Fabrication of Pneumatic Punching and Riveting Machine

PROJECT TITLE
A PROJECT REPORT
Submitted to
SUNRISE UNIVERSITY
in partial fulfilment for the award of the diploma of
POLYTECHNIC
In
MECHANICAL ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
SUNRISE UNIVERSITY
ALWAR
RAJASTHAN, INDIA
MAY 2014
Annexure1
PROJECT TITLE
<1.5 line spacing>
A PROJECT REPORT
<Italic>
Submitted to
SUNRISE UNIVERSITY
<Bold
in partial fulfilment for the award of the diploma of

<1.5 line spacing><Italic>
POLYTECHNIC
<Bold
IN MECHANICAL
ENGINEERING
<Bold
DEPARTMENT OF MECHANICAL ENGINEERING

<Bold
SUNRISE UNIVERSITY
<Bold
ALWAR RAJASTHAN,
INDIA
<Bold
MAY 2014
<Bold
CERTIFICATE
This is to certify that the project report entitled TITLE OF PROJECT WORK
submitted by NAME OF GROUP to the SunRise University Alwar,Rajasthan in partial

fulfilment for the award of Diploma of Polytechnic in Mechanical Engineering is a confide
record of the project work carried out by him under my supervision during the year 20152016.
Submitted to:
Submitted by:
Name of incharge
Name of student(Roll)
Designation
Name (Project Guide)

Designation
SUNRISE UNIVERSITY
Bagad Rajput, ALWAR-301030(Raj.)
INDIA
3
ACKNOWLEDGEMENT
I take this opportunity to express my profound gratitude and deep to my mentor Mr.
Vinayak Hemadri for his exemplary guidance, monitoring and constant encouragement
throughout the course of this thesis. The blessing, help and guidance given by him time to
time shall carry me a long way on the journey of life in which I am about to embark. I also
take this opportunity to express a deep sense of gratitude to the mentor for his cordial
support, valuable information and guidance, which helped me in completing this task through
various stages.
Lastly, I thank almighty, my parents, and friends for their constant encouragement
without which this assignment would not be completed.
ABSTRACT
In our Project work FABRICATION OF PNEUMATIC CONTROLLED
RIVETTING AND PUNCHING MACHINE we used principles of Pneumatic control
system in developing this project work., In our project we are having two control switches,
when first switch is pressed it works as a Riveting machine and when the second switch is
pressed it works as Punching machine. The vibrating mechanism is achieved by reciprocating
the double acting cylinders, which controlled by solenoid operated 5/2 way DC valve which
is actuated through the control system.
The operating pressure required for this system is 5 to 6 bar. The maintenance
required for this system is less than the other systems.
For punching operation, a counter weight is added to the pneumatic cylinder force in
order to make the punching operation effectively, and also for punching operation a separate
Punching tool is fitted and the job is placed on the die, For riveting operation a riveting head
is fitted.
TABLE OF CONTENTS
CHAPTER NO
TITLE
PAGE NO
ABSTRACT
LIST OF FIGURES
LIST OF TABLES
1. CHAPTER
1.1 INTRODUCTION
1.2 GENERAL DESCRIPTION
1.2.1 PRODUCTION OF COMPRESSED AIR
1.3 ADVANTAGES
10
1.4 DISADVANTAGES
11
CHAPTER 2
2.1 BLOCK DIAGRAM
15
2.2 NEED FOR AUTOMATION
15
2.2.1 PRINCIPLE OF OPERATION OF A PRESS

2.3 MECHANICAL ADVANTAGE
16
16
PRINCIPLE OF LEVELLERS
16
2.4 THE ARMATURE
17
2.5 THE COMMUTATOR AND BRUSHES
17
CHAPTER 3
3.1 WORKING PRINCIPLE
18
3.2 SELECTION OF PNEUMATICS
19
3.2.1 SOLENOID VALVE
19
3.3 UNIT DESCRIPTION (CONSTRUCTION)
19
3.3.1 CYLINDER
19
3.3.2 DOUBLE ACTING CYLINDER
20
3.3.3 PUNCH AND DIE
20
6
3.3.4 FULCRUM LOAD AND EFFORT ARM
21
3.3.5 COMPRESSOR
21
3.3.6 DIRECTION CONTROL VALVES
22
CHAPTER 4
4.1 WORKING PRINCIPLE
31
4.2 WORKING
31
CHAPTER 5
5.1 PROPOSED DESIGN MODEL OF
PUNCHING AND RIVETING MACHINE
36

RIVETING CYLINDER
37

PUNCHING CYLINDER
38
5.4 PROPOSED DESIGN HAND LEVER

FOR PNEUMATIC CYLINDER FOR
CRANKING THE OPTION LIKE INPUT
AND OUTPUT
39
5.5 HARDWARE USED IN PROJECT
40
5.6 TOOLS USED IN PROJECT
41
5.7 ESTIMATION OF THE PROJECT WORK
42
CHAPTER 6
CONCLUSION
43
REFERENCES
BOOKS REFERRED
44
WEBSITE
44
LIST OF FIGURES
FIGURE.NO
NAME
PAGE.NO
1.1
Riveter and Puncher
10
2.1
Pneumatic Punching And Riveting Machine
17
3.1.1
Working Of Pneumatic Jack
20
3.3.3.1
Working Of Pneumatic Unit
22
5.1
Proposed Design Model Of Punching

