PNEUMATIC SWITCH BOARD CUTTER

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 TABLE OF CONTENT
S.NO CONTENT PAGE NO
SYNOPSIS 7
1 PROJECT PLANING 8
2 METAL CUTTING THEORY 11
3 CUTTING TOOL MATERIAL 13
4 INTRODUCTION OF HACKSAW MACHINE 19
5 WOOD WORKING MACHINE 26
6 MAJOR COMPONENTS OFPNEUAMTIC 30
SWITCH BOARD CUTTER
7 WORKING PRINCIPLE 39
8 DESIGN FOR PNEUMATIC CYLINDER 40
9 ADVANTAGES& DIS ADVANTAGES 44
10 LINE DIAGRAM 45
11 COST OF ESTIMATION 46
12 CONCLUSION 47
13 BIBILOGRAPHY 48

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SYNOPSIS

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 SYNOPSIS

We have decided to do a project on design and fabrication of switch board

cutting machine. Hacksaw is one of the tool, which is used for cutting woods
metals or pipes. The existing system is cutting such kind of materials by men, but
in the proposed system this is handled by pneumatic machine, which cuts
automatically with the help of pneumatic cylinder. The project is designed by
following equipment solenoid valve, pneumatic cylinder and hacksaw frame.

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 1. PROJECT PLANNING

Before starting every project its planning is to be done. Planning is very

important task and should be taken with great care, as the efficiency of the whole
project largely depends upon its planning while planning a project each and every
details should be worked out in anticipation and should carefully is considered
with all the relating provisions in advance. Project planning consists of the
following steps.

PROJECT CAPACITY

The capacity of the project must be decided considering the amount of

money which can be invested and availability of material and machines.

DRAWINGS

Drawing been decided for the project to be manufacture. Its detailed drawing
specification for raw material and finished products should be decided carefully
along with the specification of the machines required for their manufacture.

MATERIAL EQUIPMENT

The list of materials required for manufacture is prepared from the drawings.
The list of is known as “BILL OF MATERIALS”. This passes to the store keeper
and the required materials taken from the store under permission of store keeper
operation, the necessity of operation, the person to do the job, machine to be used
to do the job are considered while planning the operation. After considering tea
above questions a best method is developed and the best method is applied to the
operation.

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MACHINE LOADING

While planning proper care should be taken to find the machining time for
each operation as correct as possible. So that the arrangement for full utilization of
machine can be made machine loading programmed is also known.

PURCHASE CONSIDERATION

It is different to manufacture all the component needed for the equipment in

the workshop itself. The decision about a particular item whether to purchase or to
manufacture is taken by planning after making through study of relative merits
demerits.

EQUIPMENT CONSIDERATION

Result obtained from “PROCESS PLANNING” and “MACHINE LODING”

helps in calculating the equipment requirement specification of the equipment
should be laid down by considering the drawing. Drawing will also help in
deciding and necessary requirement of tools, accessories.

COST CALCULATION

The cost of the project can be calculated by adding following.

1. Material Cost
2. Machining Cost
3. Overhead Expenses.

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COMPARISION

The various items in the finished project are compared to the standards for
the further correction.

REPORT

At the end of the project work report is prepared for future references. The
report consists of all the items done the project work.

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 2. METAL CUTTING THEORY

INTRODUCTION:

Metal cutting is the process of producing work piece by removing unwanted

material from a block of metal in the form of chips. The major drawback of the
process is loss of material in the form of chips.

The process is basically adopted because of the following reasons.

a) To get higher surface finish.

b) To achieve close tolerance.

c) To get complex geometric shapes.

d) Sometimes it may be economical to produce a component by machining

process.

MATERIAL REMOVAL PROCESSES

Machining of material is basically adopted to get higher surface finish, close

tolerance and complex gometric shapes which are otherwise difficult to obtain.
Metal removal is probably the most expensive one because a substantial amount of
material is removed from the raw material in the form of chips to achieve the
required shape. The choice of material removal is an option for manufacturing is
concerned when no other manufacturing process suits the purpose. Invariably all
components undergo a material removal operation at some points.

A machine tool is one which while holding the cutting tool is able to remove the
metal from a work piece to generate the required part of the given size,
configuration and finish.

