International Journal of Scientific & Engineering Research Volume 8, Issue 7, July-2017

ISSN 2229-5518
336

Machining time reduction in shaping machine

S.MADAN, N.GANESAMOORTHY, M.KARTHIKEYAN, M.MAHENDRAN, AND K.ARUNKUMAR

Abstract— Shaper is used to machine a single job by using a single sized pieces, called chips. Common cutting processes include
point cutting tool and hence it cannot be used for high production sawing, shaping (or planning), broaching, drilling, grinding, turning
rates. This project intends to use shaper for high production as well. A and milling. Although the actual machines, tools and processes for
small skeleton structure has been thus devised to demonstrate the cutting look very different from each other, the basic mechanism for
machining time reduction in shaping machines. The shaping machine causing the fracture can be understood by just a simple model called
has an idle stroke during its return motion. This project is uses the idle
for orthogonal cutting. In all machining processes, the work piece is
stroke as cutting stroke and hence increase the production rate. This
can be achieved by an addition of clapper box with a tool such that the a shape that can entirely cover the final part shape. The objective is
arrangement on tool holder has one tool clamped on the clapper box to cut away the excess material and obtain the final part. This
individually. This stroke would be a rough cutting stroke for the job, cutting usually requires to be completed in several Athe exposed
compared to the forward stroke. The pneumatic source of power with portion can be accessed by the tool to machine in that portion.
control accessories is used to drive the ram or the cylinder piston to Common fixtures include vise, clamps, 3-jaw or 4-jaw chucks, etc.
obtain the forward and return strokes. By this arrangement the Each position of holding the part is called a setup. One or more
machining time of a work piece is reduced by half the time when cutting operation may be performed, using one or more cutting
compared with the conventional machines.
tools, in each setup. To switch from one setup to the next, we must
release

Keywords— Pneumatic cylinder, Solidworks, Elecronic E

Control unit
S I. INTRODUCTION
haper is a type of machine tool that uses linear relative motion
between the work piece and a single-point cutting tool to machine a
linear tool path. A shaping machine is also called shaper is mainly
used for producing flat surfaces, which may be horizontal, vertical

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or inclined. Sometimes curved or irregular surfaces are also
produced by shapers. Shapers were very common in industrial
production from the mid-19th century through the mid-20th. In
current industrial practice, shapers have been largely superseded by
other machine tools, including milling machines, grinding
machines, and broaching machines. But the basic function of a
shaper is still sound tooling for them is minimal and very cheap to
reproduce; and they are simple and robust in construction, making
their repair and upkeep easily achievable. In shaping machines the the part from the previous fixture, change the fixture on the
stroke length can be varied by changing the distance between center machine, clamp the part in the new position on the new fixture, set
of the bull gear and pivot pin. In shaping machine the vertical slots the coordinates of the machine tool with respect to the new location
are provide on one side of the shaping machine. The slots can be of the part, and finally start the machining operations for this setup.
used to move vertically (upwards or downwards) the bull gear Therefore, setup changes are time-consuming and expensive, and so
position. In a shaper rotary movement of the drive is converted into we should try to do the entire cutting process in a minimum number
reciprocating movement by the mechanism contained within the of setups; the task of determining the sequence of the individual
column or frame of the machine. The ram holding the tool gets the operations, grouping them into (a minimum number of) setups, and
reciprocating movement. In a standard shaper metal is removed in determination of the fixture used for each setup, is called process
the forward cutting stroke, while the return stroke goes idle and no planning.
metal is removed during this period. In our project TIME
REDUCTION IN PNEUMATIC SHAPING MACHINE time is These notes will be organized in three sections:
considered to be the main criteria. (i) Introduction to the processes,
II. MANUFACTURING PROCESS (ii) The orthogonal cutting model and tool life optimization
and
Manufacturing processes are the steps through which raw
materials are transformed into a final product. The manufacturing (iii) Process planning and machining planning for milling.
process begins with the creation of the materials from which the
design is made. These materials are then modified through B. Sawing:
manufacturing processes to become the required part.
Manufacturing processes can include treating machining, or Cold saws are saws that make use of a circular saw blade
reshaping the material. The manufacturing process also includes to cut through various types of metal, including sheet metal. The
tests and checks for quality assurance during or after the name of the saw has to do with the action that takes place during the
manufacturing, and planning the production process prior to cutting process, which manages to keep both the metal and the
manufactur blade from becoming too hot. A cold saw is powered with
electricity and is usually a stationary type of saw machine rather
than a portable type of saw. The circular saw blades used with a
cold saw are often constructed of high speed steel. Steel blades of
A. Metal cutting: this type are resistant to wear even under daily usage. The end result
is that it is possible to complete a number of cutting projects before
Metal cutting or machining is the process of by removing
there is a need to replace the blade. High speed steel blades are
unwanted material from a block of metal in the form of chips.
especially useful when the saws are used for cutting through thicker
Cutting processes work by causing fracture of the material that is
sections of metal. Along with the high speed steel blades, a cold
processed. Usually, the portion that is fractured away is in small
saw may also be equipped with a blade that is tipped with tungsten