And Riveting Machine
5.2
Proposed Design Model Of

Riveting Cylinder
5.3
39
Proposed Design Model Of

Punching Cylinder
5.4
38
40
Proposed Design Hand Lever For

Pneumatic Cylinder For Cranking
The Option Like Input And Output
41
CHAPTER 1
INTRODUCTION
The press is the punching and riveting machine tool designed to punch letter or rivet
metal by applying mechanical force or pressure. The metal is punched or riveted to the
desired requirement. The presses are exclusively intended for mass production and they
represent the fastest and more efficient way to form a metal into a finished punched or riveted
product.
Press tools are used to form and cut thin metals. Press tools operation can be
simplified to a few simple operations involving a punch a die. There are Nemours types of
presses in engineering field, which are used to fulfil the requirements. We are interested to
introduce pneumatic system in presses. The main function of pneumatic press is to form or
cut thin sheet metals or non metals using pneumatic power. In this project we have used to
punching process and riveting process for simple application.
Fig 1.1: Riveter and Puncher

1.2 General Description:
1.2.1 Production of Compressed Air
Pneumatic systems operate on a supply of compressed air, which must be made
available in sufficient quantity end at a pressure to suit the capacity of the system. When a
pneumatic system is being adopted for the 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 the compressor. A
compressor is a machine that takes in air, gas or vapours at any certain pressure and delivers
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 the
compressors. Warm and moist air will result in Compressors may be classified into two types,
namely
1. Positive displacement compressors
2. Turbo compressors.
Positive displacement compressors are most frequently employed for compressed air plants
and have proved. Highly successful to supply air for pneumatic control application.
The types of positive Compressors are,
a. Reciprocating type compressors
b. Rotary type compressors.
Turbo compressors are employed where large capacity of air is required at low discharge
pressures. They cannot attain pressure necessary for pneumatic control applications unless
built in multi stage designs are seldom en counted in pneumatic service. Basically all
activities or anything in our lives, there must be the advantages and disadvantages to be
caused. And so is in the Pneumatic system.
10
1.3 Advantages:
Infinite availability of the source
Air is the most important thing in the pneumatic system, and as we all know, air is available
in the world around us in unlimited quantities at all times and places.
Easy channelled
Air is a substance that is easily passed or move from one place to another through a small
pipe, the long and winding.
Temperature is flexible
Air can be used flexibly at various temperatures are required, through equipment designed for
specific circumstances, even in quite extreme conditions; the air was still able to work.
Safe
The air can be loaded more safely than it is not flammable and does not short circuit occurs
(konsleting) or explode, so protection against both of these things pretty easily, unlike the
electrical system that could lead to fires konsleting.
Clean
The air around us are tend to clean without chemicals that are harmful, and also, it can be
minimized or cleaned with some processes, so it is safe to use pneumatic systems to the
pharmaceutical industry, food and beverages and textiles.
The transfer of power and the speed is very easy to set up
Air could move at speeds that can be adjusted from low to high or vice versa. When using a
pneumatic cylinder actuator, the piston speed can reach 3 m / s. For pneumatic motors can
spins at 30,000 rpm, while the turbine engine systems can reach 450,000 rpm.
11
Can be stored
The air can be stored through the seat tube fed excess air pressure. Moreover, it can be
installed so that the pressure boundary or the safety of the system to be safe.
Easy utilized
Easy air either directly utilized to clean surfaces such as metal and machinery, or indirectly,
ie through pneumatic equipment to produce certain movements.
1.4 Disadvantages:
Requires installation of air-producing equipment.

