PNEUMATIC HIGH SPEED HACK SAW MACHINE

Submitted in partial fulfillment of the requirement for the award of

DIPLOMA
IN
MECHANICAL ENGINEERING
BY

Under the guidance of ---------------------------

2004-2005
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

Register number: _________________________

This is to certify that the project report titled

PNEUMATIC HACK SAW MACHINE submitted by the

following

students

for

the

award

of

the

Diploma

engineering is record of bonafide work carried out by

them.

Done by
Mr. / Ms_______________________________

In partial fulfillment of the requirement for the award of

degree in
Diploma Engineering in Mechanical
During the Year (2004-2005)
_________________
Head of Department

_______________

Guide

Coimbatore 641651.
Date:
Submitted

for

the

university

examination

held

___________

_________________

________________

on

Internal Examiner
Examiner

External

---------------------------------------------------------------------------------

ACKNOWLEDGEMENT
---------------------------------------------------------------------------------

ACKNOWLEDGEMENT
At this pleasing moment of having successfully
completed our project, we wish to convey our
sincere thanks and gratitude to the management
of

our

college

and

our

beloved

chairman

, who provided all

the facilities

to us.

We would like to express our sincere thanks to

our

principal

for

forwarding us to do our project and offering

adequate duration in completing our project.
We

are

also

Department Prof.

grateful

to

the

Head

of

.., for

her constructive suggestions & encouragement

during our project.
With deep sense of gratitude, we extend our
earnest

&

sincere

thanks

to

..,
of

Mechanical

for

her

kind

encouragement during this project.

our

guide

Department
guidance

&

We also express our indebt thanks to our

TEACHING
MECHANICAL

and

NON

TEACHING

ENGINEERING

.(COLLEGE NAME).

staffs

of

DEPARTMENT,

-------------------------------------------------------------------------------------

PNEUMATIC HACK SAW

MACHINE
------------------------------------------------------------------------------------

---------------------------------------------------------------------------------

CONTENTS
---------------------------------------------------------------------------------

CONTENTS

CHAPTER
NO

1
2
3
4
5
6
7
8
9
10
11
12
13

TITLE
Introduction
Literature survey
Components and Description
Design and drawings
Working principle
Fabrication
Applications
Need for automation
Advantages and limitations
Process sheet
List of materials
Cost estimation
Conclusion
Bibliography
Photography

PAGE NO

---------------------------------------------------------------------------------------

Chapter-1
---------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------

INTRODUCTION
---------------------------------------------------------------------------------------

CHAPTER-1
INTRODUCTION

The hacksaw is a metal cutting machine tool designed to cut metal by applying
pneumatic pressure.

The machine is exclusively intended for mass production and they represent the
fastent and more efficient way to cut a metal.

Hacksaws are used to cut thin and soft metals. The operation of the unit is
simplified to a few simple operations involving a cylinder block and piston arrangement.

There are numerous types of cutting machines in Engineering field, which are
used to fulfil the requirements. We are interested to introduce pneumatic system in
Hacksaw machine.

The main function of Pneumatic hacksaw is to cut thin and soft metals by
pneumatic power.

---------------------------------------------------------------------------------------

Chapter-2
---------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------

LITERATURE SURVEY
---------------------------------------------------------------------------------------

CHAPTER-2
LITERATURE SURVEY

PNEUMATICS

The word pneuma comes from Greek and means breather wind. The word
pneumatics is the study of air movement and its phenomena is derived from the word
pneuma. Today pneumatics is mainly understood to means the application of air as a
working medium in industry especially the driving and controlling of machines and
equipment.

Pneumatics has for some considerable time between used for carrying out the
simplest mechanical tasks in more recent times has played a more important role in the
development of pneumatic technology for automation.

Pneumatic systems operate on a supply of compressed air which must be made

available in sufficient quantity and at a pressure to suit the capacity of the system. When
the pneumatic system is being adopted for the first time, however it wills indeed the
necessary to deal with the question of compressed air supply.

