DESIGN AND FABRICATION OF PNEUMATIC

SHEET METAL CUTTING MACHINE

A PROJECT REPORT
Submitted by

HARAN.G (Reg.No.822218114016)

INIYAVAN.P (Reg. No. 822218114019)

SRIBALAN.R (Reg. No. 822218114042)

SRIMAN.R (Reg. No. 822218114043)

In partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

UNIVERSITY COLLEGE OF ENGINEERING THIRUKKUVALAI

ANNA UNIVERSITY:: CHENNAI 600 025

MAY 2021

i
 ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “DESIGN AND FABRICATION OF

PNEUMATIC SHEET METAL CUTTING MACHINE” is the
bonafide work of “G.HARAN (822218114016), P.INIYAVAN
(822218114019), R.SRIBALAN (822218114042), and R.SRIMAN
(822218114043)” who carried out the project work under my
supervision.

SIGNATURE SIGNATURE

Dr.S.MAHENDRAN, ME,Ph.D, Mr.AZHAGUNAMBI, M.E,

HEAD OF THE DEPARTMENT SUPERVISOR
Department of Mechanical Engineering Department of Mechanical Engineering
University college of Engineering, University college of Engineering,
Thirukkuvalai. Thirukkuvalai.

Examined on:

INTERNAL EXAMINER EXTERNAL EXAMINER

 DECLARATION

I hereby declare that the work entitled “DESIGN AND FABRICATION

OF PNEUMATIC SHEET METAL CUTTING MACHINE” is
submitted in partial fulfillment of the requirement for the award of the
degree in B.E, University College of Engineering, Thirukkuvalai is a
record of my own work carried out by me during the academic year 2020-
2021 under the supervision and the guidance of Mr.R.AZHAGUNAMBI,
ME., Department of Mechanical Engineering, University College of
Engineering, Thirukkuvalai. The extent and source of information are
derived from the existing literature and have been indicated through the
dissertation at the appropriate places. The matter embodied in this work is
original and has not been submitted for the award of any other degree or
Diploma, either in this or any other University.

HARAN.G (822218114016)

INIYAVAN.P (822218114019)

SRIBALAN.R (822218114042)

SRIMAN.R (822218114043)

Verify that the declaration made above by the candidate is true.

Signature of the guide,

MR.R.AZHAGUNAMBI, M.E.,
TEACHING FELLLOW,
DEPARTMENT OF MECHANICAL
ENGINEERING

iii
iv
 ACKNOWLED
GEMENT

First and foremost, our thanks are to the almighty,

the great Architect of the universe, who blessed us to
successfully pursue our Bachelor of Engineering and to
successfully accomplish our project.
First of all we thank God almighty for his blessings
without which we would have not initiated the project.
We also express our heartful thanks to our honourable
Dean Dr. M. DURAIRASAN, M.E., Ph.D., for allowing
us to do this mini project.
We also thanks to Dr. S. MAHENDRAN, M.E.,
Ph.D., Head, Department of Mechanical Engineering for
his constant encouragement to carry out this thesis Work.
We are extremely grateful to our project co-
ordinator Dr. S. THULASI, M.Tech., Ph.D., for
affording all necessary permission, inspiring guidance,
advice, encouragement and extending all facilities during
the course of the mini project for the successful
completion of this project.
We express our sense of reverence and offer our
thanks with profound gratitude to our project guide Mr.
R. AZHAGUNAMBI M.E., Teaching fellow,
Department of Mechanical Engineering for him excellent
motivation and courage infused in us.
 We also thank all the faculty members of
Department of Mechanical Engineering for supported us.
We express our sincere gratitude to our dear
parents who have been the major contributor of
inspiration and encouragement to us throughout our
carrier.
 ABSTRACT

Sheet metal is simply a metal formed into thin and flat pieces. It is one of the
fundamental forms used in metal working and can be cut and bent into a variety of
different shapes. Countless everyday objects are constructed of the material.
Thicknesses can vary significantly, although extremely thin thicknesses are
considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are considered plate.
Sheet metal also has applications in car bodies, airplane wings, medical tables,
roofs for buildings (Architectural) and many other things. Sheet metal of iron and
other materials with high magnetic permeability, also known as laminated steel
cores, has applications in transformers and electric machines. There are three
primary procedures in Layout. They are Parallel, Radial, and Triangulation. The
major aim to our experiment is to study about pneumatic control system, study
about double acting cylinder, study about the advantage of pneumatic hand
operated valve and study about high speed blade.

v
 TABLE OF CONTENT

CHAPTE TITLE PAGE NO.