Compressed air should be well prepared to meet the requirements. Meet certain criteria, such
as dry, clean, and contain the necessary lubricant for pneumatic equipment. Therefore require
installation of pneumatic systems is relatively expensive equipment, such as compressors, air
filter, lube tube, dryer, regulators, etc.
Easy to leak
One of the properties of pressurized air is like to always occupy the empty space and the air
pressure is maintained in hard work. Therefore we need a seal so that air does not leak. Seal
leakage can cause energy loss. Pneumatic equipment should be equipped with airtight
equipment that compressed air leaks in the system can be minimized.
Potential noise
Pneumatic using open system, meaning that the air that has been used will be thrown out of
the system, the air comes out pretty loud and noisy so will cause noise, especially on the
exhaust tract. The fix is to put a silencer on each dump line.
12
Easy condenses
Pressurized air is easily condensed, so before entering the system must be processed first in
order to meet certain requirements, such as dry, have enough pressure, and contains a small
amount of lubricant to reduce friction in the valves and actuators.
Expected after knowing the advantages and disadvantages of the use of compressed
air we can make the anticipation that these losses can be avoided.
Despite the immense capabilities of hydraulics presented in terms of moving higher
loads and in other industrial utilization, pneumatics are still in wide use today. The article
discusses some applications and advantages of pneumatics in industry.
Pneumatics is study of mechanical motion caused by pressurized gases and how this
motion can be used to perform engineering tasks. Pneumatics is used mainly in mining and
general construction works. Pneumatic devices are used frequently in the dentistry industry
across the world. On the other hand, hydraulics means use of pressurized fluids to execute a
mechanical task. Hydraulics is frequently used in the concepts of turbines, dams, and rivers.
Air brakes in buses, air compressors, compressed air engines, jackhammers, and vacuum
pumps are some of the most commonly used types of mechanical equipment that are based on
pneumatics technology. Commonly seen hydraulics based equipment types are hydraulic
presses, hydraulic hoppers, hydraulic cylinders, and hydraulic rams. In the subsequent
sections of this article, you will learn how a pneumatic system works, what its best features
are, and its major advantages over hydraulic systems.
In order to affect mechanical motion, pneumatics employs compression of gases,
based on the working principles of fluid dynamics in the concept of pressure. Any equipment
employing pneumatics uses an interconnecting set of components: a pneumatic circuit
consisting of active components such as gas compressor, transition lines, air tanks, hoses,
open atmosphere, and passive components. Compressed air is supplied by the compressor and
13
is transmitted through a series of hoses. Air flows are regulated by valves and the pneumatic
cylinder transfers the energy provided by the compressed gas to mechanical energy. Aside
from compressed air, inert gases are also applied particularly for self-contained systems.
Pneumatics is applied in a wide range in industries, even in mining and dentistry. The
majority of industries use gas pressures of about 80 to 100 pounds per square inch.
Over pneumatics, hydraulics is capable of moving heavier loads and having greater
force, and since its working fluids are incompressible, it minimum spring actions. But at the
same time pneumatics are cleaner; the system uses no return lines and gases are exhausted to
the atmosphere. Thus leaks will be of less concern since the working fluid of pneumatics is
air, unlike oil in hydraulics. Its working fluid is also widely available and most factories are
pre-plumbed for compressed air distribution, hence pneumatic equipment is easier to set-up.
To control the system, only ON and OFF are used and the system consists only of standard
cylinders
and
other
components,
making
it
simpler
than hydraulics.
Pneumatic
systems require low maintenance and have long operating lives. Lastly the working fluid of
the pneumatic system absorbs excessive force, leading to less frequent damage to equipment.
Compressible gases are also easy to store and safer; no fire hazard is presented and machines
could be made to be overload safe.
Advantages of Pneumatics over Hydraulics

Like hydraulics, pneumatics is a type of fluid power application where instead of an
incompressible liquid, pneumatics employ gas in their system. Hydraulics present
certain advantages over pneumatics, but in a given application, pneumatic powered
equipment is more suitable, particularly in industries where the factory units are plumbed for
compressed air.
14
The air used in pneumatic devices is dried and free from moisture so that it does not create
any problem to the internal parts of the system. Moreover, to avoid corrosive actions, oil or
lubricants are added so that friction effects can be reduced. Compressed air is used in most of
the machines and in some cases compressed carbon dioxide is used. As most of the
pneumatic devices are air based, they have a less complicated design and can be made of
inexpensive material. Mass production techniques can be adopted to produce pneumatic
systems, which not only save money but save time too.
Other major advantages are listed below.
1. Initial cost is less; hydraulics equipment cost as much as twice the price of pneumatic
equipment.
2. A pneumatic water treatment automation system reduces the costs of installation and
operation compared with conventional electrical installations. For opening and closing of
underwater valves, pneumatic systems work well because they can sustain overload
pressure conditions.
3. Pneumatic actuators also have long life and perform well with negligible maintenance
requirement throughout their life cycle.
4. Very suitable for power transmission when distance of transmission is more.
The major disadvantage of pneumatic systems is that they cannot be employed for tasks
that require working under high pressures. However, modern technology is working on
finding better solutions to this address this problem so that heavy engineering tasks can be
executed using pneumatic devices. In a nutshell, in order to execute low scale engineering
and mechanical tasks, pneumatic devices would be the best suited and a viable alternative
over hydraulic systems.
15
CHAPTER 2
2.1 BLOCK DIAGRAM
Fig 2.1 Pneumatic Punching and Riveting machine
2.2 Need for Automation

Automation can be achieved through computers, hydraulics, pneumatics, robotics, etc.
Automation plays an important role in mass production. For mass production of the product,
the machining operations decide the sequence of machining. The machines designed for
producing a particular product are called transfer machines. The components must be moved
automatically from the bins to various machines sequentially and the final component can be
placed separately for packaging. Materials can also be repeatedly transferred from the
moving conveyors to the work place and vice versa. Nowadays, almost all the manufacturing
processes are being atomized in order to deliver the products at a faster rate. The
manufacturing
16
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
2.2.1 Principle of Operation of a Press:

Every press has got certain basic units. They are bed frame, sliding ram, drive for the
ram and power source. Base or bed is the lower part of the press frame. A thick plate called
bolster plate is placed on the top of the bed. A die is fitted on the top of the bolster plate. The
driving mechanism is mounted on the frame. The frame has got guide ways for the sliding
movement of the ram. The driving mechanism is connected to the ram. The punch is fitted at
the bottom of the ram. The die and punch are correctly aligned. The work piece is in the form
of sheet metal. It is fed over the die. When the ram comes down, the punch presses the sheet
metal. The required operation is carried out. As said earlier the force from the press is used to
do a particular operation. This is done by two main parts die and punch.
2.3 Mechanical Advantage