The key part of any facility for supply of compressed air is by means using
reciprocating compressor. A compressor is a machine that takes in air, gas at a certain
pressure and delivered the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and delivered and the
volume expressed is that of the air at intake conditions namely at atmosphere pressure
and normal ambient temperature.

The compressibility of the air was first investigated by Robert Boyle in 1962 and
that found that the product of pressure and volume of a particular quantity of gas.

The usual written as

PV = C

(or) PV = P2V2

In this equation the pressure is the absolute pressured which for free is about 14.7
Psi and is of courage capable of maintaining a column of mercury, nearly 30 inches high
in an ordinary barometer. Any gas can be used in pneumatic system but air is the mostly
used system now a days.

SELECTION OF PNEUMATICS

Mechanization is broadly defined as the replacement of manual effort by

mechanical power. Pneumatic is an attractive medium for low cost mechanization
particularly for sequential (or) repetitive operations. Many factories and plants already
have a compressed air system, which is capable of providing the power (or) energy
requirements and the control system (although equally pneumatic control systems may be
economic and can be advantageously applied to other forms of power).

The main advantage of an all pneumatic system are usually economic and
simplicity the latter reducing maintenance to a low level. It can also have out standing
advantages in terms of safety.

PRODUCTION OF COMPRESSED AIR

Pneumatic systems operate on a supply of compressed air, which must be made

available. In sufficient quantity and at a pressure to suit the capacity of the system. When
pneumatic system is being adopted for the first time, however it wills indeed the
necessary to deal with the question of compressed air supply.

The key part of any facility for supply of compressed air is by means using
reciprocating compressor. A compressor is a machine that takes in air, gas at a certain
pressure and delivered the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and delivered and the
volume expressed is that of the air at intake conditions namely at atmosphere pressure
and normal ambient temperature.

Clean condition of the suction air is one of the factors, which decides the life of a
compressor. Warm and moist suction air will result in increased precipitation of condense
from the compressed air. Compressor may be classified in two general types.

1. Positive displacement compressor.

2. Turbo compressor

Positive displacement compressors are most frequently employed for compressed

air plant and have proved highly successful and supply air for pneumatic control
application.

The types of positive compressor

1. Reciprocating type compressor
2. Rotary type compressor

Turbo compressors are employed where large capacity of air required at low
discharge pressures. They cannot attain pressure necessary for pneumatic control
application unless built in multistage designs and are seldom encountered in
pneumatic service.

RECIPROCATING COMPRESSORS
Built for either stationary (or) portable service the reciprocating compressor is by
far the most common type. Reciprocating compressors lap be had is sizes from the
smallest capacities to deliver more than 500 m/min. In single stage compressor, the air
pressure may be of 6 bar machines discharge of pressure is up to 15 bars. Discharge
pressure in the range of 250 bars can be obtained with high pressure reciprocating
compressors that of three & four stages.

Single stage and 1200 stage models are particularly suitable for pneumatic
applications , with preference going to the two stage design as soon as the discharge
pressure exceeds 6 bar , because it in capable of matching the performance of single stage
machine at lower costs per driving powers in the range .

---------------------------------------------------------------------------------------

Chapter-3
---------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------

COMPONENTS AND
DESCRIPTION
---------------------------------------------------------------------------------------

CHAPTER-3
COMPONENTS AND DESCRIPTION

PNEUMATIC CONTROL COMPONENT

Pneumatic cylinder

An air cylinder is an operative device in which the state input energy of

compressed air i.e. pneumatic power is converted in to mechanical output power, by
reducing the pressure of the air to that of the atmosphere.

Single acting cylinder

Single acting cylinder is only capable of performing an operating medium in only

one direction. Single acting cylinders equipped with one inlet for the operating air
pressure, can be production in several fundamentally different designs.

Single cylinders develop power in one direction only. Therefore no heavy

control equipment should be attached to them, which requires to be moved on the piston
return stoke single action cylinder requires only about half the air volume consumed by a
double acting for one operating cycle.

