AUTOMATIC PNEUMATIC FORGING

MACHINE USING PLC

Dr. Deivanathan R
School of mechanical and building sciences(SMBS)
VIT University, Chennai campus
Chennai-600127 ,Tamil Nadu
deivanathan.r@vit.ac.in

Maulik Prajapati
MTECH(Mechatronics)
VIT University, Chennai campus
Chennai-600127 ,Tamil Nadu
maulikprajapati33@gmail.com

Abstract The proposed work describes the design of automatic

pneumatic forging machine controlled by PLC and shedding light on
the working principle and the hardware structure of the system.
Forging process is one of the most important and necessary
processing step in shaping metal by using localized compressive
force. By automating this process one can have a greater control over
the process. Programmable Logic Controllers are used for the control
of the system. This system can replace existing manual feed and
operated forging machines. By interfacing PLC controls with the
conventional machines, it is possible to achieve good results in the
form of reduced manufacturing lead time, reduced cost and increased
safety of the worker.

reduced safety for the worker

PLC

KeywordsForging Machine, PLC, Pneumatics ,Ladder Logic

diagram

INTRODUCTION
In todays practical world forged-metal parts have already replaced
many expensive cast and machined products. The reason is obviously
the relative economy of operation, easier implementation for massproduction, as well as greater control on the technical parameters. In
most of the forging operations or pressing operation is the main or
initial operation is the process sequence. Automating this operation
results in reduced lead time and also can reduce human effort.
Automation can be defined as the technology concerned with
application of mechanical, electronic and computer-based systems to
operate and control production. There are many reasons for
automating the process. The reason may be to reduce manufacturing
lead time, to increase labor productivity or to improve the worker
safety, etc.

Forging Process
Forging is a manufacturing process that is used to make the shaping
of metal using compressive force to a work piece to deform it, and
create a desired geometric change to the material. The forging
process is very important in industrial metal manufacturing industry
.The forging also represent the fastest and more efficient way to form
a metal into a finished forged product.
In manual or conventional methods of forging the disadvantages may
be
angular misalignment of the metal
higher material handling time and manufacturing lead times

Fig. 1 PLC System block diagram

A Programmable controller is a solid state user programmable control

system with functions to control logic, sequencing, timing, arithmetic
data manipulation and counting capabilities.
It can be viewed as an industrial computer that has a central
processor unit, memory, input output interface and a programming
device. The central processing unit provides the intelligence of the
controller. It accepts data, status information from various sensing
devices like limit switches, proximity switches, executes the user
control program store in the memory and gives appropriate output
commands to devices like solenoid valves, switches etc.

In this project, pneumatic cylinder and PLC system is interfaced with

the conventional forging process for achieving the automation.

Working Methodology

versatile and most widely used stainless steel, available in a

wider range of products, forms and finishes than any other. It
has excellent forming and welding characteristics.
Properties of 304 stainless steel
PHYSICAL PROPERTIES

The figure shows the working diagram of forging machine.

Here ,we have fixed pneumatic cylinder on the column of the
machine which is fixed to the to the base table.
The die are fixed at the end of the pneumatic cylinder piston rod.
The pneumatic cylinder is operated through the air, which is
coming from compressor. The air stored in a compressor the
compressed air is passed to the pneumatic cylinder with the help
of the solenoid valve.
The solenoid valves are operated through the PLC which work as
control unit in this system.
The air enters into the pneumatic cylinder to one port to moves
the forging die in downward direction.
During the forging operation the forging die will moves in
upward direction.
While on the forging die moves in upward direction the port one
will release and the air will be forced into the port number two.
The two directions of the forging die are controlled by control
unit, which is PLC.
During the movement the forging die forged the work piece to
make it to the required shape and size. When no of stroke is
completed the forging process is stopped by the help of the
control unit.

Die
A die is a specialized tool that is used in manufacturing
industries to cut or shape material mostly using a press them. dies are
generally used to create products range from simple piece to
complex pieces used in advanced technology.
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.

Die Material
Type 304 stainless steel is a T 300 Series Stainless Steel austenitic. It
has a minimum of 18% chromium and 8% nickel, combined with a
maximum of 0.08% carbon. It is defined as a ChromiumNickel austenitic alloy.