R NO.
ABSTRACT V
LIST OF FIGURE Viii
1 INTRODUCTION AND BACKGROUND OF THE 1
PROJECT
1.1 SHEET METAL CUTTING PROCESS 1
1.1.1 Cutoff and Parting of Sheet Metal 2
1.1.2 Punching and Slotting 2
1.1.3 Blanking of Sheet Metal 2
1.1.4 Sheet Metal Slitting 3
1.1.5 Perforating of Sheet Metal 4
1.2 TYPES OF CUTTING MACHINES 4
1.2.1 Pneumatically Operated 4
1.2.2 Hydraulically Operated 5
1.2.3 Rack and Pinion Operated 5
1.2.4 Spring Operated 5
1.3 ADVANTAGES OF SHEET METAL 6
CUTTING MACHINE
1.4 DISADVANTAGES OF SHEET METAL 6
CUTTING MACHINE
1.5 APPLICATIONS OF SHEET METAL 6
CUTTING MACHINE
2 LITERATURE SURVEY 8
2.1 RAJ REDDY (2015) 8
2.2 KUMAR ET AL(2016) 8
2.3 BANNER AND ALI(2017) 8
2.4 HASTNAT AND KABIR 9
2.5 KUMAR AND SAIKIRAN(2018) 9
3 CONSTRUCTION AND METHODOLOGY 10
3.1 CONSTRUCTION 10
3.1.1 Double Acting Cylinder 10
3.1.2 2/2 Directional Control Valve 11
3.1.3 3/2 Directional Control Valve 11
vi
 3.1.4 5/2 Directional Control Valve 11
3.2 CONTROLING 12
3.2.1 Control Pneumatic Energy 12
3.2.2 Control of Pressure 12
3.2.3 Control of Pressure after Compression 12
3.3 DATA ANALYSIS 13
3.3.1 Cylindrical Thrust 13
3.3.2 Theoretical Air Consumption 13
3.3.3 Sheet Metal Cutting Force 13
4 DISCUSION AND CONCLUUSION 14
5 REFERENCES 15

LIST OF FIGURES

FIGURE TITLE PAGE

NO. NO.
1.1 CUTOFF VS PARTING 2
1.2 BLANKING VS PUNCHING 3
1.3 SLITTING OF SHEET METAL 3
1.4 PERFORATING 4
1.5 PNEUMATICALLY OPERATED 5
3.1 DOBLE ACTING CYLINDER 10
3.2 2/2 DIRECTIONAL CONTROL VALVE 11
3.3 3/2 DIRECTIONAL CONTROL VALVE 11
3.4 5/2 DIRECTIONAL CONTROL VALVE 12

vii
 CHAPTER 1
INTRODUCTION AND BACKGROUND OF THE PROJECT

Sheet metal is simply a metal formed into thin and flat pieces. It is one of the
fundamental forms used in metal working and can be cut and bent into a variety of different
shapes. Countless everyday objects are constructed of the material. Thicknesses can vary
significantly, although extremely thin thicknesses are considered foil or leaf, and pieces thicker
than 6 mm (0.25 in) are considered plate. Sheet metal is available in flat pieces or as a coiled
strip. The coils are formed by running a continuous sheet of metal through a roll slitter. The
thickness of the sheet metal is called its gauge. Commonly used steel sheet metal ranges from 30
gauges to about 8 gauge. The larger the gauge number, the thinner the metal. Gauge is measured
in ferrous (iron based) metals while nonferrous metals such as aluminum or copper are
designated differently; i.e., Copper is measured in thickness by ounce. There are many different
metals that can be made into sheet metal, such as aluminum, brass, copper, steel, tin, nickel and
titanium. For decorative uses, important sheet metals include silver, gold and platinum (platinum
sheet metal is also utilized as a catalyst). Sheet metal also has applications in car bodies, airplane
wings, medical tables, roofs for buildings (Architectural) and many other things. Sheet metal of
iron and other materials with high magnetic permeability, also known as Slaminated steel cores.

1.1 SHEET METAL CUTTING PROCESSES

Sheet metal cutting is a major classification for many different press working operations.
Cutting operations involve the separation of the metal of the sheet in certain areas. This
separation is caused by shearing forces acting on the metal through the edges of the punch and
die. Press working, a term referencing sheet metal operations in general, involves the working of
a sheet between two die. In press working, the upper die is called a punch. Sheet and plate
generally refers to rolled metal with a high surface area to volume ratio. The difference is that
sheet metal is less than 1/4 inch (6mm) in thickness, while plate metal is thicker. Most of the
sheet metal cutting processes discussed can be performed on both sheet and plate metal, although
for many sheet metal operations difficulties will arise with increasing plate thickness. Usually
"sheet" and "sheet metal" is also referencing plate. Some sheet metal cutting processes are

1
1.1.1 Cutoff And Parting Of Sheet Metal
Cuttoffs and partings are important basic sheet metal cutting processes performed in
manufacturing industry. Cutoffs need not be straight, rather they may be over several lines and or
curves. Partings are similar, in that a discrete part is cut from a sheet or strip of metal along a
desired geometric path. The difference between a cutoff and a parting is that a cutoff can be
nestled perfectly on the sheet metal, due to its geometry. With cutoffs, the cutting of sheet metal
can be done over one path at a time and there is practically no waste of material. With partings,
the shape cannot be nestled precisely. Partings involve cutting the sheet metal along two paths
simultaneously. Partings waste a certain amount of material that can be significant.

Fig.1.1. Cutoff Vs Parting

1.1.2 Punching And Slotting

Punching is also a basic sheet metal cutting process that has many different forms and
applications in press working manufacture. Punching involves cutting out a piece of material
from a metal sheet. The material removed may be round or some other shape. This excess metal,
once punched out, is called a slug and is usually discarded as scrap. Slotting is a type of
punching operation. Slotting refers specifically to the punching of rectangular or elongated holes.