Mechanical advantage can be defined as the ratio or the load lifted to the power or the effort
applied in the system to overcome the load successfully.
17
Principle of Levellers
The points A and B through which the load and effort is applied are known as load
and effort point respectively. F is the fulcrum about which the lever is capable of turning. The
perpendicular distance between the load point and the fulcrum is known as the load arm. The
perpendicular distance between the effort point and the fulcrum is called as effort arm.
2.4 The Armature

The armature takes the place of the nail in an electric motor. The armature is an
electromagnet made by coiling thin wire around two or more poles of a metal core. The
armature has an axle, and the commutator is attached to the axle. In the diagram above you
can see three different views of the same armature: front, side and end-on. In the end-on view
the winding is eliminated to make the commutator more obvious. The commutator is simply a
pair of plates attached to the axle. These plates provide the two connections for the coil of the
Electromagnet.
2.5 The Commutator and brushes

The "flipping the electric field" part of an electric motor is accomplished by two parts:
the commutator and the brushes. The diagram at the right shows how the commutator and
brushes work together to let current flow to the electromagnet, and also to flip the direction
that the electrons are flowing at just the right moment. The contacts of the commutator are
attached to the axle of the electromagnet, so they spin with the magnet. The brushes are just
two pieces of springy metal or carbon that make contact with the contacts of the commutator.
18
CHAPTER 3
3.1 Working Principle
Selection of Pneumatics
Mechanization is broadly defined as the replacement of manual effort by mechanical
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
advantageously applied to other forms of power).
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 outstanding advantages in terms
of safety.
Fig.3.1.1 Working Of Pneumatic Jack

19
The pneumatic punching and riveting machine consists of the following components to fulfil
the requirements of complete operation of the machine.
i. Pneumatic cylinder
ii. Solenoid valve
iii. Flow control value
iv. Connectors and
v. Hoses
3.2 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.
3.3 UNIT DESCRIPTION (CONSTRUCTION):
3.3.1 CYLINDER
An (pneumatic) air cylinder is an operative device in which the state input energy of
compressed air; (i.e.) pneumatic power is converted into mechanical output power, by
reducing the pressure of the air to that of the atmosphere. The bore of the cylinder has very
20
smooth finishing reduces friction and losses. There are to angle plates welded to the cylinder
as fitting means.
3.3.2 DOUBLE ACTING CYLINDER
A double acting cylinder is employed in a control system with a full pneumatic
cushioning and it is essential when the cylinders itself is required heavy masses. The normal
escape of air is out by cushioning piston.
3.3.3 PUNCH AND DIE

Die and punch are known as press tools. Die is the lower part of press tool. It is
clamped on the bolster plate of the press. It remains stationary during the operation. The die
has a cavity to receive the punch. The cavity may be with clearance or without clearance.
Punch is the upper part of the press tool. It is attached to the lower end of the ram of the
press. It sheds with the ram during the operation and is forced into the die cavity. Die and
punch must be in prefect alignment for proper operation.
Fig.3.3.3.1 Working Of Pneumatic unit
21
Die and punches are always used together. Dies are classified according to either the
type of construction or operation to be performed. High speed steel, satellite or cemented
carbide is the materials used for making dies and punches. The die materials selected depend
on the type of production, operation, sheet metal thickness and accuracy.
3.3.4 FULCRUM LOAD AND EFFORT ARM

A lever is a mechanical devices used to lift heavy loads by application of a small
effort. It is a rigid rod or bar, which turns about a fixed point called fulcrum. A lever may be
straight or curved. Lever works on the same principle as that of principle of moments.
The load W is applied to the point A and hence the point A is known as load point and point
B is effort point. The point F is fulcrum. The perpendicular distance (L1) between the load
point A is load arm and L2 between is known as effort arm. The ratio of effort arm and load
arm is called as leverage. The ratio of load lifted and the effort applied is mechanical
advantage. Taking moments about fulcrum P*L2 =W*L1
3.3.5 COMPRESSOR
The compressor forms the main part of the pneumatic system by producing the
compressed air. Compressor capacity is the actual quantity of air compressed and delivered
and the volume expressed is that of the air intake conduction, namely at atmospheric pressure
and normal ambient temperature. The clear conduction of the suction air one of the factors
which decide the life of a compressor. Compressor is generally classified into two types,
namely
1. Positive displacement compressor
2. Turbo compressor
22
3.3.6 DIRECTION CONTROL VALVES

Direction control valves control the way the air passes and used for controlling the
commencements, termination and direction of air flow. Depending on the number of paths
the air is allowed to pass, directional valves termed two way, three way, and four way or
multi way valves.
The different number of rays by means the number of controlled connection of the
valve. Inlet connection to the compressed air supplies outlet connections to the air consumer
and exhaust connection to the atmosphere. The solenoid valve is used to control the air flow
direction. This is the direction control valve in our project.
Pneumatic systems require air to operate successfully. As a result of air being extremely
abundant, and free, it is easy to restock the system. Safety: As a result of pneumatic systems
running on air, safety hazards are significantly reduced. There are limited occurrences of fires
because air is non-flammable, and leakages in the system do not negatively effect the outside
environment
Cost effectiveness: The initial cost of manufacturing a pneumatic device is minimal as a