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TYPE OF MACHINE TOOLS

Casting and metal working are the primary manufacturing processes where the
metal is first given an intermediate shape, which is usually brought to its final form
through metal cutting processes. There is a large verity of metal removal processes
available such as

· Turning machines (lathes)

· Drilling machines

· Boring machines

· Milling machines

· Grinding machines

· Shaping and planning machines

· Gear cutting machines

· Unconventional machining machines

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 3. CUTTING TOOL MATERIAL

Characteristic: The characteristics of the ideal material are:

1. Hot hardness. The material must remain harder than the work material at
elevatedoperating temperatures.

2. Wear resistance. The material must withstand excessive wear even though the
relative hardness of the tool-work materials changes.

3. Toughness. The term ‘ toughness’ actually implies a combination of strength

and ductility. The material must have sufficient toughness to withstand shocks and
vibrations and to prevent breakage.

4. Cost and easiness in fabrication. The cost and easiness of fabrication should
have within reasonable limit.

TYPE OF TOOL MATERIALS:

The selection of proper tool material depends on the type of service to which the
tool will be subjected. No material is superior in all respects, but rather each has
certain characteristics which limit its field of application.

The principal cutting materials are:

1. Carbon steels.

2. Cemented carbides.

3. Medium alloy steels.

4. Ceramics.

5. High-speed steels.

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6. Diamonds.

7. Stellites

8. Abrasives.

1. CARBON STEELS:

Carbon steels contain carbon in amounts ranging from 0.08 to 1 .5 percent. A

disadvantage of carbon tool steels is their comparatively low-heat and wear-
resistance.

They lose their required hardness at temperatures from 200ºC to 250º C.

2. MEDIUM ALLOY STEELS:

The high carbon medium alloy steels have a carbon content akin to plain carbon
steels, but in addition there is, say, up to 5 per cent alloy content consisting of
tungsten, molybdenum, chromium and vanadium.

Small additions of one or more of these elements improve the performance of the
carbon steels in respect of hot hardness, wear resistance, shock and impact
resistance and resistance to distortion during heat treatment.

The alloy carbon steels, therefore, broadly occupy a midway performance position
between plain carbon and high speed steels. They lose their required hardness at
temperatures from 250ºC to 350ºC.

HIGH-SPEED STEEL :

High-speed steel (hss) is the general purpose metal for low and medium cutting
speeds owing to its superior hot hardness and resistance to wear.

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High-speed steels operate at cutting speeds 2 to 3 times higher than for carbon
steels and retain their. It is used as popular operations of drilling, tapping, hobbing,
milling, turning etc.

There are three general types of high-speed steels; high tungsten, high
molybdenum, and high cobalt.

Tungsten in h.s.s. provides hot hardness and form stability, molybdenum or

vanadium maintains keen ness of the cutting edge, while addition of cobalt
improves hot hardness and makes the cutting tool more wear resistant.

Three general types of high-speed steels are as follows:

a. 18-4-1 high-speed steels (T-series). This steel containing 18 per cent tungsten, 4
per cent chromium and I per cent vanadium, is considered to be one of the best of
all purpose tool steels. In some steels of similar composition the percentage of
vanadium is slightly increased to obtain better results in heavy-duty work.

b. Molybdenum high-speed-steel (M-series).

This steel containing 6 per cent molybdenum, 6 per cent tungsten, 4 per cent
chromium and 2 per cent vanadium have excellent toughness and cutting ability.
There are other molybdenum high speed steels now marketed, having various
tungsten molybdenum ratios, with or without cobalt, or with variations in
percentages of the minor alloys chromium and vanadium.

c. Cobalt high-speed steels: This is sometimes called super high-speed steel. Cobalt
is added from 2 to 15 per cent to increase hot hardness and wear resistance. One
analysis of this steel contains 20 per cent tungsten, 4 per cent chromium, 2 per cent
vanadium and 12 percent cobalt.

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4. STELLITES:

Stellite is the trade name of a nonferrous cast alloy composed of cobalt, chromium
and tungsten. The range of elements in these alloys is 40 to 48 per cent cobalt, 30
to 35 per cent chromium, and 12 to 19 per cent tungsten.

In addition to one or more carbide forming elements, carbon is added in amounts

of 1.8 to 2.5 per cent. They can not be forged to shape, but may be deposited
directly on the tool shank in an oxy-acetylene flame; alternately, small tips of cast
stellite can be brazed into place.

Stellites preserve hardness up to 1000ºC and can be operated on steel at cutting

speeds 2 times higher than for high-speed steel.

These materials are not widely used for metal cutting since they are very brittle,
however, they are used extensively in some non-metal cutting application, such as
in rubbers, plastics, where the loads are gradually applies and the support is firm
and where wear and abrasion are problems.