1.1.3 Blanking Of Sheet Metal

Blanking is the cutting of a sheet metal part along a closed contour in one step. The piece

2
cut out is called a blank and may be further processed. Many blanks are often continuously cut
out of a sheet or strip. Blanking will waste a certain amount of material. When designing a sheet
metal blanking process, the geometry of the blanks should be nestled as efficiently as possible to
minimize material waste. A distinction should be made between the two sheet metal cutting
processes of blanking and punching, since essentially they are the same process. In punching, the
piece cut out is waste. In blanking, the piece cut out is the work and is kept.

Fig.1.2.Blanking Vs Punching

1.1.4 Sheet Metal Slitting

Slitting is a shearing process in which the sheet metal is cut by two opposing circular
blades, like a can opener. Slitting can be performed in a straight line or on a curved path. The
circular sheet metal cutters can be driven, or the work may be pulled through idle cutters. Slitting
usually produces a burr that must be removed.

Fig.1.3.Slitting of Sheet Metal

3
1.1.5 Perforating Of Sheet Metal
Sometimes it is desirable to punch many holes in a piece of sheet metal, often in a certain
pattern. These holes may be round or some other shape. Perforating sheet metal will allow for the
passage of light or fluid material through the sheet. It can often serve in ventilation and filtration
of fluid substances. Perforated sheet metal is also used in structure and machine construction, to
reduce weight and for cosmetic appearance. Special equipment is employed that punches many
holes at once, at a high rate. In industrial manufacturing practice, the size of these holes is
usually from .04 inches to 3 inches, (1-75mm). The upper rate at which some special perforating
machines can punch holes is 100,000 to 300,000 per minute.

Fig.1.4.Perforating

1.2 TYPES OF CUTTING MACHINES

1.2.1 Pneumatically operated

Here is the advancement of the header which is carried out in the upward and downward
direction using the pneumatic double acting piston and cylinder unit arrangement along with the
foot operated direction control valve. In this type of machine high pressure air is used as the
working fluid for the transfer of power and the motion.

1.2.2 Hydraulically operated

4
 Here the lowering and rising of the header which is carried over using the hydraulic
piston and cylinder arrangement. To actuate the piston and cylinder, the oil is allow entering the
cylinder for front or backing side of the piston. But the oil is comparatively cost layer and it is
leakage may cause so many problem.

1.2.3 Rack and pinion operated

Here the lowering and raising of the header carried out manually using the rack and
pinion arrangement. In this case the required pressure is applied manually using direct hand
pressure on the rack using pinion and leaver arrangement. Since the machine robust and required
large pressure, hence it is not suitable.

1.2.4 Spring operated

The working of spring operated machine is similar to rack and pinion operated machine
but differs for it in construction. Here the lowering and the raising of the heating handle are
carried out manually and it required too much pressure for its operation also there possibility to
having damage to the work piece if not handled carefully. To prepare any machine part, the type
of material should be properly selected, considering design, safety. Selection of material for
engineering application is given by following factor:
1. Availability of material.
2. Suitability of the material for the required component.
3. Cost of the material.

1.3 ADVATAGES OF PNUEMATIC CUTTING MACHINE

 No fire hazard problem due to over Easy maintenance and repair.
 Low investing cost.
 Air is available every wear can be stored easily.
 High speed operation performed.
 Relatively low cost is produced
 Continuous operation is possible without stopping.
 All movement is pneumatically operated.

5
  Clear and non-pollutant.
 Technology can be easily learned.
 Simple in construction.
 No fire hazard problem due to over loading.

1.4 DISADVANTAGES OF PNEUMATIC SHEET METAL CUTTING

MACHINE
 Silencer must be use while compressing the air.
 High torque cannot be obtained.
 Load carrying capacity is low.

1.5 APPLICATIONS
 This machine is very useful for small scale industries.
 These machines use to cut roller sheet metal.
 All industrial applications.
 Car bodies.
 Air plane wings.
 Medical tables.
 Roof s for building (architectural) and many other things.

6
 CHAPTER 2
LITERATURE SURVEY

Mr. K. krantikumar & K. V. Saikiran, “Pneumatic Sheet Metal Cutting

Machine” International Journal and Magazine of Engineering, Technology,
Management and Research, 2016, ISSN No: 2348- 4845.
We are using scissors for simple sheet metal cutting. It is a manual method so that sheet
metals are to be wasted sometime because of mistakes happened such as wrong dimensions etc.,
and also even a simple cutting may take long time.Hydraulic machines are also available for
sheet metal cutting. But this method is used for only heavy metal cutting and its cost is very high.
We are using a pneumatic system for sheet metal cutting in a easy way. It is operated by a
pneumatic hand lever of two ways control valve.Control valve is operated by a compressor.

Mr. Shubhkumar Bandari, Prof. Rajkumar B. Chadge, “Methodology of

Special Purpose Sheet Metal Cutting Machine” International Journal of Pure
and Applied Research in Engineering and Technology, 2014, ISSN:2319-
507X,Volume2 (9): 1-8.
Special purpose machines are not available off the shelf. These machines are designed
and made as per the customer's specific requirements. It is designed for getting higher efficiency
and economy in desired condition. The recent developments in digital technology, have now
enabled us to make low cost machines for real time applications. The aim of this paper is to
present the concept of special purpose mild steel sheet cutting machine using single point cutting
tool and easily available low cost microcontrollers.