Double acting cylinders :

A double acting cylinder is employed in control systems with the full

pneumatic cushioning and it is essential when the cylinder itself is required to retard
heavy messes. This can only be done at the end positions of the piston stock. In all
intermediate position a separate externally mounted cushioning derive most be provided
with the damping feature.

The normal escape of air is out off by a cushioning piston before the end of the stock
is required. As a result the sit in the cushioning chamber is again compressed since it
cannot escape but slowly according to the setting made on reverses. The air freely enters
the cylinder and the piston stokes in the other direction at full force and velocity.

VALVES

a) 5/2 Double Acting Solenoid Valve

The directional valve is one of the important parts of a pneumatic system.

Commonly known as DCV, this valve is used to control the direction of air flow in the
pneumatic system. The directional valve does this by changing the position of its internal
movable parts.

This valve was selected for speedy operation and to reduce the manual effort and
also for the modification of the machine into automatic machine by means of using a
solenoid valve.

A solenoid is an electrical device that converts electrical energy into straight line
motion and force. These are also used to operate a mechanical operation which in turn
operates the valve mechanism. Solenoids may be push type or pull type. The push type
solenoid is one in which the plunger is pushed when the solenoid is energized electrically.
The pull type solenoid is one is which the plunger is pulled when the solenoid is
energized. The name of the parts of the solenoid should be learned so that they can be
recognized when called upon to make repairs, to do service work or to install them.

Working of 5/2 Solenoid Valve

The solenoid valve has 5 openings. This ensure easy exhausting of 5/2 valve. The
spool of the 5/2 valve slide inside the main bore according to spool position; the ports get
connected and disconnected. The working principle is as follows.

Position-1

When the spool is actuated towards outer direction port P gets connected to B
and S remains closed while A gets connected to R

Poisition-2

When the spool is pushed in the inner direction port P and A gets connected to
each other and B to S while port R remains closed.

Parts of Solenoid Valve

1. Coil
The solenoid coil is made of copper wire. The layers of wire are separated by
insulating layer. The entire solenoid coil is covered with an varnish that is not affected by
solvents, moisture, cutting oil or often fluids.

Coils are rated in various voltages such as 115 volts AC, 230 volts AC, 460 volts
AC, 575 Volts AC, 6 Volts DC, 12 Volts DC, 24 Volts DC, 115 Volts DC & 230 Volts DC.
They are designed for such frequencies as 50 Hz to 60 Hz.

2. Frame

The solenoid frame serves several purposes. Since it is made of laminated sheets,
it is magnetized when the current passes through the coil. The magnetized coil attracts
the metal plunger to move. The frame has provisions for attaching the mounting. They
are usually bolted or welded to the frame. The frame has provisions for receivers, the
plunger. The wear strips are mounted to the solenoid frame, and are made of materials
such as metal or impregnated less fiber cloth.

3. Solenoid Plunger

The Solenoid plunger is the mover mechanism of the solenoid. The plunger is
made of steel laminations which are riveted together under high pressure, so that there
will be no movement of the lamination with respect to one another. At the top of the
plunger a pin hole is placed for making a connection to some device. The solenoid
plunger is moved by a magnetic force in one direction and is usually returned by spring
action.

Solenoid operated valves are usually provided with cover over either the solenoid
or the entire valve. This protects the solenoid from dirt and other foreign matter, and
protects the actuator.

In many applications it is necessary to use explosion proof

solenoids.

Flow control valve:

In any fluid power circuit, flow control valve is used to control the speed of
the actuator. The floe control can be achieved. By varying the area of flow through which
the air in passing.

When area is increased, more quantity of air will be sent to actuator as a

result its speed will increase. If the quantity of air entering into the actuator is reduced,
the speed of the actuator is reduced.