5. CEMENTED CARBIDES:

Cemented carbides are so named because they are composed principally of carbon
mixed with other elements.The basic ingredient of most cemented carbides is
tungsten carbide which is extremely hard. Pure tungsten powder is mixed under
high heat, at about 1500ºC, with pure carbon (lamp black) in the ratio of 94 per
cent and 6 per cent by weight.

The new compound, tungsten carbide, is then mixed with cobalt until the mass is
entirely homogeneous. This homogenous mass is pressed, at pressures from 1,000
to 4,200 kg/cm2, into suitable blocks and then heated in hydrogen. Boron, titanium

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and tantalum are also used to form carbides. The amount of cobalt used will
regulate the toughness of the tool.

6. CERAMICS:

The latest development in the metal-cutting tools uses aluminium oxide generally
referred to as ceramics.

Ceramics tools are made by composing aluminium oxide powder in a mould at

about 280 kg/cm2 or more. The part is then sintered at 2200ºC.This is known as
cold pressing.

Hot pressed ceramics are more expensive owing to higher mould costs. Ceramic
tool materials are made in- the form of tips that are to be clamped on metal shops.

Other materials used to produce ceramic tools include silicon carbide, boron
carbide, and titanium carbide and titanium boride.

7. DIAMOND:

The diamonds used for cutting tools are industrial diamonds, which are naturally
occurring diamonds containing flaws and therefore of no value as gemstones.

Alternatively they can be also artificial. The diamond is the hardest known material
andcan be run at cutting speeds about 50 times greater than that for H.S.S. tool, and
at temperatures up to 1650º C.

In addition to its hardness the diamond is incompressible, is of a large grain

structure,readily conducts heat, and has a low coefficient of friction.

8. ABRASIVE:

Abrasive grains in various forms loose, bonded into wheels and stone, and
embedded in papers and cloths-find wide application in industry.

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They are mainly used for grinding harder materials and where a superior finish is
desired on hardened or unhardened materials.For most grinding operations there
are two kinds of abrasives in general use, namely aluminium oxide (carborundum)
and silicon carbide.The aluminium oxide abrasives are used for grinding all high
tensile materials, whereas silicon carbide abrasives are more suitable for low
tensile materials and non-ferrous metals.

9. CUBIC BORON NITRIDE (CBN):

This material, consisting atoms of boron and nitrogen, is considered as the

hardest tool material available next to diamond. It is having high hardness, high
thermal conductivity and tensile strength. Uncertain application a thin layer ~ (0.5
mm) of CBN is C applied on cemented carbide tools to obtain better machining
performance. It can also be made in terms of index able inserts in standard form
and size.

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 4. INTRODUCTION OF HACKSAW MACHINE

A hacksaw is a fine-tooth hand saw with a blade held under tension in a frame,
used for cutting materials such as metal or plastics. Hand-held hacksaws consist of
a metal arch with a handle, usually a pistol grip, with pins for attaching a narrow
disposable blade. A screw or other mechanism is used to put the thin blade under
tension. The blade can be mounted with the teeth facing toward or away from the
handle, resulting in cutting action on either the push or pull stroke. On the push
stroke, the arch will flex slightly, decreasing the tension on the blade, often
resulting in an increased tendency of the blade to buckle and crack. Cutting on the
pull stroke increases the blade tension and will result in greater control of the cut
and longer blade life.

Design Blades

Blades are available in standardized lengths, usually 10 or 12 inches for a standard

hand hacksaw. "Junior" hacksaws are half this size. Powered hacksaws may use
large blades in a range of sizes, or small machines may use the same hand blades.

The pitch of the teeth can be anywhere from fourteen to thirty-two teeth per inch
(tpi) for a hand blade, with as few as three tpi for a large power hacksaw blade.
The blade chosen is based on the thickness of the material being cut, with a
minimum of three teeth in the material. As hacksaw teeth are so small, they are set
in a "wave" set. As for other saws they are set from side to side to provide a kerf or
clearance when sawing, but the set of a hacksaw changes gradually from tooth to
tooth in a smooth curve, rather than alternate teeth set left and right.

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Hacksaw blades are normally quite brittle, so care needs to be taken to prevent
brittle fracture of the blade. Early blades were of carbon steel, now termed 'low
alloy' blades, and were relatively soft and flexible. They avoided breakage, but also
wore out rapidly. Except where cost is a particular concern, this type is now
obsolete. 'Low alloy' blades are still the only type available for the Junior hacksaw,
which limits the usefulness of this otherwise popular saw.