Khagendra barman and near Ali (2017), “Fabrication of a pneumatic sheet

metal cutting machine” published by Chittagong University of Engineering
and technology.
Sheet metal is simply a metal formed into thin and flat pieces. It is one of the
fundamental forms used in metal working and can be cut and bent into a variety of different

7
shapes. Countless everyday objects are constructed of the material. Thicknesses can vary
significantly, although extremely thin thicknesses are considered foil or leaf, and pieces thicker
than 6 mm (0.25 in) are considered plate. Sheet metal also has applications in car bodies,
airplane wings, medical tables, roofs for buildings (Architectural) and many other things. Sheet
metal of iron and other materials with high magnetic permeability, also known as laminated steel
cores, has applications in transformers and electric machines. There are three primary procedures
in Layout. They are Parallel, Radial, and Triangulation. The major aim to our experiment is to
study about pneumatic control system, study about double acting cylinder, study about the
advantage of pneumatic hand operated valve and study about high speed blade.

Aryan Pratihar, “Design and Fabrication of Pneumatic Sheet Metal Cutting

and Punching Machine” July 2020; International Journal of Engineering and
Technical Research 
Metal in the form of sheets is paramount in the manufacturing industry. Its applications
are countless. But metal in the form of sheets cannot be directly used, operations like cutting,
punching, blanking, bending, trimming, etc. are needed to be carried out on the metal sheets in
order to fully utilize them. For these operations, most large scale manufacturing industries use
hydraulically operated machines. But since hydraulic machines are not cost-effective, most small
and medium scale industries use hand-operated machines for carrying out sheet metal operation.
The problem with hand-operated machines is that they are slow and cannot be automated. This
is where the concept of pneumatics will prove itself advantageous. We are developing a
pneumatically operated cutting and punching machine which will use the help of compressed air
to drive a shearing blade and punch to carry out the operations on a metallic sheet. The machine
is designed to cut 1mm thick aluminium sheets and 0.5mm thick copper sheets very easily. The
main components of developed pneumatic system are compressor, pipelines, double-acting
cylinder, an actuator, and flow control valves. This machine will thus, prove it cost-effective
and also save a lot of time in manufacturing process as two operations can be performed on the
same platform.

8
Asha P B, Raju B R, Prakash B, Rithwick V M, Vikram K, Yahiya Khan,
“Automatic Pneumatic Sheet Metal Cutting Machine’, 2018 IJCRT | Volume
6, Issue 2 April 2018 | ISSN: 2320-2882; International Journal of Creative
Research Thoughts (IJCRT)
The recent advancements in technology have now enabled us to make low-cost machines
for Real time applications. This paper presents a simple way of designing and implementing an
automatic sheet metal cutting machine using easily available low-cost pneumatic, sensor &
micro-controllers. A pressure from the pneumatic cylinder is enough for operating the shearing
machine unit. The pressurized air from the compressor, actuates the pneumatic cylinder, power
from the piston is transmitted to the shear cutting blades. Sheet metal is fed through the roller
and the sensor fixed at a particular position senses the sheet and sends command to the blades to
cut the sheet metal. This entirely eliminates the human intervention.

AvinashJathar, AvinashKushwaha,Utkarsh Singh, Prof. Subhash Kumar,

Fabrication and Review of Hydraulic Heavy Sheet Metal Cutting machine,
Journal of Emerging Technologies and Innovative Research , Volume 3, Issue
4, April 2016,pp 37-41.
This machine is for sheet metal industry and can be made into multiple machines and
should be used as circle cutting cum straight cutting machine .The machine is simple to maintain
easy to operate. Hence we tried out hands on Hydraulic Shearing Machine in shearing operation
as the punch descends upon the metal, the pressure exerted by the punch first cause the plastic
deformation of the metal. Since the clearance between the punch and the die is very small, the
plastic deformation takes place in a localized area and the metal adjacent to the cutting edges of
the punch and die edges becomes highly stressed, which causes the fracture to start on both sides
of the sheet as the deformation progresses. The idea of the project generated due to a manual
sheet metal sheering machine in workshop of our college. In that machine sheet metal is placed
in between the two sheering blades of machine and the lever is pulled down to move the upper
movable blade and cut the work-piece.

AvinashJathar, AvinashKushwaha,Utkarsh Singh, Prof. Subhash Kumar,

9
Fabrication and Review of Hydraulic Heavy Sheet Metal Cutting machine,
Journal of Emerging Technologies and Innovative Research , Volume 3, Issue
4, April 2016,pp 37-41.
This machine is for sheet metal industry and can be made into multiple machines and should
be used as circle cutting cum straight cutting machine .The machine is simple to maintain easy to
operate. Hence we tried out hands on Hydraulic Shearing Machine in shearing operation as the
punch descends upon the metal, the pressure exerted by the punch first cause the plastic
deformation of the metal. Since the clearance between the punch and the die is very small, the
plastic deformation takes place in a localized area and the metal adjacent to the cutting edges of
the punch and die edges becomes highly stressed, which causes the fracture to start on both sides
of the sheet as the deformation progresses. The idea of the project generated due to a manual
sheet metal sheering machine in workshop of our college. In that machine sheet metal is placed
in between the two sheering blades of machine and the lever is pulled down to move the upper
movable blade and cut the work-piece.

