Professional Documents
Culture Documents
A PROJECT REPORT
Submitted By
H.PRAKASH (111816114339)
S.PADMANABAN (111816114338)
T.V.KULOTHUNGAN (111816114324)
Of
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
RVS PADMAVATHY COLLEGE OF ENGINEERING & TECHNOLOGY
CHENNAI
ANNA UNIVERSITY
CHENNAI 600025
APRIL 2019
SIGNATURE SIGNATURE
Mr. M.KISHOR M.TECH Mr. M.KISHOR M.TECH
HEAD OF THE DEPARTMENT. GUIDE
Submitted for the project work and Viva-voice Exam held on __________________.
personnel whom we wish to recognize with dutiful respect and abundant gratitude with
We are greatly indebted to our beloved chairman Thiru Dr. K.V.KUPPUSAMY and
Trustees Mr. C.S.SATISH and DR. U.VISHALKUMAR for acting as a chief support by
providing us excellent infrastructure in our college. We are greatly indebted our beloved
Mr. M.KISHORE, Head of the Department of Mechanical Engineering for his guidance
Our sincere thanks to our project guide Mr. M.KISHORE, Assistant professor for
having extended their fullest co-operation and guidance. We also thank them for their
constant support and patience. We also take this opportunity to thank all the staffs of our
We also thank our parents for their unparallel love and moral support & finally the
almighty for showering his generous blessings on us, without whom we would have not got
this far.
CONTENTS
ACKNOWLEDGEMENT
1. SYNOPSIS
2. INTRODUCTION
3. SELECTION OF PNEUMATICS
6. PRINCIPLE OF OPERATION
7. AIR LEAKS
8. PROCESS SHEET
12. CONCLUSION
BIBLIOGRAPHY
PHOTOGRAPHY
CHAPTER-1
SYNOPSIS
This report deals with design and fabrications of pneumatic multipurpose presses, which is
used for fixing bearings of rotors in the shaft, bending and bend removing with the help of a
compressor.
Initially the shaft is held between two fixtures; top of the bearing is freely located on the
step in the shaft and the other one is placed on the bottom fixture. As one of the bearing
(located on the shaft step) is compressed, both the bearings are inserted in the shaft
simultaneously as the top fixture moves down words. Similarly bending and bend
INTRODUCTION
The pneumatic multipurpose press is used for fixing the bearings in the shaft by
holding the shaft between two fixtures. One of the fixtures is movable and the other is
fixed.
The pneumatic multipurpose press is also used to remove the bend in the shaft and
The principle of operation is the same as the conventional simple press. The
difference is only in the type of drive and the type of fixtures used.
The following points reveals why we have to make use of this type of press
By using this machine the bearings can be inserted in the various lengths of shat (up
to 600mm).
CHAPTER-3
SELECTION OF PNEUMATICS
power. Pneumatics 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 both the power or energy requirements and the
control system (although equally pneumatic control systems may be economic and can be
The main advantages of an all-pneumatic system are usually economy and simplicity,
the latter reducing maintenance to a low level. It can also have out standing advantages in
terms of safety.
CHAPTER-4
The pneumatic bearing press consists of the following components to fulfill the
i. Pneumatic cylinder
v. Pressure gauge
vii. Hoses
1. CYLINDER:
The cylinder is a double acting cylinder one, which means that the air pressure
operates alternatively (forward and backward). The air from the compressor is passed
through the regulator which controls the pressure to required amount by adjusting its
knob. A pressure gauge is attached to the regulator for showing the line pressure.
Then the compressed air is passed through the directional control valve for supplying
the air alternatively to either sides of the cylinder. Two hoses take the output of the
directional Control valve and they are attached to two ends of the cylinder by means of
connectors. One of the outputs from the directional control valve is taken to the flow
Barrel:
Piston Rod:
Seals:
End Covers:
Piston:
Aluminium.
Media:
Air.