For several decades now, hacksaw blades have used high speed steel for their teeth,
giving greatly improved cutting and tooth life. These blades were first available in
the 'All-hard' form which cut accurately but were extremely brittle. This limited
their practical use to benchwork on a workpiece that was firmly clamped in a vice.
A softer form of high speed steel blade was also available, which wore well and
resisted breakage, but was less stiff and so less accurate for precise sawing. Since
the 1980s, bi-metal blades have been used to give the advantages of both forms,
without risk of breakage. A strip of high speed steel along the tooth edge is
electron beam welded to a softer spine. As the price of these has dropped to be
comparable with the older blades, their use is now almost universal.

Hacksaw blade specifications: The most common blade is the 12 inch or 300 mm
length. Hacksaw blades have two holes near the ends for mounting them in the saw
frame and the 12 inch / 300 mm dimension refers to the center to center distance
between these mounting holes.[1]

12 Inch Blade:

Hole to Hole: 11 7/8 inches / 300 mm

Overall blade length: 12 3/8 inches / 315 mm (not tightly controlled)

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Mounting Hole diameter: 9/64 to 5/32 inch / 3.5 to 4 mm (not tightly controlled)

Blade Width: 7/16 to 33/64 inch / 11 to 13 mm (not tightly controlled)

Blade Thickness: 0.020 to 0.027 inches / 0.5 to 0.70 mm (varies with tooth pitch
and other factors)

The kerf produced by the blades is somewhat wider than the blade thickness due to
the set of the teeth. It commonly varies between 0.030 and 0.063 inches / 0.75 and
1.6 mm depending on the pitch and set of the teeth.

The 10 inch blade is also fairly common and all the above dimensions apply
except for the following:

Hole to Hole: 9 7/8 inches / 250 mm

Overall blade length: 10 3/8 inches / 315 mm (not tightly controlled)

Variants

Panel hacksaw eliminates the frame, so that the saw can cut into panels of sheet
metal without the length of cut being restricted by the frame. Junior hacksaws are
the small variant, while larger mechanical hacksaws are used to cut working pieces
from bulk metal.

A power hacksaw (or electric hacksaw) is a type of hacksaw that is powered either
by its own electric motor or connected to a stationary engine. Most power
hacksaws are stationary machines but some portable models do exist. Stationary
models usually have a mechanism to lift up the saw blade on the return stroke and
some have a coolant pump to prevent the saw blade from overheating.[2]

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While stationary electric hacksaws are reasonably uncommon they are still
produced but saws powered by a stationary engines have gone out of fashion. The
reason for using one is that they provide a cleaner cut than an angle grinder or
other types of saw. Large, power hacksaws are sometimes used in place of a
bandsaw for cutting metal stock to length

The frame and the blade make up the common hacksaw.

TYPES OF HACKSAW BLADE

Hacksaw blades, designed to cut mainly metal, are categorized by the number of
teeth per inch. The standard hacksaw blade has 14 to 32 teeth per inch. The set of
the teeth, how they are angled in relation to the sides of the blade, determines how
well the blade cuts. Hacksaw blades cut many things from thin copper tubing to
unruly rusted bolts. Garden hose, water pipes, plastics and old fencing all succumb
to the hacksaw blade. Does this Spark an idea?

32 teeth per inch

A hacksaw blade with 32 teeth per inch gives a finer cut and is good for cutting
thin gauge steel or thin-walled tubing, copper tubing or heating duct.

24 teeth per inch

Hacksaw blades with 24 teeth per inch are used for medium steel and regular
walled tubing. According to the Aviation; Integrated Publishing web site, 24 teeth
per inch are also good for cutting angle iron, heavy pipe, brass and copper. Lug
nuts, stubborn bolts and iron re-bar are cut with this blade.

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18 teeth per inch

Hacksaw blades with 18 teeth per inch are used for hard metal iron pipe and large
pieces of steel. If you are cutting an old metal water pipe or a chain link fence
frame, use this blade.

14 teeth per inch

Hacksaw blades with 14 teeth per inch work well with soft metals like aluminum
and tin. This blade cuts electrical wire, aluminum chairs and plastic for windows.

12 teeth per inch, bi-metal

Bi-metal hacksaw blades have 12 teeth per inch and are used for pipe, tubing,
plastic, wood or high speed steel. This blade is good for cutting garden hose,
picture frames and plastic chairs.

Set of the teeth

The blade on the right shows the wave set pattern.