Swapnil Laxman Gaikwad, Rohit Ramnath Pawar, Mayur Bapu Gunjal,

Pritam Bajirao Bhawar, Design & development of pneumatic shearing
machine, International Journal of Advanced Research in Science &
Engineering, January 2017
Today in the rapid competition of the industries to get the best quality of the product in
the minimum required time is the main aim of industries. To get the best quality and maximum
production most advanced machines are used. But there is no facts that use nly the advanced
machines, to maintain their performance is real requirement of the industries, also to give proper
facilities to the workers with good environmental condition and to reduce their efforts is one of
the objects to achieve the best quality and high production.

Madhu Kumar V “ Design and Fabrication of Pneumatic Sheet Metal Cutting

and Bending Machine. International Journal of Engineering Research And
Advanced Technology (IJERAT).

10
 Metal in the form of sheets is paramount in the manufacturing industry. Its applications
are countless. But metal in the form of sheets cannot be directly used, operations like cutting,
punching, blanking, bending, trimming, etc. are needed to be carried out on the metal sheets in
order to fully utilize them. For these operations, most large scale manufacturing industries use
hydraulically operated machines. But since hydraulic machines are not cost-effective, most small
and medium scale industries use hand-operated machines for carrying out sheet metal operation.
The problem with hand-operated machines is that they are slow and cannot be automated. This
is where the concept of pneumatics will prove itself advantageous. We are developing a
pneumatically operated cutting and punching machine which will use the
help of compressed air to drive a shearing blade and punch to carry out the operations on a
metallic sheet. The machine is designed to cut 1mm thick aluminium sheets and 0.5mm thick
copper sheets very easily. The main components of developed pneumatic system are
compressor, pipelines, double-acting cylinder, an actuator, and flow control valves. This
machine will thus, prove itself cost-effective and also save a lot of time in manufacturing process
as two operations can be performed on the same platform.

Vishal Tambat, Nilkanth Rane, Omkar Savant, 4Pankaj Yadav. Pneumatic

Shearing and Bending Machine, IJRRCME, Vol. 2, Issue 1, pp: (9-18),
Month: April 2015 – September 2015.
The shearing machine and bending machine is most important in sheet metal industry.
This machine should be used for straight cutting machine with wide application. But in some
industry hand sheet cutter and hand bender are used. For that machine to operate the human
effort are required. The machine should be simple to operate and easy to maintain, hence we
tried out to develop the Pneumatic Shearing and Bending Machine. In shearing operation as the
punch descends upon the metal, the pressure exerted by the punch first cause the plastic
deformation of the metal. Since the clearance between the punch and the die is very small, the
plastic deformation takes place in a localized area and the metal adjacent to the cutting edges. In
bending operation the bend has been made with the help of punch which exerts large force on the
work clamped on the die. The bending machine is designed in such a way that, it works
automatically. The machine is designed by observing the factors to improve the efficiency and to
reduce the cycle time by producing quality output. Automation of machine is achieved with the

11
help of pneumatic system. This paper involves the design of an efficient system which reduces
the human effort and help to increase production output. It also includes pneumatic system,
pneumatic component and shearing die and bending die.

Aniruddha Kulkarni, Mangesh Pawar “Sheet Metal Bending Machine.

IJIERT, I SSN: 2394-3696 VOLUME 2, ISSUE 3, March.-2015
In the work of liberalization (more freedom in action) the civil & mechanical sector has
taken much importance in advancement & technology in various fields, and also much than the
core industrial sector. In most developed cities need a lot of man power to split bar in to small
parts. This man power requires various equipment viz. Hammer, chisel, hacksaw etc. Thus in
order to avoid these project benefits in various ways. Use this lightweight tool to cut steel bars
and other materials anywhere. Hydraulic power means minimum operator effort and a smooth
guillotine-action reduces the risk of jamming Double-acting operation Cutting range 8 to14 mm
in stroke. Hydraulic fluids also called hydraulic liquids are the medium by which power is
transferred in hydraulic ma-chinery. The hydraulic fluid also known as tractor fluid, hydraulic
fluid is the life of the hydraulic circuit. It is usually petroleum oil with various additives. Some
hydraulic machines require fire resistant fluids, depending on their applications. In some
factories where food is prepared, either an edible oil or water is used as working fluid for health
and safety reasons. In addition to transferring energy, hydraulic fluids needs to lubricate
components, suspend contaminants and metal filling for transport to the filter and to function
well to several hundred degree Fahrenheit or Celsius.

