vertical

motion of the knife, the fabric is not cut in good manner. Thus the fabric is cut by

using electrical and pneumatic circuit.

Figure 6.1 Fabrication Project

Figure 6.1 shows the fabrication model of fabric cutting machine. This project

gives the accurate result in cutting a different kind of materials in fabric. Cutting force

is depends on the material which is used.

20

6.1 ADVANTAGES

The advantages of the fabric cutting machines are,

In this machine, skilled labours are not required to operate.

This machine very compact in size compared to the existing machine.

Cost of cutting is minimum and cost of this machine is also minimum.

This machine is produced even for a textile shops

Accuracy of cutting is maximum

Manual operation is less in this machine

21

CHAPTER 7

CONCLUSION

The fabric cutting machine is used to cut the fabrics for the desired length. This

project is mainly used to increase the productivity, efficiency of the industry and avoid

manual errors. This machine is very accurate and compact. The machine can be

purchased at affordable cost. Because of the vertical movement of the knife, the

cutting operation is not effective. So in the future we are going to use the shearing

motion of the knife. This shearing mechanism will cut the fabric more effectively and

the cost will be quite low.

22

APPENDIX

Air Consumption of Double-Acting Cylinders

BORE ROD Ø ACTION

OPERATING PRESSURE (BAR)

2 3 4 5 6 7 8 9 10

8 4 Vo 0.002 0.002 0.003 0.003 0.004 0.004 0.005 0.005 0.006

Vi 0.001 0.002 0.002 0.002 0.003 0.003 0.003 0.004 0.004

10 4 Vo 0.002 0.003 0.003 0.004 0.005 0.005 0.006 0.007 0.007

Vi 0.002 0.003 0.003 0.003 0.004 0.004 0.005 0.006 0.006

12 6 Vo 0.003 0.005 0.006 0.007 0.008 0.009 0.010 0.011 0.012

Vi 0.003 0.003 0.004 0.005 0.006 0.007 0.008 0.008 0.009

16 6 Vo 0.006 0.008 0.010 0.012 0.014 0.016 0.018 0.020 0.022

Vi 0.005 0.007 0.009 0.010 0.012 0.014 0.016 0.017 0.019

20 8 Vo 0.009 0.013 0.016 0.019 0.022 0.025 0.028 0.031 0.035

Vi 0.008 0.011 0.013 0.016 0.019 0.021 0.024 0.026 0.029

25 10 Vo 0.015 0.020 0.025 0.030 0.034 0.039 0.044 0.049 0.054

Vi 0.012 0.017 0.021 0.025 0.029 0.0337 0.037 0.041 0.045

32 12 Vo 0.024 0.032 0.040 0.048 0.056 0.064 0.072 0.082 0.088

Vi 0.021 0.028 0.035 0.042 0.049 0.056 0.063 0.070 0.076

40 16 Vo 0.038 0.050 0.063 0.076 0.088 0.100 0.113 0.126 0.188

Vi 0.030 0.040 0.050 0.060 0.070 0.080 0.090 0.100 0.110

50 20 Vo 0.059 0.079 0.098 0.118 0.137 0.157 0.177 0.196 0.216

Vi 0.051 0.068 0.085 0.102 0.120 0.137 0.154 0.170 0.188

63 20 Vo 0.093 0.125 0.156 0.187 0.218 0.249 0.280 0.312 0.343

Vi 0.072 0.109 0.136 0.164 0.191 0.218 0.245 0.273 0.300

80 25 Vo 0.150 0.200 0.250 0.301 0.351 0.402 0.452 0.502 0.552

Vi 0.139 0.186 0.232 0.279 0.325 0.372 0.418 0.464 0.510

100 25 Vo 0.236 0.314 0.382 0.471 0.549 0.628 0.706 0.785 0.862

Vi 0.214 0.286 0.357 0.429 0.500 0.571 0.643 0.714 0.786

125 32 Vo 0.368 0.490 0.613 0.736 0.859 0.981 1.104 1.226 1.349

Vi 0.346 0.462 0.578 0.694 0.809 0.925 1.040 1.156 1.272

160 40 Vo 0.603 0.804 1.005 1.206 1.407 1.608 1.809 2.010 2.211

Vi 0.565 0.754 0.942 1.130 1.319 1.507 1.696 1.884 2.072

200 40 Vo 0.942 1.256 1.570 1.884 2.198 2.512 2.826 3.140 3.454

Vi 0.904 1.206 1.507 1.809 2.110 2.412 2.713 3.014 3.316

23

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