4. ELECTRONIC CONTROL UNIT:-

4A-230V X 3
47K
L1
4

TRIAC X 3

16
3

7
10K

IC
555

6
2

1N4007 X 3
L2

4017
3

2
14

L3

4
13

100F

1N4007 X 4

1N4007
1000F

230/9V
230V A/C I/P

Here the 555 IC has been used as a multi vibrator. The output of IC 555 is fed to
the input pin (pin no 14) of CD 4017 continues counting. The output of the IC becomes
available at pin Nos. 3, 2 and 4. The output pulse of any one of output pin triggers (Puts
ON) the Triac and current starts flowing across the load connected. This process
continues on other pins at different time intervals and the cycle continues. The frequency
interval (Time) of the cycle can be adjusted by the pre-set look connected to pin 6 of 555
Timer IC.

IC 555 TIMER

The IC SE / NE 555 monolithic circuit is a highly stable controller capable of

producing accurate time delays or oscillations. Additional terminals are provided for
triggering or resetting if desired. In the timing operations, the time is precisely controlled
by one external resistor and a capacitor, by the operation as an oscillator, the free running
frequency and the duty cycle are both accurately contributed with the external RC
constants.
PIN DIAGRAM:
GROUND

TRIGGER

DISCHARGE
2

7
IC
NE 555

OUTPUT
RESET

SUPPLY (Vcc)

THERSOLD

CONTROL

PIN NO: 1
It is ground terminal.
PIN NO: 2
The trigger voltage to
the lower comparator is
applied. It has constant
voltage that is atleast
one third of the supply
voltage, when trigger
voltage falls below this
level the flip-flop changes its state and output becomes high.

PIN NO: 3
It is the output terminal, in low state output is equal to zero and when at higher state
output is equal to Vcc.

PIN NO: 4
It controls the flip flop directly. It turns the device to its original position when reset
pin is connected to ground the output is approximately equal to zero. When reset is not
used it is connected to Vcc.

PIN NO: 5
It is the control voltage terminal. It is connected to ground through a capacitor of 0.01
F. Any external voltage at pin: 5 will change both the threshold voltage and the trigger
voltage reference level.

PIN NO: 6
Threshold voltage of upper comparator is applied from this terminal. The resistor Rt
connected to Vcc and pin: 6 is grounded by an external capacitor. The output is high
capacitor charges by resistor Rt. When the capacitor changes to the threshold level, the
output becomes low.

PIN NO: 7
It is the discharge pin for external capacitor. Usually pin: 7 is connected with pin: 6
directly to by a resistor. When the output becomes low then the external capacitor
discharges by internal discharge transistor remains at cut-off and the external capacitor
charges to Vcc.

PIN NO: 8
It is the positive supply terminal. A dc voltage from +5 to + 15 can be applied.

The important features of IC555 can be summarized as follows.

1.

Timing range from microseconds to hours.

2.

Mono-stable and Astable operation is possible through IC555.

3.

The duty cycle can be adjusted according to our necessity.

4.

It has the ability to operate from a wide range of supply Voltage.

5.

The output of 555 is compatible with CMOS, DTL and TTL, logic. But

when used with a 5V supply.

6.

Triggering and reset inputs are logically compatible.

7.

Output can be operated as normal ON and normal OFF.

8.

High temperature stability.

9.

Unlike RC timers, 555 provide a time intervals that is virtually

independence of supply voltage Vcc. This because that, the charge rate of CT and
the reference voltage to the threshold comparator are all directly proportional to
the supply voltage.
IC 555 SPECIFICATION
Supply Voltage (Vcc)

4.5 to 15V

Supply Current (Vcc=5V/2)

3 to 6mA

Supply Current (Vcc=25V/2)

10 to 15mA

Output Current

200mA (maximum)

Power dissipation

600mw

Operating temperature

0-70 degree Celsius.

SPECIFICATION OF THE FITTINGS

Body Material

High Strength Plastic

Collet/Collet Holder/Threaded Nipple

Brass

Seal

Nitrate, Rubber, Neoprene

Fluid Used

Air

Max. Operating Pressure

10 bar

Ambient Temperature

5 to 60 C

Max. Air Temperature

60C

Pipe Threads

Male BSPT
Female -

Tolerance on OD of the tubes

0.10mm

Min. Wall thickness of tubes

1mm

BSP

Bulk Head Union:

It is the one type of fitting to joint the two independent flexible hoses. It is used to
connect tubes in panel installations. It is easy to install hoses as well as remove it from
maintenance purpose.

