Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

CHAPTER 1
INTRODUCTION
The conventional machines used for binding works occupy more than half a room and are
more costly. And are difficult for transportation and even consume more power.
This hydraulic paper cutting and punching machine will overcome these
disadvantages effectively.This also reduces cost, power and working space.
This project is an integration of both cutting and punching operations. And hence meet the
requirement of both small and large capacity binding operation based on hydraulic system
design.
Pascals law forms the basis for hydraulic machines as like ours.
Pascals law states that when a confined fluid is placed under pressure, the pressure is
transmitted equally in all directions and on all faces of the container.
The below figure illustrates the Pascals law

.
Fig 1.1 Pressure distribution in container.

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University Visvesvaraya College of Engineering
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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

This is the principle used to extend the ram on a hydraulic cylinder. By applying a force to
move the piston on one end, the piston on the other end will move the same distance with
same amount of force.
The below figure shows the ram actions.

Fig 1.2 Ram action

All hydraulic circuits are essentially the same regardless of the application.
There are four basic components required:
1.

A reservoir to hold the fluid.

2.

A pump to force the fluid through the system.

3.

Valves to control the flow.

4.

An actuator to convert the fluid energy into mechanical force to do the work.

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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

CHAPTER 2
HYDRAULIC PAPER CUTTING AND PUNCHING MACHINE
The conventional machines used for binding works occupy more than half a room and are
more costlier.And are difficult for transportation and even consume more power.
This hydraulic paper cutting and punching machine will overcome these
disadvantages effectively. This also reduces cost, power and working space.
This project is an integration of both cutting and punching operations. And hence meet the
requirement of both small and large capacity binding operation based on hydraulic system
design.

2.1 Disadvantages of Present Machines

Large floor space is required
Difficult for women operators
High initial and maintenance cost
Highly skilled operators(programmers)
Not affordable for small shops
Many machines are not integrated to perform cutting and punching operations

2.2 Engineering
Use of standard hydraulic power pack
( 40 mm * 75 mm stroke)
Use of polished ms supporting plates
(50 mm width*16mm thickness*280 mm length)
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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

Use of standard diameter punches (6mm*60mm length)
Use of springs (di=22mm*60 mm length)
Use of standard guide rods (20mm*150mm length)
Use of en8 cutting tool material (80mm w*10 mm t*280mm l).

2.3 Processes
Drilling on supporting plates for guide rods (20.5mm)
Drilling on punch plate (6 mm)
Thread cutting on guide rod and tapping on die plate (M16)
Counter sinking on punch plate for brazing operation (45 *2mm)
Brazing operations

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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

The below figure shows our Removable integrated cutting and punching tool

Fig 2.1 Removable tooling

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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

The below figure shows the fabricated integrated hydraulic cutting and punching machine

Figure 2.2 Hydraulic press with tooling.

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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

2.4 Design calculations

Cylinder specifications
Capacity=100*105 N /mm2.
Diameter of piston=40mm
Stroke=75mm
A=D2/4

=1256.6mm2

100*(105) =F/1256.6
F =12.56KN

Spring design
Formula from design data hand book

Where, C=D/di
D= (Outside dia. + Inside dia.)/2
= (22+25)/2
D=23.5mm, l=60mm
di =22mm
C=

=1.068

Now,

K =12.60 N/mm
Where,
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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

F=K*x
F=12.60*25
F=300N
For two springs,
F=600N
Then,
Total force on each punch=
=1708.37 N/punch
(Square and ground end spring is used).

Punch design
Specifications and Materials
4037 Alloy steel
303-316 Stainless steel
Diameter of punch, D=6mm
Length of punch,

l=60mm

Surface hardness, RC-60minimum

Core hardness, RC-47minimum
Yield strength, 0 =758MPa
Shear stress in one paper, = shear force/shear area
= s f/3.142*d*t
=700*10-3/(3.14*6*.137)
=0.271066 N/mm2
Shear stress for 15 papers = 15*0.271066
= 4.066N/mm2
Shear yield strength of Punch = 0/ 2
=758 / 2
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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

= 379 N/mm2 > shear strength for 15 papers
Hence design is safe.

CHAPTER 3
PARTS DRAWING

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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

Fig 3.1 Punch drawing

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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

Figure 3.2 Supporting plate drawing

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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

Figure 3.3 Die plate drawing

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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

Figure 3.4 Guide rod drawing.

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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

Figure 3.5 Spring drawing.

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University Visvesvaraya College of Engineering
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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

Figure 3.6 Tool assemblies drawing.

TABLE 3.1

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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

CHAPTER 4
ADVANTAGES AND APPLICATIONS
The advantages and applications of our machine are as follows:

4.1 Advantages
Less floor area required
Integration of cutting and punching operations
Ease of repair as it has removable tools
Low initial and maintenance cost
Can be used in small shops
No need of skilled operators

5.1 Applications of our machine

The machine can be used by binders and Xerox shops.
Any other hydraulic press operations as it have removable tooling.
It can perform cutting and punching operations at once.
It can also be used as simple hydraulic clamping device.

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University Visvesvaraya College of Engineering
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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

CHAPTER 5
CONCLUSION
5.1 Conclusion of the project
The hydraulic paper cutting and punching machine with removable tooling, which
can be removed and repaired easily.
Simple design using hydraulic press makes it economical and efficient.

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University Visvesvaraya College of Engineering
Bangalore

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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

CHAPTER 6
SCOPE FOR IMPROVEMENT
The hydraulic system used is of small capacity and uses manual pump so this can be
further improved by using large capacity power pack and automatic pump so that
even large pressing operations can be performed.
Even three side cutting and one side punching operations can be performed by further
improvements.
Design analysis and optimization using any FEA Package
Process simulation of cutting and punching using simulation software.

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University Visvesvaraya College of Engineering
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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

CHAPTER 7
COSTING
8.1 Material cost
Table 8.1 shows material costs involved in project.

8.2 Process cost

Table 8.2 shows process cost involved in project.

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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

8.3 Total Cost

Total cost of the project excluding sponsorship
=Material cost + process cost
=13,200+850
= Rs. 14,050

CHAPTER 8
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Design and Fabrication of Hydraulic Paper Cutting And Punching Machine

REFERENCES
I.

Stephen Timoshenko, strength of materials, 3rd edition,cbs publishers and distributors

pvt.ltd.2002.

II.

K.Mahadevan and K.Balaveera reddy, Design data handbook, 3rd edition,cbs

publishers and distributors pvt.ltd.2010.

III.

Esposite Anthony, fluid power with applications, PHI publications 4th edition 2004.

IV.

R.s.khurmi and J.k.gupta, a text book of machine design, Eurasia publications.

Department of Mechanical Engineering

University Visvesvaraya College of Engineering
Bangalore

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