12
 CHAPTER 3
CONSTRUCTION OF EXPERIMENTAL MODEL

3.1 PROPOSED METHOD

Pneumatic system is used for the automation of machine and to solve industrial labour problems.
Sheet metals have a variety of applications in making car bodies, roofs for buildings, medical tables etc.
Now a day’s sheet metal is also used in making furniture and cupboard.
Cutting processes are those in which sheet metal is separated by applying enough force to cause
the material to fail. The most common process is shearing process as in this the cutting processes are
performed by applying shearing force. The shear stress in the material will exceed the ultimate shearing
strength when a greater shearing force is applied and the material will fail and separate at the cut location.
This shearing force is applied by two tools, one above and one below the sheet. These tools can be upper
and lower blades or a punch and die. The tool above the sheet delivers a quick downward blow with
certain force to the sheet metal that rests over the lower tool. A very small clearance is present between
the blades i.e. edges of the upper and lower tools, which facilitates the fracture in the sheet metal. An
attempt has been made to review the literature in pneumatic systems in sheet cutting, based on various
criteria. Pneumatic is a branch of engineering that makes use of pressurized air or gas.

13
 Fig.3.1.schematic representation of proposed methodology
3.2 CONSTRUCTION
The most common cutting processes are performed by applying a shear force, and are
therefore sometimes referred to as shearing processes. Cutting processes are those in which a
piece of sheet metal is separated by applying a great enough force to cause the material to fail
.When a great enough shearing force is applied, the shear stress in the material will exceed the
ultimate shear strength and the material will fail and separate at the cut location. This shearing
force is applied by two tools, one above and one below the sheet. Whether these tools are a
punch and die or upper and lower blades, the tool above the sheet delivers a quick downward
blow to the sheet metal that rests over the lower tool. A small clearance is present between the
edges of the upper and lower tools, which facilitates the fracture of the material. The effects of
shearing on the material change as the cut progresses and are visible on the edge of the sheared
material. When the punch or blade impacts the sheet, the clearance between the tools allows the
sheet to plastically deform and “rollover” the edge. As the tool penetrates the sheet further, the
shearing results in a vertical burnished zone of material, finally, the shear stress is too great and
the material fractures at an angle with a small burr formed at the edge. The height of these
portions of the cut depends on several factors, including the sharpness of the tools and the

14
clearance between the tools.
.
The common components of this pneumatic sheet metal cutting machine are:
 Pneumatic cylinder,
 Pneumatic hand operated valve and
 high speed steel blade,
 Air pipe etc.

3.3 WORKING
The pneumatic machine includes a table with support arms to hold the sheet, stops or
guides to secure the sheet, upper and lower straight - edge blades, a gauging device to precisely
position the sheet. The table also includes the two way directional valve. The two way
directional valve is connected to the compressor. The compressor has a piston for a movable
member. The piston is connected to a crankshaft, which is in turn connected to a prime mover
(electricmotor, internal combustion engine). At inlet and outlet ports, valves allow air toenter and
exit the chamber. When the compressor is switched ON, the compressed air is flow to inlet of the
pneumatic cylinder.
The sheet is placed between the upper and the lower blade. The lower blade remains
stationary while the upper blade is forced downward. The upper blade is slightly offset from the
lower blade, approximately 5 – 10% of the sheet thickness. Also the upper blade is usually
angled so that the cut progresses from one end to the other, thus reducing the required force.
When the pneumatic hand operated lever is moved forward, the piston starts moving in
the forward direction. The upper blade which are then forced against the sheet, cutting the
material. When the pneumatic hand operated lever is moved backward, the upper blade will
come to the original position (i.e., the upper blade will move upwards). After the material is cut,
adjust the pneumatic hand lever to the mid position (i.e., normal position) and then the
compressor is switched OFF.

15
 Fig.3.1.functioning

3.2 CONTROLLING.

3.2.1 Control of Pneumatic Energy –

Working energy transmitted pneumatically must be directed and under complete control
at all times. If not under control, useful work will not be done and machinery or machine
operators might be harmed. One of the advantages of transmitting energy pneumatically is that
energy can be controlled relatively easily by using valves.

3.3.1 Sheared edge

A variety of cutting processes that utilize shearing forces exist to separate or remove
material from a piece of sheet stock in different ways. Each process is capable of forming a
specific type of cut, some with an open path to separate portion of material and some with a
closed path to cut out and remove that material. By using many of these processes together, sheet
metal parts can be fabricated with cut outs and profiles of any 2D geometry. Such cutting process
includes the following:

16
 Shearing – Separating material into two parts
 Blanking – Removing material to use for parts
 Conventional blanking
 Fine blanking
 Punching – Removing material as scrap
 Piercing
 Slotting
 Perforating
 Notching
 Nibbling
 Lancing
 Slitting
 Parting
 Cutoff
 Trimming
 Shaving
 Dinking

17
 Fig.3.1.Sheared edge

3.3.2 Shearing
As mentioned above, several cutting processes exist that utilize shearing force to cut
sheet metal. However, the term “shearing” by itself refers to a specific cutting process that
produces straight line cuts to separate a piece of sheet metal. Most commonly, shearing is used to
cut a sheet parallel to an existing edge which is held square, but angled cuts can be made as well.
For this reason, shearing is primarily used to cut sheet stock into amaller sizes in preparation for
other processes. Shearing has the following capabilities
Sheet thickness: 0.005 – 0.25 inches
Tolerence: 0.1 inches
The shearing is performed on a shear machine, often called asquaring shear

18
or power shear, that can be operated manually or by hydraulic, pneumatic, or
electric power. A typical shear machine includes a table with support arms to hold
the sheet, stops or guides to secure the sheet, upper and lower straight - edge
blades, a gauging device to precisely position the sheet. The sheet is placed
between the upper and the lower blade, which are then forced together against the
sheet, cutting the material. In most devices, the lower blades remain stationary
while the upper blade is forced downward. The upper blade is slightly offset from
the lower blade, approximately 5 – 10% of the sheet thickness. Also the upper
blade is usually angled so that the cut progresses from one end to the other, thus
reducing the required force. The knife edge and are available in different materials,
such as low alloy steel and high carbon steel.

