Professional Documents
Culture Documents
DIPLOMA
IN
MECHANICAL ENGINEERING
BY
2004-2005
them.
Done by
Mr. / Ms_______________________________
_________________ _______________
Head of Department Guide
Coimbatore –641651.
Date:
___________
_________________ ________________
Internal Examiner External
Examiner
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ACKNOWLEDGEMENT
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ACKNOWLEDGEMENT
CONTENTS
CHAPTER
NO TITLE PAGE NO
1 Introduction
2 Literature survey
3 Components and Description
4 Design and drawings
5 Working principle
6 Fabrication
7 Applications
8 Need for automation
9 Advantages and limitations
10 Process sheet
11 List of materials
12 Cost estimation
13 Conclusion
Bibliography
Photography
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Chapter-1
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INTRODUCTION
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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
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
Hacksaw machine.
The main function of Pneumatic hacksaw is to cut thin and soft metals by
pneumatic power.
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Chapter-2
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LITERATURE SURVEY
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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
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
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
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
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.
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
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
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
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
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
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.
2. Turbo compressor
air plant and have proved highly successful and supply air for pneumatic control
application.
The types of positive compressor
Turbo compressors are employed where large capacity of air required at low
discharge pressures. They cannot attain pressure necessary for pneumatic control
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 m³/min. In single stage compressor, the air
pressure in the range of 250 bars can be obtained with high pressure reciprocating
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
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COMPONENTS AND
DESCRIPTION
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CHAPTER-3
Pneumatic cylinder
one direction. Single acting cylinders equipped with one inlet for the operating air
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
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
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
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
Position-1
When the spool is actuated towards outer direction port ‘P’ gets connected to ‘B’
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.
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
AC, 575 Volts AC, 6 Volts DC, 12 Volts DC, 24 Volts DC, 115 Volts DC & 230 Volts DC.
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
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
solenoids.
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
result its speed will increase. If the quantity of air entering into the actuator is reduced,
4A-230V X 3
47K
L1
TRIAC X 3
4 8 16 1N4007 X 3
3 L2
7 IC 4017
555 2
10K 6 3 14
L3
2 1 4
13 8
100µF 1N4007 X 4
1N4007
1000µF
230/9V
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
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 SUPPLY (Vcc)
1 8
TRIGGER DISCHARGE
2 7
IC
OUTPUT NE 555 THERSOLD
3 6
RESET CONTROL
4 5
PIN NO: 1
It is ground terminal.
PIN NO: 2
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
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
μF. Any external voltage at pin: 5 will change both the threshold voltage and the trigger
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
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
5. The output of 555 is compatible with CMOS, DTL and TTL, logic. But
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
IC 555 SPECIFICATION
Female - BSP
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.
Flexible Hoses:
which permits operation at higher pressure. The standard tubing outside diameter is 1/16
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/cm². 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.
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Chapter-4
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The pneumatic auto feed drilling machine consists of the following components to
2. Solenoid Valve
4. Connectors
5. Hoses
Technical Data
Quantity : 1
Piston : EN – 8
Media : Air
Temperature : 0-80 º C
2. Solenoid Valve
Technical data
Size : 0.635 x 10 ˉ² m
Quantity : 1
Technical Data
Port size : 0.635 x 10 ֿ² m
Media : Air
Quantity : 1
4. Connectors
Technical data
Temperature : 0-100 º C
Material : Brass
5. Hoses
Technical date
Outer diameter : 6 mm = 6 x 10 ˉ ³m
= p x (Πd² / 4)
= 6 x {( Π x 4² ) / 4 }
P = 73.36 Kgf
Design Stress(σy) = σy / F0 S
= 36 / 2 = 18 Kgf/mm²
= P / (Π d² / 4 )
∴d = √ 4 p / Π [ σy ]
= √ 4 x 75.36 / {Π x 18}
= √ 5.33 = 2.3 mm
Where,
t = 0.019 cm = 0.19 mm
= 40 + ( 2 x 2.5 ) = 45 mm
Design of Piston rod:
= 6 x (Π / 4) x (4)²
= 73.36 Kgf
= 0.15
dp = 0.38 cm = 3.8 mm
By standardizing dp = 15 mm
= 232 mm
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WORKING PRINCIPLE
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CHAPTER-5
WORKING PRINCIPLE
PNEUMATIC CIRCUIT:
Since pneumatic circuit plays a vital role in this device, it is very necessary to
Initially starting with air compresses, its function is to compress air from a low
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
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
Through a variety of direction control value are available, a hand operated spool
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.
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
The weight attached at the end of the hacksaw frame gives constant loads which
The stroke length of the piston can be changed by making suitable adjustment in
the timer.
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Chapter-6
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FABRICATION
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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
Base Plate:
All the components of the machine are mounted on the base plate. It withstands
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.
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.
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
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
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.
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Chapter-7
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APPLICATION
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CHAPTER-7
APPLICATIONS
1. Agriculture:
Crop forming
Stock breeding
Foresting
2. Utilities:
Power Station
Nuclear Engineering
Water Supply
3. Mining
4. Chemical Industry
Non-ferrous metals
Foundries
8. Leather Industry
9. Textile Industry
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NEED FOR AUTOMATION
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CHAPTER-8
deliver the products at a faster rate. The manufacturing operation is being atomized for
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Chapter-9
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ADVANTAGES AND
LIMITATIONS
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CHAPTER-9
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.
It is a compact one
Less Maintenance
LIMITATIONS
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Chapter-10
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PROCESS SHEET
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CHAPTER-10
PROCESS SHEET
FABRICATED PARTS:
Sl. PART OPERATION MACHINE TOOL GAUGES
No. DESCRIPTION
1. i) Turning Lathe Turning Tool Micrometers
ii) Shaping Shaper
iii) Drilling Drilling Right hand -
Ф8x22.5mm 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 Micrometer
3. Base Plate
L-722 mm
B-254mm Bending Bending Bending Tool --
H-78mm Machine
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Chapter-11
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LIST OF MATERIALS
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CHAPTER-11
LIST OF MATERIALS
PROCURED PARTS:
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COST ESTIMATION
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CHAPTER-12
COST ESTIMATION
LABOUR COST
OVERHEAD CHARGES
TOTAL COST
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Chapter-13
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CONCLUSION
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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.
Antonio Esposito - Fluid power with application. Prentice hall of India private
limited, 1980.
Oxford,1997.
Wurzburg, 1998.
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PHOTOGRAPHY
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PHOTOGRAPHY