Temperature Range:
0^c to 85^c
Cushions:
Technical Data:
Size : ¼”
Pressure : 0 to 10 kg / cm2
Media : Air
Working Principle:
Double acting cylinder are controlled by 2 way 5 port two position valve as shown in
the fig. This valve has one inlet port (P), two cylinder ports (A and B), and two exhaust
In this position of the valve supply is directed to cylinder port no. A, with cylinder port B
connected to exhaust port R. The air supply is connected to cylinder port B; with cylinder
By operating the valve in two positions the cylinder piston can get the forward stroke
Size : ¼”
Pressure : 0 to 10 kg / cm2
Media : Air
( b ) Purpose:
This valve is used to speed up the piston movement and also it acts as an one – way
restriction valve which means that the air can pass through only one way and it can’t
return back.
By using this valve the time consumption is reduced because of the faster movement
of the piston.
Specification:
Pressure control valves may be designed to vary the pressure to a desired level within
The air is passed through the throttling orifice by adjusting its knob in the desired
direction.
By adjusting the knob we can get different pressure ranges so that the load applied by
Technical data:
Pressure gauges are usually fitted with the regulators. So the air pressure adjusted in
the regulator is indicated by the pressure gauge and also the pressure indicated in the
pressure gauge is the line pressure of the air taken to the cylinder.
(VI) CONNECTIORS:
In our pneumatic system there are two types of connectors used; one is the hose
Hose connectors normally comprise an adapter (connector) hose nipple and cap nut.
Reducers are used to provide inter connection between two pipes or hoses of
different sizes. They may be fitted straight, tee, “V” or other configurations. These
reducers are made up of gunmetal or other materials like hardened steel etc.
(VII) HOSES:
Hoses used in this pneumatic system are made up of polyrethane. These hoses can
The various sizes polyurethane tubes and its specifications are shown in the table 2.
TABLE 2
NOMENCLATURE
DESIGN NO.:1
DESIGN NO.: II
S Slenderness ratio
R Least radius of the cross section d/4 for circular cross section, cm
DESIGN NO.:III
Deflection = Y = P / 48 E1
L = 300 mm
12 12
Maximum load acting at the --- 430kgf (from the Manufacturers catalogue)
= 301kgf
P = 3010 N
=ν = -----------------------------------
Long and slender shafts, axially loaded, should be checked for stability in bucking.
Rankine’s formula for calculation for stability in buckling should be used if the
Where,
L = 90cm
D 4.2
4 4
90
1.05
As the slenderness ratio for the pillar is with in the range of 20 to 100, Rankine’s
Π d^2 σ c/4
Pcr = -------------------------
[L +k (L/R) ^2]
Where
D = 4.2cm
σ c = 22090 kgf/cm^2
L = 90cm
R = 1.05cm
Π (4.2) ^2 x (2200/4)
Pcr = --------------------------------
90 + 1/25000(90/10.5) ^2
30479.723
Pcr = ---------------
90.29
For the pillar based on its material and dimensions, the critical load for bucking that
But as only a maximum load of 150.5 kgf is applied on each pillar while working, the
design is safe.
Selecting a PSG 3hp T.E.F.C motor, the bearing and shaft sizes at driving and non-
DRIVING END:
(SKF) Bearing:
d = 30mm
B = 19MM
Shaft:
= 30+0.009
NON DRIVING END
Bearing:
d = 25mm
D = 62mm
B = 17mm
Shaft:
Size = 25j6
= 25+0.009
To get the minimum clearance between the shaft and bearing, the shaft and bearing
DRIVING END:
= 29.99mm
= 30.009mm
29.990
-----------------
00.019mm
-----------------
= 24.99mm
= 25.009mm
Bearing = 25.009
24.990
--------
00.019
--------
2
0.019 + 0.019
= ---------------------------------
For the maximum size of the shaft and bearing for which the machine is designed the
minimum mean clearance (between the shaft and the bearing) is calculated to be 0.019 mm
or 19 micros. Even though the fit is a clearance one, the bearing cannot be mounted on the
shaft by hand force and also hammering would result in reduced life of the bearing. So, a
constant force should be applied for which the machine is designed to perform.