result of the low cost design materials. Plastics, zinc, and aluminium are all relatively
affordable materials that are commonly found in pneumatic designs.
Cleanliness- As a result of the system being powered solely by air, the pneumatic device
typically requires limited cleaning. Pressurized air constantly pushes out dirt or debris that
get stuck in the system. If there is a blockage, the simplicity of the design also helps. Due to
the limited amounts of tubes, the system can be easily disassembled and cleaned.
Maintenance- In order for the system to properly operate it must be lubricated with oil
consistently but they have less plumbing than hydraulic systems. Control and Speed- Air is a
23
compressible gas, which makes control and speed in a pneumatic system more difficult, in
comparison to electric or hydraulic systems. When specific speeds are needed, additional
devices have to be attached to the pneumatic system in order to procure the desired result.
Maintenance- Pneumatic systems are less durable that hydraulic counterparts. Due to
moisture accumulation the system can freeze up. Safety: Pipes that feed the system air have
the ability to move on uncontrollably on their own, which could cause serious injuries to
those nearby
The word pneumatics is a derivative of the Greek word pneuma, which means air,
wind, or breath. Pneumatics can be defined as that branch of engineering science that pertains
to gaseous pressure and flow. As used in this manual, pneumatics is the portion of fluid
power in which compressed air, or other gas, is used to transmit and control power to
actuating mechanisms. This section discusses the basic principles of pneumatics,
characteristics of gases, heavy-duty air compressors, and air compressor maintenance. It also
discusses the hazards of pneumatics, methods of controlling contamination, and safety
precautions associated with compressed gases.
Basic Principles of Pneumatics Gases differ from liquids in that they have no definite
volume, that is, regardless of the size or shape of a vessel, a gas will completely fill it. Gases
are highly compressible, while liquids are only slightly so. Also, gases are lighter than equal
volumes of liquids, making gases less dense than liquids.
Boyles Law When the automobile tire is initially inflated, air that normally occupies
a specific volume is compressed into a smaller volume inside the tire. This increases the
pressure on the inside of the tire. Charles Boyle, an English scientist, was among the first to
experiment with the pressure-volume relationship of gas. During an experiment when he
compressed a volume of air, he found that the volume decreased as pressure increased, and
24
by doubling the force exerted on the air, he could decrease the volume of the air by half
Temperature is a dominant factor affecting the physical properties of gases. It is of particular
concern in calculating changes in the state of gases. Therefore, the experiment must be
performed at a constant temperature. The relationship between pressure and volume is known
as Boyle's law. Boyle's law states when the temperature of a gas is constant, the volume of an
enclosed gas varies inversely with pressure. Boyle's law assumes conditions of constant
temperature. In actual situations this is rarely the case. Temperature changes continually and
affects the volume of a given mass of gas.
Charles Law Jacques Charles, a French physicist, provided much of the foundation
for modem kinetic theory of gases. Through experiments, he found that all gases expand and
contract proportionally to the change in absolute temperature, providing the pressure remains
constant. The relationship between volume and temperature is known as Charles's law.
Charles's law states that the volume of a gas is proportional to its absolute temperature if
constant pressure is maintained.
Kinetic Theory of Gases In an attempt to explain the compressibility of gases,
consider the container shown in as containing a gas. At any given time, some molecules are
moving in one direction, some are travelling. Gas compressed to half its original size by a
doubled force. Figure 9-36 Molecular bombardment that creates pressure. NAVEDTRA
14264A 9-32 directions, and some may be in a state of rest. The average effect of the
molecules bombarding each container wall corresponds to the pressure of the gas. As more
gas is pumped into the container, more molecules are available to bombard the walls, thus the
pressure in the container increases. Increasing the speed with which the molecules hit the
walls can also increase the gas pressure in a container. If the temperature of the gas is raised,
the molecules move faster, causing an increase in pressure. This can be shown by considering
the automobile tire. When you take a long drive on a hot day, the pressure in the tires
25
increases, and a tire that appeared to be soft in cool morning temperature may appear normal
at a higher midday temperature.
Compressibility and Expansion of Gases Gases can be readily compressed and are
assumed to be perfectly elastic. This combination of properties gives gas the ability to yield
to a force and return promptly to its original condition when the force is removed. These are
the properties of air that are used in pneumatic tires, tennis balls, and other deformable
objects whose shapes are maintained by compressed air.
Pneumatic Gases serve the same purpose in pneumatic systems as liquids serve in
hydraulic systems. Therefore, many of the same qualities that are considered when selecting a
liquid for a hydraulic system must be considered when selecting a gas for a pneumatic
system.
Qualities The ideal fluid medium for a pneumatic system must be a readily available
gas that is non-poisonous, chemically stable, non-flammable, and free from any acids that can
cause corrosion of system components. It should be a gas that will not support combustion of
other elements. Gases that have these desired qualities may not have the required lubricating
power. Therefore, lubrication of the components must be arranged by other means. For
example, some air compressors are provided with a lubricating system, some components are
lubricated upon installation, or in some cases lubrication is introduced into the air supply line
(inline oilers). Two gases that meet these qualities and are most commonly used in pneumatic
systems are compressed air and nitrogen. Since nitrogen is used very little except in gascharged accumulators, we will discuss only compressed air.
Compressed Air Compressed air is a mixture of all gases contained in the atmosphere.
However, in this manual it is referred to as one of the gases used as a fluid medium for
pneumatic systems. The unlimited supply of air and the ease of compression make
26
compressed air the most widely used fluid for pneumatic systems. Although moisture and
solid particles must be removed from the air, a pneumatic system does not require the
extensive distillation or separation process required in the production of other gases.
Compressed air has most of the desired characteristics of a gas for pneumatic systems. It is
non-poisonous and non-flammable but does contain oxygen, which supports combustion. The
most undesirable quality of compressed air as a fluid medium for a pneumatic system is
moisture content. The atmosphere contains varying amounts of moisture in vapour form.
Changes in the temperature of compressed air will cause condensation of moisture in the
system. This condensed moisture can be very harmful to the system and may freeze the line
and components during cold weather. Moisture separators and hair dryers are installed in the
lines to minimize or eliminate moisture in systems where moisture would deteriorate system
performance. An air compressor provides the supply of compressed air at the required
volume and pressure. In most systems the compressor is part of the system with distribution
lines leading from the compressor to the devices to be operated. Compressed air systems are
categorized by their operating pressure as follows:
High-pressure (HP)3,000 to 5,000 psi
Medium-pressure (MP )151 to 1,000 psi
Low-pressure (LP)150 psi and below
Heavy-Duty Air Compressors are used in pneumatic systems to provide requirements
similar to those required by pumps in hydraulic systems. They furnish compressed air as
required to operate the units of the pneumatic systems. Even though manufactured by
different companies, most compressors are quite similar. They are governed by a pressure
control system that can be adjusted to compress air to the maximum pressure. Rotary the
rotary compressor has a number of vanes held captive in slots in the rotor. These vanes slide
27
in and out of the slots, as the rotor rotates an end view of the vanes in the slots. The rotor
revolves about the centre of the shaft that is offset from the centre of the pumping casing.
Centrifugal force acting on the rotating vanes maintains contact Rotary compressor operation.
This feature causes the vanes to slide in and out of the slots as the rotor turns. Notice in the
variation in the clearance between the vanes and the bottom of the slots, as the rotor revolves.
The vanes divide the crescent-shaped space between the offset rotor and the pump casing into
compartments that increase in size and then decrease in size as the rotor rotates. Free air
enters each compartment as successive vanes pass across the air intake. This air is carried
around in each compartment and is discharged at a higher pressure due to the decreasing
compartment size (volume) of the moving compartments as they progress from one end to the
other of the crescent-shaped space. The compressor is lubricated by oil circulating throughout
the unit. All oil is removed from the air by an oil separator before the compressed air leaves
the service valves
Screw The screw compressors used in the NCF are direct drive, two-stage machines
with two precisely matched spiral-grooved rotors The rotors provide positive displacement
internal compression smoothly and without surging. Oil is injected into the compressor unit
and mixes directly with the air as the rotors turn, compressing the air. The oil has three
primary functions:
As a coolant, it controls the rise in air temperature normally associated with the heat
of compression.
It seals the leakage paths between the rotors and the stator and also between the
rotors themselves.
It acts as lubricating film between the rotors, allowing one rotor to directly drive the
other, which is an idler. After the air/oil mixture is discharged from the compressor unit, the
28
oil is separated from the air. The oil that mixes with the air during compression passes into
the receiver-separator where it is removed and returned to the oil cooler in preparation for reinjection. All large volume compressors have protection devices that shut them down
automatically when any of the following conditions develop
: The engine oil pressure drops below a certain point.
The engine coolant rises above a predetermined temperature.
The compressor discharge rises above a certain temperature.
Any of the protective safety circuits develop a malfunction. Other features that may
be observed in the operation of the air compressors is a governor system whereby the engine
speed is reduced when less than full air delivery is used.
An engine- and compression-control system prevents excessive build-up in the
receiver Screw compressor. When air is compressed, heat is generated. This heat causes the
air to expand, thus requiring an increase in power for further compression. If this heat is
successfully removed between stages of compression, the total power required for additional
compression may be reduced by as much as 15 percent. In multistage reciprocating
compressors, this heat is removed by means of intercoolers that are heat exchangers placed
between each compression stage. Rotary air compressors are cooled by oil and do not use
intercoolers After coolers It is obvious that the presence of water or moisture in an air line is
not desirable. The water is carried along through the line into the tool where the water washes
away the lubricating oil, causing the tool to run sluggishly and increases maintenance.
The effect is particularly pronounced in the case of high-speed tools where the
wearing surfaces are limited in size, and excessive wear reduces efficiency by creating
internal air leakage. Further problems may result from the decrease in temperature caused by
29
the sudden expansion of air at the tool. This low temperature creates condensation that
freezes around the valves, ports, and outlets. This condition obviously impairs the operational
efficiency of the tool and cannot be allowed. The most satisfactory means of minimizing
these conditions is the removal of the moisture from the air immediately after compression
and before the air enters the distribution system. This may be accomplished in reciprocating
compressors through the use of an after cooler that is an air radiator that transfers heat from
the compressed air to the atmosphere. The after cooler reduces the temperature of the
compressed air to the condensation point where most of the moisture is removed. Cooling the
air not only eliminates the difficulties which moisture causes at points where air is used but
also ensures better distribution
Receiver Tank The receiver tank is of welded steel construction and is installed on the
discharge side of the compressor. It acts as a surge tank as well as a condensation chamber
for the removal of oil and water vapours. It stores enough air during operation to actuate the
pressure control system and is fitted with at least one service valve, a drain or blow-by valve,
and a safety valve. Pressure-Control System All portable air compressors are governed by a
pressure-control system. The control system is designed to balance the compressor's air
delivery and engine speed with varied demands for compressed air. The rotary compressor
output is governed by varying the engine speed. The engine will operate at the speed required
to compress enough air to supply the demand at a fairly constant pressure. When the engine
has slowed to idling speed as a result of low demand, a valve controls the amount of free air
that may enter the compressor. A screw compressor output is governed by automatic control
that provides smooth, steeples capacity regulation from full load to no load in response to the
demand for air. From a full load down to no load is accomplished by a floating-speed engine
control in combination with the variable-inlet compressor.
30
Air Compressor Maintenance A number of built-in features make portable