3.3.3 Pneumatic transmission of energy

The reason for using pneumatics, or any other type of energy transmission
on amachine, is to perform work. The accomplishment of work requires the
applicationof kinetic energy to a resisting object resulting in the object moving
through adistance. In a pneumatic system, energy is stored in a potential state
under the formof compressed air. Working energy (kinetic energy and pressure)
results in apneumatic system when the compressed air is allowed to expand. For
example, atank is charged to 100 PSIA with compressed air. When the valve at the
tank outletis opened, the air inside the tank expands until the pressure inside the
tank equals theatmospheric pressure. Air expansion takes the form of airflow.
To perform any applicable amount of work then, a device is needed which
cansupply an air tank with a sufficient amount of air at a desired pressure. This
deviceis positive displacement compressor.

19
What a Positive Displacement Compressor Consists of
A positive displacement compressor basically consists of a movable member
insidea housing. The compressor has a piston for a movable member. The piston
isconnected to a crankshaft, which is in turn connected to a prime mover
(electricmotor, internal combustion engine). At inlet and outlet ports, valves allow
air toenter and exit the chamber.

How a Positive Displacement Compressor Works:

As the crankshaft pulls the piston down, an increasing volume is formed
within the housing. This action causes the trapped air in the piston bore to expand,
reducing its pressure. When pressure differential becomes high enough, the inlet
valve opens, allowing atmospheric air to flow in. With the piston at the bottom of
its stroke, inlet valve closes. The piston starts its upward movement to reduce the
air volume which consequently increases its pressure and temperature. When
pressure differential between the compressor chamber and discharge line is high
enough, the discharge valve opens, allowing air to pass into an air receiver tank for
storage.

3.3.4 Control of Pneumatic Energy

Working energy transmitted pneumatically must be directed and under complete
control at all times. If not under control, useful work will not be done and
machinery or machine operators might be harmed. One of the advantages of
transmitting energy pneumatically is that energy can be controlled relatively easily
by using valves.

3.2.2 Control of Pressure –

Pressure in a pneumatic system must be controlled at two points - after the compressor

20
and after the air receiver tank. Control of pressure is required after the compressor as a safety for
the system. Control of pressure after an air receiver tank is necessary so that an actuator receives
a steady pressure source without wasting energy.

3.2.3 Control of Pressure after compression –

In a pneumatic system, energy delivered by a compressor is not generally used

immediately, but is stored as potential energy in air receiver tank in the form of compressed air.
In most instances, a compressor is designed into a system so that it operates intermittently. A
compressor is a device that usually delivers compressed air to a receiver tank until high pressure
is reached, then it is shut down. When air pressure in the tank decreases, the compressor cuts in
and recharges the tank. Intermittent compressor operation in this manner is a power saving
benefit for the system. A common way of sensing tank pressure and controlling actuation and de-
actuation of relatively small (2-15 HP) compressors is with a pressure switch.

3.3 DATA ANALYSIS

3.3.1 Cylinder thrust:

Cylinder thrust for double acting in forward stroke then Cylinder thrust for double acting
in return stroke – 𝐹 = (𝜋 /4) × (𝐷 – 𝑑) 2 × 𝑃 ,

Where,
D = Diameter of bore in mm.
P = Pressure in bar. (1 bar = 0.1N/mm2)
d = Piston rod diameter in mm

3.3.2 Theoretical air consumption-

𝐶 = {(π /4) × 𝐷2 × (P + 1) × L}/1000

21
where,
P= pressure in bar
D= Diameter of bore in cm
L= Length of stroke in cm.

3.3.3 Sheet metal cutting force-

Cutting force = 𝐿 × 𝑆 × 𝑇𝑚𝑎𝑥

Stripping force =10% -20% of cutting force
L = Length of periphery to be cut in mm
S = Sheet thickness in mm
𝑇𝑚𝑎𝑥 = Shear strength in N/mm2
𝑇𝑚𝑎𝑥 = 80% of tensile strength.

22
 CHAPTER 4
HARDWARE IMPLEMENTATION

3.1.1 Pneumatic cylinders

Pneumatic cylinders (sometimes known as air cylinders) are mechanical devices which
use the power of compressed gas to produce a force in a reciprocating linear motion.
Like hydraulic cylinders, pneumatic cylinders use the stored potential energy of a fluid,
in this case compressed air, and convert it into kinetic energy as the air expands in an attempt to
reach atmospheric pressure. This air expansion forces a piston to move in the desired direction.
The piston is a disc or cylinder, and the piston rod transfers the force it develops to the object to
be moved. Engineers prefer to use pneumatics sometime because they are quieter, cleaner, and
do not require large amounts or space for fluid storage.
Because the operating fluid is a gas, leakage from a pneumatic cylinder will not drip out
and contaminate the surroundings, making pneumatics more desirable where cleanliness is a
requirement. For example, in the mechanical puppets of the Disney Tiki Room, pneumatics are
used to prevent fluid from dripping onto people below the puppet.