Female Elbow:
This type of fitting is instead of where the pneumatic bend circuit is required.
Connect the tubes at the right angles (90) to male connections.

Flexible Hoses:
. Hose is fabricated in layer of elastomer or synthetic rubber and braided fabric,
which permits operation at higher pressure. The standard tubing outside diameter is 1/16
inch. If the hose is subject to rubbing, it should be encased in a protective sleeve.

AIR COMPRESSOR:
The main function of the air compressor is to compress the air up to the required
pressure. The maximum capacity of the compressor is 12kg/cm. The power rating is
1HP. This is a two stage or two cylinders are for low and high compression. The air
pressure is measured at various places by the use of pressure gauges. The power rating
and speed of the motor that is fitted to the compressor in 3 HP and 2880 RPM
respectively V-belt and the pulley are used to drive the compressor.

-------------------------------------------------------------------------------------

Chapter-4
-------------------------------------------------------------------------------------

---------------------------------------------------------------------------------

DESIGN AND DRAWING

---------------------------------------------------------------------------------

CHAPTER 4
DESIGN OF EQUIPMENT AND DRAWING
Pneumatic components and its specification

The pneumatic auto feed drilling machine consists of the following components to
full fill the requirements of complete operation of the machine.

1. Double acting pneumatic cylinder

2. Solenoid Valve
3. Flow control Valve
4. Connectors
5. Hoses

1. Double acting pneumatic cylinder

Technical Data

Stroke length

Cylinder stoker length 170 mm = 0.17 m

Piston rod

18 mm = 18 x 10 m

Quantity

Seals

Nitride (Buna-N) Elastomer

End cones

Cast iron

Piston

EN 8

Media

Air

Temperature

0-80 C

Pressure Range

8 N/m

Size

0.635 x 10 m

Part size

G 0.635 x 10 m

2. Solenoid Valve
Technical data

Max pressure range :

0-10 x 10 N/m

Quantity

3. Flow control Valve

Technical Data

Port size

0.635 x 10 m

Pressure

0-8 x 10 N/m

Media

Air

Quantity

4. Connectors
Technical data

Max working pressure

10 x 10 N/m

Temperature

0-100 C

Fluid media

Air

Material

Brass

Max pressure

10 x 10 N/m

Outer diameter

6 mm = 6 x 10 m

Inner diameter

3.5 mm = 3.5 x 10 m

5. Hoses
Technical date

PNEUMATIC CYLINDER
Design of Piston rod:
Load due to air Pressure.

Diameter of the Piston (d)

40 mm

Pressure acting (p)

6 kgf/cm

Material used for rod

C 45

Yield stress (y)

36 kgf/mm

Assuming factor of safety

Force acting on the rod (P) =

Design Stress(y)

Pressure x Area

p x (d / 4)

6 x {( x 4 ) / 4 }

73.36 Kgf

y / F0 S

36 / 2

18 Kgf/mm

P / ( d / 4 )

4 p / [ y ]

4 x 75.36 / { x 18}

5.33 =

2.3 mm

Minimum diameter of rod required for the load

2.3 mm

We assume diameter of the rod

15 mm

Material used

Cast iron

Assuming internal diameter of the cylinder

40 mm

Design of cylinder thickness:

Ultimate tensile stress

250 N/mm

Working Stress

Ultimate tensile stress / factor of safety

2500 / 4

Assuming factor of safety

Working stress ( ft )

According to LAMES EQUATION

2500 gf/mm

625 Kgf/cm

Minimum thickness of cylinder ( t )

ri { (ft + p) / (ft p ) -1 }

Where,
ri

inner radius of cylinder in cm.

ft

Working stress (Kgf/cm)