compressors easy to maintain:
An automatic blow down valve for releasing air pressure when the engine is
stopped.
A valve for draining moisture that accumulates in the receiver tank.
A drain cock at the bottom of the piping at the bottom of the oil storage tank.
An air filter service indicator to show when the filter needs servicing.
A demister, or special filter, that separates lubricating oil from compressed air.
Remember: a good maintenance program is the key to a long machine life. So it is up to both
the operator and the mechanic to ensure that the maintenance is performed on time, every
time.
Air Cleaner Servicing The air cleaner contains a primary and secondary dry filter
element An air filter restriction indicator is located at the rear of the air filter housing to alert
the operator of the need to service the filters. When a red band appears in the air filter
restriction indicator, secure the compressor and service the filters. Use compressed air to
clean the primary element; however, never let the air pressure exceed 30 psi. The secondary
filter is not cleanable and should be replaced when necessary. Reverse flush the primary
element by directing compressed air up from the inside out. Continue reverse flushing until
all dust is removed. Should any oil or greasy dirt remain on the filter surface, replace the
element.
31
CHAPTER 4
4.1 WORKING PRINCIPLE:
Compressed air from a compressor is used to press the work by means of the piston
and piston rod, cylinder through a lever. The high pressurized air striking against the piston
tends to push it upwards. This force is transmitted to a punch by means of a lever by its
mechanical advantage. The punch forced downward pierces the work material. This is the
main principle of the unit.
4.2 WORKING
The compressed air from the compressor at the pressure of 5 to 7bar is passed through
a pipe connected to the Solenoid valve with one input. The Solenoid Valve is actuated with
Control Timing Unit. The Solenoid valve has two outputs and one input. The air entering into
the input goes out through the two outputs when the timing control unit is actuated. Due to
the high air pressure at the bottom of the piston, the air pressure below the piston is more than
the pressure above the piston. So these moves the piston rod upwards which move up the
effort are, which is pivoted by control unit. This force acting is passed on to punch which also
moves downwards.
The punch is guided by a punch guide who is fixed such that the punch is clearly guided to
the die. The materials are in between the punch and die. So as the punch comes down the
materials are sheared to the required profile of the punch and the blank is moved downwards
through the die clearance. Pneumatic systems require air to operate successfully. As a result
of air being extremely abundant, and free, it is easy to restock the system. Safety: As a result
of pneumatic systems running on air, safety hazards are significantly reduced. There are
limited occurrences of fires because air is non-flammable, and leakages in the system do not
negatively effect the outside environment
32