There are four different sets, or angles, of the teeth, according to the Aviation;
Integrated Publishing website: Alternate set, where one tooth leans to the left and
one tooth to the right the length of the blade; double alternate set, with two teeth to
the right and two to the left; raker set, where single teeth alternate, but every third
tooth is straight; and the wave set, where short sections of teeth bend opposite each
other. According to Builder Bill, this wave pattern, with its fine cut, works best on
sheet materials.

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POWER HACKSAW

Power hacksaws are used to cut large sizes (sections) of metals such as steel.
Cutting diameters of more than 10/15mm is very hard work with a normal hand
held hacksaw. Therefore power hacksaws have been developed to carry out the
difficult and time consuming work.

The heavy ‘arm’ moves backwards and forwards, cutting on the backwards stroke.

 The metal to be cut is held in a machine vice which is an integral part of the base.
Turning the handle tightens or loosens the vice. The vice is very powerful and
locks the metal in position.

When cutting is taking place, the metal and especially the blade heats up quickly.
Coolant should be fed onto the blade, cooling it down and lubricating it as it cuts
through the metal.Without the use of coolant the blade will over heat and
break/snap. This can be dangerous as the blade can break with powerful force,
shattering. When the metal is placed and fixed in the vice, the blade is lowered
onto its top surface. The diagram below shows the ‘arm’ being lowered with the
‘adjusting handle’.

Blades of power hacksaws are graded according to the material they are made from
and the number of teeth per inch. Top quality blades are manufactured from High

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Speed Steel. although there are cheaper alternatives such as carbon steel blades.
In general the number of teeth per inch (TPI) range from 14 to 24. The more teeth
per inch - the smoother the cut.

Every power hacksaw should have a foot switch / emergency switch. This allows
the operator to turn the machine off quickly by using his/her foot to step on the
switch. The foot switch is normally positioned at the front or side of the machine. 

Power hacksaws have electric motors that power the blade through a pulley
system. Some have ratchet systems. The pulley system shown below shows how
rotary power is transferred from the motor and changed to reciprocating motion,
allow the blade to cut through the material.

Most power hacksaws have two pulley wheels. If the belt is placed on the smaller
pulley wheel the speed of cut will be fast. Changing the belt so that it runs round
the larger pulley wheel will reduce the speed.

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 5. WOOD WORKING MACHINE

A Woodworking machine is a machine that is intended to process wood. These

machines are usually powered by electric motors and are used extensively in
woodworking. Sometimes grinding machines (for grinding woodworking tools) are
also considered a part of woodworking machinery.

Types of woodworking machinery

Artisanal and hobby machines

These machines are used both in small-scale commercial production of timber

products and by hobbyists. Most of these machines may be used on solid timber
and on composite products. Machines can be divided into the bigger stationary
machines where the machine remains stationary while the material is moved over
the machine, and hand-held power tools, where the tool is moved over the
material.

Hand-held power tools

 Biscuit joiner
 Domino jointer
 Chain saw
 Hand-held circular saw
 Electric drill
 Jig saw
 Miter saw

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  Nail gun
 Hand-held electric plane
 Reciprocating saw
 Rotary tool
 Router
 Hand-held sanders, including belt sander, orbital sander, random orbit
sander

Stationary machines

 Bandsaw
 Combination machine
 Double side planer
 Four sided planer or timber sizer
 Drill press
 Drum sander
 Bench grinder
 Jointer
 Wood lathe
 Mortiser
 Panel saw
 Pin router
 Radial arm saw
 Scroll saw
 Spindle moulder (Wood shaper)

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  Stationary sanders, including stroke sanders, oscillating spindle sander, belt
sander, disc sander (and combination disc-belt sander).
 Table saw
 Tenoner or tenoning machine
 Thicknesser or Thickness planer
 Round pole milling machine
 Round pole sanding machine

Panel Line Woodworking machines

These machines are used in large-scale manufacturing of cabinets and other

wooden or panel products.