Fig.3.1.Pneumatic Cylinder

23
3.1.2 2/2 Directional control valve –

The structure of a 2/2 directional control valve is very simple. It uses the thrust from the
spring to open and close the valve, stopping compressed air from flowing towards working tube
‘A’ from air inlet ‘P’. When a force is applied to the control axis, the valve will be pushed open,
connecting ‘P’ with ‘A’ as shown in Fig.7. The force applied to the control axis has to overcome
both air pressure and the repulsive force of the spring. The control valve can be driven manually
or mechanically, and restored to its original position by the spring.

Fig.3.2.2/2Directional control valve

3.1.3 3/2 Directional control valve –

3/2 directional control valve can be used to control a s-ingle acting cylinder (Fig. 8). The
open valves in the middle will close until ‘P’ and ‘A’ are connected together. Then another valve
will open the sealed base between ‘A’ and ‘R’ (exhaust) as shown in Fig 8.The valves can be
driven manually mechanically, electrically or pneumatically. 3/2 directional control valves can
further be divided into two classes: Normally open type (N.O.) and normally closed type.

24
 Fig.3.3.3/2Directional control valve

3.1.4 5/2 Directional control valve –

When a pressure pulse is input into the pressure control port ‘P’, the spool will move to
the left, connecting inlet ‘P’ and work passage ‘B’. Work passage ‘A’ will then make release of
air through ‘R1’ and ‘R2’as shown in Fig 9. The directional valves will remain in this
operational position until signals of the contrary are received. Therefore, this type of directional
control valves is said to have the function of ‘memory.On the other hand there exists many
important components like: High speed steel blade, Special Air pipe, Stainless Steel and most
important Air compressor

25
 Fig.3.4.5/2Directional control valve

HIGH SPEED STEEL BLADE:

A blade is used to cut the sheet metal in a desired dimension. Here we are using
high speed steel blades to cut the sheet metal.

Stainless steel:
The three most common stainless steel grades available in sheet metal are
304, 316, and 410.  Grade 304 is the most common of the three grades. It offers
good corrosion resistance while maintaining formability and weldability. Available
finishes are #2B, #3, and #4. Note that grade 303 is not available in sheet form. 
Grade 316 offers more corrosion resistance and strength at elevated temperatures
than 304. It is commonly used for pumps, valves, chemical equipment, and marine
applications. Available finishes are #2B, #3, and #4.  Grade 410 is a heat treatable
stainless steel, but does not offer as good corrosion resistance. It is commonly used
in cutlery. The only available finish is dull.

26
 CHAPTER 5
ADVANTAGES AND FUNCTIONALITIES

5.1 USAGE OF Sheet metals

 Car bodies
 Airplane wings
 Medical tables
 Roofs for buildings (Architectural) and many other things
 Sheet metal of iron and other materials with high magnetic permeability,
also known as laminated steel cores, has applications in transformers and
electric machines.
 Historically, an important use of sheet metal was in plate armor worn by
cavalry, and sheet metal continues to have many decorative uses, including
in horse tack.

5.2 ADVANTAGES OF PROPOSED WORK

 Low cost
 Less consumption of time
 Easy to handle
 Skilled labor is not required
 Less maintenance
 High accuracy
 Good surface finish
 Less floor space

27
 CHAPTER 4
CONCLUSION AND FUTURE SCOPE

Pneumatic systems are used in controlling train doors, automatic production lines, and
Mechanical clamps. The sheet metal cutting process is a main part of the all industries. Normally
the sheet metal cutting machine is manually hand operated one for medium and small scale
industries. The sheet metal cutting machine works with the help of pneumatic double acting
cylinder. The piston is connected to the moving cutting tool. Sheet metal cutting machine can be
used to cut the sheet metal of minimum thickness without manual hard work. This machine can
also be installed in the lab for the experiment and demonstration to engineering students. In this
project I have tried my best to fabricate a pneumatic sheet metal cutting machine which can cut
the sheet metal in small pieces.

Pneumatic Sheet metal cutting machine is very cheap as compared to hydraulic cutting
machine or laser cutting machine. The range of the cutting thickness can be increased by
arranging a high pressure compressor and installing more hardened blades. This machine is
advantageous to small sheet metal cutting industries as they cannot afford the expensive
machine. Pneumatic sheet metal cutting machine can be used in various industries or workshops.

FUTURE SCOPE
The above conclusions set a new platform for further researches in common cutting edge
concept as shows its effectiveness in utilizing sheet material and reducing the length of cutting
path. Although this particular work is evaluated for the rectangular parts, it can be enhanced for
the nesting of irregular geometrical shapes. Further by considering appropriate process
parameters, this common cutting edge concept can be applied to other two dimensional cutting
processes such as blanking and plasma cutting. The cutting of the parts with the common edge
having different profiles can also be studied.

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 CHAPTER 5
REFERENCES

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