result of the low cost design materials. Plastics, zinc, and aluminum are all relatively
those nearby
Environment suitability: Devices are known to fail over long periods of time due to the
dampening of inside edges in the tubes. Additionally, systems cannot operate underwater and
are sensitive to changing temperatures and vibrations
When the piston is at the extreme point of the stock length, the exhaust valve is
opened and the air is exhausted through it and the pressurized air come in at the top of the
piston and it pushes the piston downwards. So the one side of the air is pulled downwards and
the other side is lifted upwards. So the punch is therefore pulled upwards from the die. Now
33
the piston reaches the bottom point of the required stroke length. Now the material is fed and
the next stroke of the piston is made ready.
When the material is correctly positioned then this machine is again actuated automatically.
The time duration of the succeeding punching is adjusted with the help of control timing unit.
Pneumatic systems require air to operate successfully. As a result of air being extremely
abundant, and free, it is easy to restock the system. Safety: As a result of pneumatic systems
running on air, safety hazards are significantly reduced. There are limited occurrences of fires
because air is non-flammable, and leakages in the system do not negatively effect the outside
environment

34
Loudness: Pneumatic systems are the loudest type of designs that power machines. Actuators
that run the system are the source of the noise and are sometimes placed in a separate room to
limit sound pollution.
Toxins and chemicals: Sometimes, pneumatic systems use hazardous chemicals in their
design. This can result in accidental launches of chemicals into the air, which can be harmful
to the surrounding environment.
those nearby Pneumatic systems require air to operate successfully. As a result of air being
extremely abundant, and free, it is easy to restock the system. Safety: As a result of
pneumatic systems running on air, safety hazards are significantly reduced. There are limited
occurrences of fires because air is non-flammable, and leakages in the system do not
negatively effect the outside environment

35
those nearby
36
CHAPTER 5
FABRICATION OF PNEUMATIC PUNCHING AND RIVETING
MACHINE
5.1 PROPOSED DESIGN MODEL OF PUNCHING AND RIVETING
MACHINE
37
5.2 PROPOSED DESIGN MODEL OF RIVETING CYLINDER
38
5.3 PROPOSED DESIGN MODEL OF PUNCHING CYLINDER
39
5.4 PROPOSED DESIGN HAND LEVER FOR PNEUMATIC