Working pressure in Kgf/cm

Substituting values we get,

t

2.0 { (625 + 6) / ( 625 6) -1}

0.019 cm

0.19 mm

We assume thickness of cylinder

2.5 mm

Inner diameter of barrel

40 mm

Outer diameter of barrel

40 + 2t

40 + ( 2 x 2.5 ) =

45 mm

Pressure x area =

p x /4 (d)

Design of Piston rod:

Diameter of Piston Rod:
Force of piston Rod (P)

Also, force on piston rod (P)

6 x ( / 4) x (4)

73.36 Kgf

(/4) (dp) x ft

(/4) x (dp) x 625

73.36

(/4) x (dp) x 625

dp

73.36 x (4/) x (1/625)

0.15

0.38 cm

15 mm

dp

By standardizing dp

3.8 mm

Length of piston rod:

Approach stroke

160 mm

Length of threads

2 x 20 =

Extra length due to front cover

12 mm

Extra length of accommodate head

20 mm

Total length of the piston rod

160 + 40 + 12 + 20

232 mm

230 mm

By standardizing, length of the piston rod

40mm

---------------------------------------------------------------------------------------

Chapter-5
---------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------

WORKING PRINCIPLE
---------------------------------------------------------------------------------------

CHAPTER-5
WORKING PRINCIPLE
PNEUMATIC CIRCUIT:

Since pneumatic circuit plays a vital role in this device, it is very necessary to
explain the working of this circuit.

Initially starting with air compresses, its function is to compress air from a low
inlet pressure (usually atmospheric) to a higher pressure level. This is an accomplished
by reducing the volume of the air.

Air compressors are generally positive displacement units and are either of the
reciprocating piston type or the rotary screw or rotary vane types. The air compressor
used here is a typically small sized, two-stage compressor unit. It also consists of a
compressed air tank, electric rotor and pulley drive, pressure controls and instruments for
quick hook up and use. The compressor is driver by a 10HP motor and designed to
operate in 145 175 PSI range. If the pressure exceeds the designed pressure of the
receiver a release value provided releases the excesses air and thus stays a head of any
hazards to take place.

The stored air from compressor is passed through an air fitter where the
compressed air is filtered from the fine dust particles. However, before the suction of air
into compressor a filter process take place, but not sufficient to operate in the circuit here
the filter is used.

Then having a pressure regulator where the desired pressure to the operated is set.
Here a variable pressure regulator is adopted.

Through a variety of direction control value are available, a hand operated spool
value with detent is applied.

The spool value used here is 5 ports, 3 positions. There are two exhaust ports, two
outlet ports and one inlet port. In two extreme positions only the directions can be
changed while the Centro ore is a neutral position and no physical changes are incurred.

The 2 outlet ports are connected to an actuator (Cylinder).

The pneumatic

activates is a double acting, single rod cylinder. The cylinder output is coupled to further
purpose. The piston end has an air horning effect to prevent sudden thrust at extreme
ends.

PRINCIPLES OF WORKING
The compressed air from the compressor reaches the solenoid valve. The solenoid
valve changes the direction of flow according to the signals from the timing
device.

 The compressed air pass through the solenoid valve and it is admitted into the
front end of the cylinder block. The air pushes the piston for the cutting stroke. At
the end of the cutting stroke air from the solenoid valve reaches the rear end of the
cylinder block. The pressure remains the same but the area is less due to the
presence of piston rod. This exerts greater pressure on the piston, pushing it at a
faster rate thus enabling faster return stroke.

The weight attached at the end of the hacksaw frame gives constant loads which
lower the hacksaw to enable continuous cutting of the work.

The stroke length of the piston can be changed by making suitable adjustment in
the timer.

---------------------------------------------------------------------------------------

Chapter-6
---------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------

FABRICATION
---------------------------------------------------------------------------------------

CHAPTER-6
FABRICATION
COMPONENTS:
Piston
Actuating rod
Base Plate
Bush
Hacksaw Frame
Vise
Solenoid Valve
Timing Device
Flexible hoses
Cylinder block

Piston:
The piston is fitted in the cylinder block and reciprocates inside. When the
solenoid valve supplies the air in the front end of the piston, the piston is pushed forward.
This moves the hacksaw and the cutting stroke takes place. Then the solenoid valve
supplies air to the rear end of the piston. The pressure is same but the contact area is less

due to the presence of the piston rod and pushes the piston at a greater pressure thus
resulting in a fast return stroke. The material for the piston is Aluminum.