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International Journal of Scientific & Engineering Research Volume 8, Issue 7, July-2017
ISSN 2229-5518
337

carbide. This type of blade construction also helps to resist wear and  Single acting cylinder.
tear. One major difference is that tungsten tipped blades can be re-
sharpened from time to time, extending the life of the blade. This  Double acting cylinder
type of blade is a good fit for use with sheet metal and other
metallic components that are relatively thin in design.
D. Double acting pneumatic cylinder
III. COMPONENTS AND DESCRIPTION
The cylinder is a double acting cylinder one, which means
The major parts that are effectively employed in the design and
that the air pressure (forward and backward). The air from the
the fabrication of the pneumatic machining time reduction in
compressor is passed through the regulator which controls the
shaping machine are described below:
pressure to required amount by adjusting its knob. A pressure
gauge is attached to the regulator for showing the line pressure.
Then the compressed air is passed through the directional control
valve for supplying the air alternatively to either sides of the
cylinder. Two hoses take the output of the directional control valve
 Pneumatic cylinder,
and they are attached to two ends of the cylinder by means of
 Solenoid valve, connectors. One of the outputs from the directional control valve is
taken to the flow control valve from taken to the cylinder. An air
 Flow control valve, cylinder is an operative device in which the state input energy of
compressed air i.e. pneumatic power is converted in to mechanical
 Electronic control unit, output power, by reducing the pressure of the air to that of the
 Flexible hoses, atmosphere. A double acting cylinder is employed in control
systems with the full pneumatic cushioning and it is essential when
 Clapper box and dead weight arrangement, the cylinder itself is required to retard heavy messes. This can only
be done at the end positions of the piston stock. In all intermediate
Air compressor. position a separate externally mounted cushioning derive most be
provided with the damping feature. The normal escape of air is out
A. Pneumatic cylinder
off by a cushioning piston before the end of the stock is required.
Mechanization is broadly defined as the replacement of As a result the sit in the cushioning chamber is again compressed

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manual effort by mechanical power. Pneumatics is an attractive since it cannot escape but slowly according to the setting made on
medium for low cost mechanization particularly for sequential or reverses. The air freely enters the cylinder and the piston stokes in
repetitive operations. Many factories and plants already have a the other direction at full force and velocity
compressed air system, which is capable of providing both the
power or energy requirements and the control system (although E. Single acting pneumatic cylinder
equally pneumatic control systems may be economic and can be A single-acting cylinder in a reciprocating engine is
advantageously applied to other forms of power).The main a cylinder in which the working fluid acts on one side of the
advantages of an all-pneumatic system are usually economy and piston only. A single-acting cylinder relies on the load, springs,
simplicity, the latter reducing maintenance to a low level. It can other cylinders, or the momentum of a flywheel, to push the piston
also have outstanding advantages in terms of safety. back in the other direction. Single-acting cylinders are found in
most kinds of reciprocating engine. They are almost universal
B. Selection of pneumatics
in internal combustion engines (e.g. petrol and diesel engines) and
Mechanization is broadly defined as the replacement of are also used in many external combustion engines such as Stirling
manual effort by mechanical power. Pneumatic is an attractive engines and some steam engines. They are also found in pumps and
medium for low cost mechanization particularly for sequential (or) hydraulic rams.
repetitive operations. Many factories and plants already have a
compressed air system, which is capable of providing the power (or)
energy requirements and the control system (although equally
pneumatic control systems may be economic and can be
advantageously applied to other forms of power).The main
advantage of an all pneumatic system are usually economic and
simplicity the latter reducing maintenance to a low level. It can also
have outstanding advantages in terms of safety.