CYLINDER FOR CRANKING THE OPTION LIKE INPUT AND
OUTPUT
40
5.5 HARDWARE USED IN PROJECT:

Fabricated Pneumatic Jack
Mounting Plate
Threaded Screw
Base Plate
Bearing
Coupling
Movable Joints
Steel Plates For Supporting
Welding Electrodes
Cylinder worming
Cylinder stroke
Motor
Hardwares To Fit
Power Supply
Switch
PU fitting
Teflon tape
Polyurethane hose
Riveting mount
Punching mount
41
5.6 TOOLS USED IN PROJECT:

Welding Machine
Screw driver
Spanner
Soldering Rod
Soldering flux
Cutter
Lathe
Knurling Tool
Tapper Tool
Machine Vice
Axe Frame
42
5.7 ESTIMATION OF THE PROJECT WORK:
HARDWARE WORKS
ESTIMATION OF COST
CYLINDER 32*50 FITTING
1050
CYLINDER 20*50 FITTING
950
RIVETER AND PUNCHER
350
SILENCER
200
HAND LEVER
900
PU FITTING
200
POLYURETHANE HOSE
250
H.S TEFLON TAPE
50
MOULED PLASTIC HANDLE
50
PU Y FITTING
150
STEEL SHEET COATING
450
CYLINDER RINGS
625
INNER WINDINS
200
LATHE WORK (LABOUR)
175
WELDING
175
OTHER EXPENSES
225
TOTAL
6000
43
CHAPTER 6
CONCLUSION:
The pneumatic punching and riveting has been successfully completed with fullest
satisfaction. We are optimistic based on the revolution, the machine is going to make in the
pressing field. This project may be further developed into a unit with an automatic material
handling system.
44
REFERENCES
BOOKS REFERRED
Machine design by RS KHURMI
Work shop technology by RK JAIN
WEBSITE
Production Technology - R.B. Gupta
Manufacturing Process - R.B. Gupta B.K. Gupta
Pneumatic Control - Werner Deepest, Kust Stoll
A Text Book on Machine Design - R.S. Khurmi
Press Working Shecklos, S.Elanger
PSG Design Data - PSG Mech. Dept
Catalogue of Janatics pneumatic product,
Janatics Private Limited Coimbatore
P.S.G. College of technology, Coimbatore
Design data book Complied by faculty of mechanical engineering
45

Fabrication of Pneumatic Punching and Riveting Machine

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PROJECT TITLE

DEPARTMENT OF MECHANICAL ENGINEERING

in partial fulfilment for the award of the diploma of

DEPARTMENT OF MECHANICAL ENGINEERING

submitted by NAME OF GROUP to the SunRise University Alwar,Rajasthan in partial

Name (Project Guide)

1.2 GENERAL DESCRIPTION

1.2.1 PRODUCTION OF COMPRESSED AIR

2.2 NEED FOR AUTOMATION

2.2.1 PRINCIPLE OF OPERATION OF A PRESS

2.4 THE ARMATURE

2.5 THE COMMUTATOR AND BRUSHES

3.2 SELECTION OF PNEUMATICS

3.2.1 SOLENOID VALVE

3.3 UNIT DESCRIPTION (CONSTRUCTION)

3.3.2 DOUBLE ACTING CYLINDER

3.3.3 PUNCH AND DIE

3.3.4 FULCRUM LOAD AND EFFORT ARM

3.3.6 DIRECTION CONTROL VALVES

5.2 PROPOSED DESIGN MODEL OF

5.3 PROPOSED DESIGN MODEL OF

5.4 PROPOSED DESIGN HAND LEVER

5.5 HARDWARE USED IN PROJECT

5.6 TOOLS USED IN PROJECT

5.7 ESTIMATION OF THE PROJECT WORK

Riveter and Puncher

Pneumatic Punching And Riveting Machine

Working Of Pneumatic Jack

Working Of Pneumatic Unit

Proposed Design Model Of Punching

Proposed Design Model Of

Proposed Design Model Of

Proposed Design Hand Lever For

Fig 1.1: Riveter and Puncher

Requires installation of air-producing equipment.

Advantages of Pneumatics over Hydraulics

Fig 2.1 Pneumatic Punching and Riveting machine

2.2 Need for Automation

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

2.2.1 Principle of Operation of a Press:

2.3 Mechanical Advantage

2.4 The Armature

2.5 The Commutator and brushes

Fig.3.1.1 Working Of Pneumatic Jack

3.2 Solenoid valve:

3.3.3 PUNCH AND DIE

Fig.3.3.3.1 Working Of Pneumatic unit

3.3.4 FULCRUM LOAD AND EFFORT ARM

3.3.6 DIRECTION CONTROL VALVES

Cost effectiveness: The initial cost of manufacturing a pneumatic device is minimal as a

Air Compressor Maintenance A number of built-in features make portable

Cost effectiveness: The initial cost of manufacturing a pneumatic device is minimal as a

Cost effectiveness: The initial cost of manufacturing a pneumatic device is minimal as a

Cost effectiveness: The initial cost of manufacturing a pneumatic device is minimal as a