Actuating Rod:
The actuating rod is fitted inside the bush. It is connected at one end to the piston
rod and at the other end it is connected to the hacksaw frame. It reciprocates inside the
bush. The material for the actuating rod is mild steel.

Base Plate:
All the components of the machine are mounted on the base plate. It withstands
the vibrations encountered during machining. It is mounted on the bench.

Hacksaw Frame:
The hacksaw frame is connected to one end of the actuating rod and the weights
are mounted at the other end. The hacksaw is fitted in the slots provided in the frame.
The material for the frame is mild steel.

Vise:
The vise is mounted on the base plate below the hacksaw frame. It is used for
holding the work piece. It should have sufficient strength to withstand the cutting forces.
The material for vise is cost iron.

Solenoid Valve:
It is a 2x3 positional control valve. It receives the compressed air from the
compressor and supplies to the cylinder block according to the signal, given by the timing
device. During one position it supplies air to the frond end of the cylinder block. During
the next position it supplies air to the rear end of the cylinder block.

Timing Device:
The timing device supplied signal alternatively to the solenoid valve. The clock
fitted in the device actuates the operation of the valve. The timing can be changed to
obtain different speeds.

Flexible Hose:
The flexible hoses connect the solenoid valve and the cylinder block. Hoses are
made of in layer of elastomer (or) synthetic rubber and braided fabric which takes up the
higher pressure. If the hose is subjected to rubbing, it should be enclosed in a protective
sleeve.

Cylinder block:
The cylinder block has two opening for admitting air inside the block for
achieving the reciprocation motion of the piston. The material for cylinder block is
Aluminium.

Bush:

It is cylindrical in shape with a central hole. It supports the actuating rod. The
actuating rod reciprocates in the bore at the bush. The material for the bush is mild steel.

---------------------------------------------------------------------------------------

Chapter-7
---------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------

APPLICATION
---------------------------------------------------------------------------------------

CHAPTER-7
APPLICATIONS

1. Agriculture:
Crop forming
Stock breeding
Animal food industries
Foresting

2. Utilities:
Power Station
Nuclear Engineering
Water Supply

3. Mining
4. Chemical Industry
5. Plastics and rubber industries

6. Stone, Ceramic and glass industries

7. Metal Industries:
Iron and Steel
Non-ferrous metals
Foundries
Scrap and recycled metals

8. Leather Industry
9. Textile Industry
10. Paper and Printing Industry

---------------------------------------------------------------------------------------

Chapter-8
---------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------

NEED FOR AUTOMATION

---------------------------------------------------------------------------------------

CHAPTER-8
NEED FOR AUTOMATION

Nowadays almost all the manufacturing process is being atomized in order to

deliver the products at a faster rate. The manufacturing operation is being atomized for
the following reasons.

To achieve mass production

To reduce man power

To increase the efficiency of the plant

To reduce the work load

To reduce the production cost

To reduce the production time

To reduce the material handling

To reduce the fatigue of workers

To achieve good product quality

Less Maintenance

---------------------------------------------------------------------------------------

Chapter-9
---------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------

ADVANTAGES AND
LIMITATIONS
---------------------------------------------------------------------------------------

CHAPTER-9
ADVANTAGES AND LIMITATIONS
ADVANTAGES:
There is no need of giving feed during every cut due to the presence of weight.
The cutting speed can be varied according to our needs by adjusting the timer.
It is portable
It does not have any Prime mover, like electric motor related to the unit.
As the air is freely available, we can utilize the air to cut the metal and hence it is
economical.
Simple in construction than mechanical hacksaw
It is a compact one
Less Maintenance

LIMITATIONS
Only smaller size and soft metal can be cut
It is costlier than the mechanical hacksaw because of compressor unit.
Less efficiency when compressed to mechanical device.
Leakage of air affects the working of the unit.