C. Production of compressed air

Pneumatic systems operate on a supply of compressed air,
which must be made available, in sufficient quantity and pressure to
suit the capacity of the system. When pneumatic system is being
adopted for the first time, however it wills indeed the necessary to
deal with the question of compressed air supply. The key part of any
F. Solenoid valve
facility for supply of compressed air is by means using The directional valve is one of the important parts of a
reciprocating compressor. A compressor is a machine that takes in
pneumatic system. Commonly known as DCV, this valve is used to
air, gas at a certain pressure and delivered the air at a high pressure.
control the direction of air flow in the pneumatic system. The
Compressor capacity is the actual quantity of air compressed and
directional valve does this by changing the position of its internal
delivered and the volume expressed is that of the air at intake
movable parts. This valve was selected for speedy operation and to
conditions namely at atmosphere pressure and normal ambient
reduce the manual effort and also for the modification of the
temperature. Clean condition of the suction air is one of the factors,
machine into automatic machine by means of using a solenoid
which decides the life of a compressor. Warm and moist suction air
valve.
will result in increased precipitation of condense from the
compressed air. Cylinder is mainly classified into two types namely,

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International Journal of Scientific & Engineering Research Volume 8, Issue 7, July-2017
ISSN 2229-5518
338

changes of pressure or flow and will open/close the valve.

Automatic Control Valves do not require an external power source,
meaning that the fluid pressure is enough to open and close the
valve. Automatic control valves include: pressure reducing valves,
flow control valves, back-pressure sustaining valves, altitude
valves, and relief valves. An altitude valve controls the level of a
tank. The altitude valve will remain open while the tank is not full
and it will close when the tanks reaches its maximum level. The
opening and closing of the valve requires no external power source
(electric, pneumatic, or man power), it is done automatically, hence
its name. Process plants consist of hundreds, or even thousands, of
control loops all networked together to produce a product to be
offered for sale. Each of these control loops is designed to keep
A solenoid is an electrical device that converts electrical energy some important process variable such as pressure, flow, level,
into straight line motion and force. These are also used to operate a temperature, etc. within a required operating range to ensure the
mechanical operation which in turn operates the valve mechanism. quality of the end product. Each of these loops receives and
Solenoids may be push type or pull type. The push type solenoid is internally creates disturbances that detrimentally affect the process
one in which the plunger is pushed when the solenoid is energized variable, and interaction from other loops in the network provides
electrically. The pull type solenoid is one in which the plunger is disturbances that influence the process variable.
pulled when the solenoid is energized.
H. Electronic control unit
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 In automotive electronics, Electronic Control Unit (ECU)
service work or to install them. is a generic term for any embedded system that controls one or
more of the electrical system or subsystems in a motor vehicle.
Types of ECU include Electronic/engine Control Module (ECM),
Power train Control Module (PCM), Transmission Control Module
(TCM), Brake Control Module (BCM or EBCM), Central Control
Module (CCM), Central Timing Module (CTM), General Electronic

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Module (GEM), Body Control Module (BCM), Suspension Control
Module (SCM), control unit, or control module. Taken together,
these systems are sometimes referred to as the car's computer.
Technically there is no single computer but multiple ones.
Sometimes one assembly incorporates several of the individual
control modules. Some modern motor vehicles have up to 80
ECUs. Embedded software in ECUs continues to increase in line
count, complexity, and sophistication. Managing the increasing
complexity and number of ECUs in a vehicle has become a key
challenge for original equipment manufacturers (OEMs).In our
project we use the control unit for controlling the DC motor that
activates/deactivates the vehicle braking system. It is very simple in
operation that, when the solenoid valve is connected to the
The solenoid valve has 5 openings. This ensure easy electronic control unit the electronic control unit acts as the
exhausting of 5/2 valve. The spool of the 5/2 valve slide inside the actuating device for the solenoid valve and it controls the flow
main bore according to spool position; the ports get connected and direction of the air through the pneumatic cylinder.
disconnected. The working principle is as follows.
I. Flexible hoses
Hose is fabricated in layer of elastomer or synthetic rubber
Position-1
and braided fabric, which permits operation at higher pressure. The
When the spool is actuated towards outer direction port ‘P’ standard tubing outside diameter is 1/16 inch. If the hose is subject
gets connected to ‘B’ and ‘S’ remains closed while ‘A’ gets to rubbing, it should be encased in a protective sleeve.
connected to ‘R’.
J. Clapper box and dead weight arrangement
Poisition-2
The clapper box arrangement is fixed to the one end of the
When the spool is pushed in the inner direction port ‘P’ guide bush. The clapper box is having dead weight and tool feeding
and ‘A’ gets connected to each other and ‘B’ to ‘S’ while port ‘R’ arrangement. The screw is used to feeding the depth of cut into the
remains closed. work piece.
G. Flow control valve K. Air compressor
A flow control valve regulates the flow or pressure of An air compressor is a device that converts power (using
a fluid. Control valves normally respond to signals generated by an electric motor, diesel or gasoline engine, etc.) into potential
independent devices such as flow meters or temperature gauges. energy stored in pressurized air (i.e., compressed air). By one of
Control valves are normally fitted with actuators and positioners. several methods, an air compressor forces more and more air into a
Pneumatically-actuated globe valves and Diaphragm Valves are storage tank, increasing the pressure. When tank pressure reaches its
widely used for control purposes in many industries, although upper limit the air compressor shuts off. The compressed air, then,
quarter-turn types such as (modified) ball, gate and butterfly valves is held in the tank until called into use. The energy contained in the
are also used. compressed air can be used for a variety of applications, utilizing
the kinetic energy of the air as it is released and the tank
Control valves can also work with hydraulic actuators (also
depressurizes. When tank pressure reaches its lower limit, the air
known as hydraulic pilots). These types of valves are also known as
compressor turns on again and re-pressurizes the tank. There are
Automatic Control Valves. The hydraulic actuators will respond to