Technical Data
Quantity : 2
Piston : EN – 8
Media : Air
Temperature : 0-80 º C
Technical Data
Media : Air
Quantity : 1
3. Connectors
Technical data
Temperature : 0-100 º C
Material : Brass
4. Hoses
Technical date
Outer diameter : 6 mm = 6 x 10 ˉ ³m
PRINCIPLE OF OPERATION
The pneumatic multipurpose press is used for fixing bearings in the shaft up to a
length of 600mm. In the pneumatic multipurpose press the main thing being the
The air in that compressor is passed to the double acting cylinder through the
control valves. There are two control valves used in this press. One is pressure control
When the compressed air is passed to the pressure control valve, the required
pressure is obtained by adjusting its knob. When the air is passed to the flow control
valve, the speed of movement of piston is controlled by adjusting the knob. The
A bottom fixture is fixed on the bottom plate by using ‘T’ bolts or hexagonal
First one of the bearings is placed on the bottom fixture. Then the shaft is taken
and the other bearing is kept ion the step in the shaft. When the shaft is kept vertically
on the bottom fixture some portion of the shaft goes inside the bottom fixture.
At the same time the compressor is loaded to get the pressure required and the
hand operated valve is manually actuated from the neutral position to the input
position to move the piston. The top fixture in the piston had inserted to its required
down ward movement; at the same time the entire shaft will move downward so that
the another bearing placed on the bottom fixture also gets inserted. Then the valve is
brought to the output position in which the air moves the piston upward and the shaft
is removed.
The shaft is kept vertically between the bottom fixture and top fixture. The bearing
which is removed is in the top of the fixture. The remaining portion of the shaft touches
At the same time the compressor is loaded to get the pressure required and the
hand operated valve is manually actuated from the neutral position to the input
position to move the piston. The top fixture in the piston had inserted to its required
position rod pushes the bearing which is placed on the shaft. When the bearing had
removed to its required position, there will not be any further down ward movement.
Then the valve is brought to the output position in which the air moves the piston
Air leaks are not hazardous, but they can be extremely waste full of power. In a
typical system as much as 10% of the power requirements at any period can be made
Se Operation Machin Setting Speed Feed No. Machining Tools Gauges Rem
q. details e Time (rpm) Mm/r of Time ark
No (min) ev cots (min)
.
1 Chucking Lathe 16 - - - - Chuckke Surface -
y gauge
2 Facing Lathe 20 120 0.5 4 45 Facing Vernier -
tool
3 Turning Lathe 12 120 0.5 4 30 R.H. tool Meter -
Scale
4 Reversing The Lathe 30 Chuckke Surface -
job & chucking y gauge
- - - -
5 Facing Lathe 20 120 0.5 4 45 Facing Vernier -
tool
6 Turning Lathe 12 120 0.5 4 30 R.H. tool Meter -
Scale
to another M/C - - - - - y - -
Nut
10 Reversing Milling 15
M/C cutter
nut
30mm M/C - -
Seq. Operation Machine Setting Speed Feed No. Machining Tools Gauges Remarks
gauge
chucking
tool pitch
guage
another
m/c &
fixing
9 slotting Milling 20 250 10 3 60 End milling - -
m/c cutter
Sheet No. :3
Seq. Operation Machine Setting Spee Feed No. Machining Tools Gauges Remar
n) (rpm v) cuts
ey e
gauge
tool
chucking gauge
tool scale
tool r
job to ey
another m/c
spanne
Merits:
Demerits:
LIST OF MATERIALS
DC Valve Aluminium 1
punch En8 1
die En8 1
Hose Polyurethane 3m
Pneumatic connecter Brass 8
CHAPTER-11
COST ESTIMATION
1. MATERIAL COST:
PART MATERIAL QUANTITY AMOUNT(Rs)
Pneumatic cylinder Cast iron 1
DC Valve Aluminium 1
punch En8 1
die En8 1
Hose Polyurethane 3m
3. OVERHEAD CHARGES
TOTAL COST
CONCLUSION
This multipurpose press is used for pressing stampings, bearing of rotors, removing
The design of this machine can be improved to reduce further manual work by
By incorporating FRL (Filter, Regulator, and Lubrication) unit, the functioning of the
3. Machine tool design hand book - Central machine tool Institute, Bangalore.