Grade 304 is the standard "18/8" stainless; it is the most

Approxima
te
Chemical
Compositi
on

density

0.803g/cm3

Electrical
resistivity

72
microhmcm

Specific heat

0.50kj/kg-k

17 -

16.2 w/m-k

19%

Thermal
conductivity
Modulus
of
elasticity(Mpa)
Melting point

193*10^3

Ni

2550-2650
F

F
e

MECHANICAL PROPERTIES
Tensile strength, Mpa

515

Proof Strength,(offset 0.2%), Mpa

310205

Elongation(Percent in 50mm)

55%

Hardness(Brinell)

170

Endurance(fatigue) limit, Mpa

240

Modeling of system

811%
BAL

Modeling and design of die

Force and pressure calculation

Upper die
A = Cross sectional area of work-piece
0 = Yield stress of the metal
h = instantaneous height of the metal bar during forging
0 = Original height of the metal bar
0 = Original diameter of the metal bar
e = Engineering strain
= True strain
P = pressure applied to the metal bar
F = Compressive force acting on a metal bar
p = Compressive stress produced by the force

Cross sectional area of work-piece

=2
=3.14*202
=1256 2

Compressive force acting on metal bar

F = 0*A
=215*1256
=270040 N

Compressive stress produced by the force

40

P=

Lower die
=

0 2 0

4215 125610
3.14102 10

=3440 N/2

Engineering strain
e=

0
0

= 1020
20
=-0.5

True strain

=
=

20
10

=0.69

Pressure applied on the metal bar

P=
=

270040
1256

=215 N/2

Design of pneumatic circuit of the system

Compressor is used to supply the air to the cylinder

The whole operation work on a air such as the air

from compressor passed to FRL unit that filter the air
and pressure relief valve maintain the pressure and
that is applied to direction control valve which give
the direction of cylinder for forward or reverse
direction and passing through the flow control valve.

Ladder Logic Programming:

Ladder logic is a programming language that represents a
program by a graphical diagram based on the circuit diagrams
of relay logic hardware. It was primarily used to develop
software for programmable logic controllers (PLCs) used in
industrial control applications. The name is based on the
observation that programs in this language resemble ladders,
with two vertical rails and a series of horizontal rungs between
them.

Ladder logic diagram

Fig.3 Pneumatic circuit

The figure shows the pneumatic circuit for

the operation of forging machine.

Here we have use a double acting cylinder

for extending and retracing position.

Two non-return flow control valve is used

to control the speed of the cylinder

5/2 directional control spring operated

Solenoid Valve is used to change the
direction of the Cylinder that is forward
or reverse.

Pressure relief valve is used to control the

pressure that is applied to the cylinder.

FRL unit is used to filter the air that comes

from compressor

FIG.4 Ladder diagram to control the pneumatic system

Sequence of Operation:

The figure shows the ladder diagram to control the

pneumatic circuit.

When the start button is pressed ,CR1 is latched and which

energized the solenoid valve TA+ and which change the
position of the valve and air is supply to the cylinder for the
forward stroke.

When forward stroke occurs the CR2 is latched and

unlatched the forward stoke and which energized the
solenoid valve TA- and again valve change the position and
air is supply to the cylinder for the return stroke.

The cylinder will continue forward and return stoke ,when

the start button is pressed.

To stop the cylinder moment we have to pressed the stop

button.

After pressing the stop button , the current inside the circuit
will not flow and which cannot run the circuit.

So, here input are start and stop button and output are
double acting cylinder.

Conclusion:
In this paper a method of controlling the operations of forging
machines is discussed. By using Programmable Logic Controllers as
the controller of the system, good control over the system can be
achieved, manufacturing lead time of the system can be reduced by
developing automatic feeding mechanism and worker safety can be
increased by reducing the human participation in the process.

References

Kamman, J. W. and Jennings, A. System Identification and

Control of a Pneumatic Cylinder. Western Michigan University.
Technical Report Number: MAE-05-07. 2005

Aditya Polapragada, Sri Varsha, Pneumatic Auto Feed Punching

and Riveting Machine, International Journal of Engineering
Research & Technology (IJERT), Vol. 1 Issue 7, September
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Vijaylaxmi.G.Biradar,

Siddharam Patil , R M Lathe,

Automation of Sheet Bending Machine Using Electro Pneumatic
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Research Volume 3, Issue 9, September-2012 1 ISSN 2229-5518

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Majumdar-Tata MCGRAW hill handbooks.