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International Journal of Scientific & Engineering Research Volume 8, Issue 7, July-2017
ISSN 2229-5518
339

numerous methods of air compression, divided into either positive- sudden thrust at extreme ends.
displacement or negative-displacement types.

Due to adiabatic heating, air compressors require some

method of disposing of waste heat. Generally this is some form of
air- or water-cooling, although some (particularly rotary type)
compressors may be cooled by oil (that is then in turn air- or water-
cooled) and the atmospheric changes also considered during cooling
of compressors.

The main function of the air compressor is to compress the

air up to the required pressure. The maximum capacity of the
compressor is 10 105 to 12 105 N/m2. This is a two stages or
two-cylinder reciprocating air compressor. The two cylinders are for
low and high compression. The air pressure is measured at various
places by the use of pressure gauges. V-belt and pulley are used to
drive the compressor. A. Principles of working

Compressors can be broadly classifieds into two groups. They are: The compressed air from the compressor reaches the
solenoid valve. The solenoid valve changes the direction of flow
according to the signals from the timing device.
 Positive Displacement Compressor The compressed air pass through the solenoid valve and it
is admitted into the front end of the cylinder block. The air pushes
 Dynamic Compressors
the piston for the cutting stroke. At the end of the cutting stroke air
A. Positive displacement compressor from the solenoid valve reaches the rear end of the cylinder block.
The pressure remains the same but the area is less due to the
Successive volumes of air isolated and then compressed to presence of piston rod. This exerts greater pressure on the piston,
a higher pressure. There are essential two forms of positive pushing it at a faster rate thus enabling faster return stroke.
displacement compressor, reciprocating and rotary.
The screw attached is fixed to the clapper box frame gives

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B. Dynamic compressors constant loads which lower the sapper to enable continuous cutting
of the work.
These are rotary continuous machines in which a high
speed rotating element accelerates the air and converts the resulting The stroke length of the piston can be changed by making
velocity head into pressure. Positive displacement compressors suitable adjustment in the timer.
work on the principle of increasing the pressure of a definite volume
in an enclosed chamber. Dynamic (turbo) compressor employs V. CONCLUSION
rotating vanes or impellers to impart velocity and pressure to the Thus the machining time is reduced and quick response is
flow of the air being handled. The pressure comes from the dynamic achieved. The equipment is simple in construction and easy to
effects such maintain and repair. Cost of the unit is less when compared to other
as centrifugal force. Machines. No fire hazard problem due to over loading.
Comparatively the operation cost is less. The speed of forward and
IV. WORKING PRINCIPLE reverse stroke is varied. Continuous operation is possible without
stopping
Initially starting with air compresses, its function is to
compress air from a low inlet pressure (usually atmospheric) to a VI. REFERENCES
higher pressure level. This is an accomplished by reducing the
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Air compressors are generally positive displacement units 12.
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4. Manufacturing & Investment Around The World: An
The compressed air goes to the solenoid valve through International Survey Of Factors Affecting Growth &
flow control valve. The flow control valve is used to control the Performance, ISR Publications/Google Books, revised second
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International Journal of Scientific & Engineering Research Volume 8, Issue 7, July-2017
ISSN 2229-5518
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8. "Factory jobs: 3 million lost since 2000". USATODAY.com. April 10. "Manufacturing, value added (current US$) for EU and
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