---------------------------------------------------------------------------------------

Chapter-10
---------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------

PROCESS SHEET
---------------------------------------------------------------------------------------

CHAPTER-10
PROCESS SHEET

FABRICATED PARTS:
Sl.

PART

No.
1.

DESCRIPTION

OPERATION

MACHINE

TOOL

GAUGES

i)

Turning

Lathe

Turning Tool

Micrometers

ii)

Shaping

Shaper

iii)

Drilling

Drilling

Right hand

8x22.5m

Machine

Round nose Plug Gauge

tool

Drill bit
2.

Bush
D-53mm

(i)

Turning

Lathe

Turning Tool

Micrometer

d-30mm

(ii)

Drilling

Drilling

Drill Bit

Plug Gauge

I-70mm

(iii)

Boring

Machine

Boring Bar

Inside

Lathe
3.

Micrometer

Base Plate
L-722 mm
B-254mm
H-78mm

Bending

Bending

Bending Tool

--

Machine

---------------------------------------------------------------------------------------

Chapter-11
---------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------

LIST OF MATERIALS
---------------------------------------------------------------------------------------

CHAPTER-11
LIST OF MATERIALS

PROCURED PARTS:
Sl. No.
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.

PARTS
Cylinder block (with piston)
Solenoid valve
Machine vice
Timing control unit
Flexible hoses
Hack Saw frame
Bolts & Nuts
PU Connectors
Flow Control Valve

Qty.
1
1
1
1
2 Meter
1
1

MATERIAL
EN8
ALU.
C.I
POLYURETHENE
M.S
M.S
BRASS
ALU.

---------------------------------------------------------------------------------------

Chapter-12
---------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------

COST ESTIMATION
---------------------------------------------------------------------------------------

CHAPTER-12
COST ESTIMATION

Sl. No.
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.

PARTS
Cylinder block (with piston)
Solenoid valve
Machine vice
Timing device
Flexible hoses
Hack Saw frame
Bolts & Nuts
PU Connectors
Flow Control Valve
TOTAL

Qty.
1
1
1
1
1
1

Cost

LABOUR COST
LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS CUTTING:
Cost =

OVERHEAD CHARGES

The overhead charges are arrived by Manufacturing cost

Manufacturing Cost =

Material Cost + Labour cost

=
=
Overhead Charges =
=

20% of the manufacturing cost

TOTAL COST
Total cost

Material Cost + Labour cost + Overhead Charges

=
=
Total cost for this project

---------------------------------------------------------------------------------------

Chapter-13
---------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------

CONCLUSION
---------------------------------------------------------------------------------------

CHAPTER-13
CONCLUSION
In the pneumatic hacksaw variable speeds can be obtained by adjusting the timer
device and pressure of the compressed air. Since the mechanism is so simple and
versatile it can be handled by any operator, constriction of the unit is very simple.
Handling the machine is easy and smooth operation is achieved.

--------------------------------------------------------------------------------

BIBLIOGRAPHY
--------------------------------------------------------------------------------

BIBLIOGRAPHY

Antonio Esposito - Fluid power with application. Prentice hall of

India private

limited, 1980.
Bolton,W.,Pneumatic and hydraulic systems,Butterworth-Heinemann,Jordan Hill,
Oxford,1997.
Catalogue of Janatics pneumatic product, Janatics Private Limited Coimbatore.
Design data book compiled by faculty of mechanical engineering
P.S.G. college of technology,Coimbatore
Festo Didactic KG Fundamentals of control technology, Esslingen-1998.
Festo Pneumatic Catlogue - Festo Pvt Ltd. Bangalore.
Werner Deppert/Kurt Stoll., Cutting Cost With Pneumatics, Vogel Buchverlag
Wurzburg, 1998.

--------------------------------------------------------------------------------

PHOTOGRAPHY
--------------------------------------------------------------------------------

PHOTOGRAPHY