Panel surface processing

Panel dividing equipment

Panel dividing equipment, classified by number of beam, loading system, saw

carriage speed

Double end tenoner

Double end tenoner, classified by conveyor type

 Rolling chain system conveyor speed 40 to 120 m/min

 Sliding chain system conveyor speed 10 to 30 m/min

Panel edge processing equipment

Panel edge processing equipment, classified by conveyor speed

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  High speed edgebander conveyor speed >= 100 m/min
 Heavy duty edgebander conveyor speed >= 24 m/min
 Light duty edgebander conveyor speed < 20 m/min (i.e. 8, 12 or 16 m/min)

Panel boring equipment

Classified by number of boring heads

 Single line boring machine

 Multi line boring machine

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 6. MAJOR COMPONENTS OFPNEUAMTIC SWITCH BOARD CUTTER

1. Compressor
2. Pneumatic cylinder assembly
3. Direction control valve
4. Hoses
5. Structure
6. Cutting tool

1.COMPRESSOR:

The air under high pressure is given by a compressor. It is driven by an

electric motor. The compressor delivers air to inlet of the cylinder. An air
compressor as the same indicates is a machine to compress the air and to raise its
pressure. The air compressor sucks air from the atmosphere, compresses it and
then delivers the same under a high pressure to a storage vessel from the storage
vessel it may be conveyed by a pipeline to a place where the supply of compressed
air is required.

2.PNEUMATIC CYLINDER

Double Acting Cylinder

In this the force exerted by the compressed air moves the piston in two
directions. They are used partially when the piston is required to perform work not
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only on the advance movement but also on the return stroke. This principle, the
stroke length is unlimited, although bucking and bending must be considered
before selecting the particular size of piston diameter, rod length and stroke length.

The different parts of double acting cylinder are:

 Barrel
 Piston rod
 Top Cover
 Bottom Cover
 Wiper Cover
 Retaining ring
 Piston
 Piston guide
 Bearing Cap
 ‘O’ ring for piston guide
 Hexagonal socket head screw
 Check nut

The double acting cylinder is made up of cast aluminium. The inner and
outer surface of the cylinder should be machined accurately. The internal diameter
of the cylinder should be accurate in order to provide a smooth surface for the
packing. The appearance of the outer diameter should be good.

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 The outer most part of the bottom and top cover contains internal threads for
inserting bolts to clamp the cylinder. In case of double acting cylinder a force is
developed in both the directions. The moving member inside the cylinder is
nothing but a piston which is found to be moving forward and backward due to
high-pressure air. The cylinder top and lower plate are flanged together by means
of bolts and nuts. The bottom of the cylinder is also flanged with end covers for
the movement of the piston in reciprocating manner.

3.DIRECTIONAL CONTROL VALVE

● To control the to and fro motion of cylinder, the fluid energy has to be
regulated, controlled and reversed with a predetermined sequence in a
pneumatic system.
● Similarly one may have to control the quantity of pressure and flow rate
to generate the desired level of force and speed of actuators. To achieve
these functions, valves are used. Valves are fluid power elements used
for controlling and regulating the working medium.

The main functions of the valves are,

Start and stop the fluid energy

Control the direction of flow of compressed air

Control the flow rate of the fluid

Control the pressure rating of the fluid

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● This is operated by a hand lever. There are two inlet parts, two exhaust
parts and one main inlet from the compressor. The two inlet parts of
valve is connected to each one of the end covers. The rod in the centre
of the valve has two grooves.
● Each groove connects at a time only one inlet and exhaust ports. This is
operated by the hand lever.
● They are generally specified using the number of ports and the number
of switching positions. It can be represented in general form as np/ns,
where np is the number of ports connected to the direction control valve
and ns the number of switching positions.
● In addition, the method of actuation and the return method can also be
specified. Considering the valve in the given figure, it will be specified
as 4-way, 3-position direction control valve or 4/3 DCV since there are
four ports and three switching positions for the valve.
● Spool-type valves are widely used because they can be shifted to two,
three, or more positions for routing fluid between different combinations
of inlet and outlet ports. They are used extensively for directional
control of actuators because a single valve can produce extension,
retraction, and neutral. However, these same functions can be
accomplished with digital valves.
● With all valves in the neutral condition, as shown, fluid flow to and
from the pump, reservoir, and actuator is blocked. Energizing
valveA routes pressurized fluid to the cap end of the cylinder, causing
the rod to extend. Simultaneously energizing valveD routes fluid from
the cylinder's rod end to the reservoir

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4. HOSES

● A h ose is a
hollow tube
designed to
carry fluids fro
m one location to another. Hoses are also sometimes called  pipes(the
word  pipe  usually refers to a rigid tube, whereas a hose is usually a
flexibleone), or more generally tubing. The shape of a hose is
usually cylindrical (having a circular cross section)
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 ● Hose design is based on a combination of application and performance.
Common factors are Size, Pressure Rating, Weight, Length, Straight
hose or Coilhose and Chemical Compatabiltiy.

● Hoses are made from one or a combination of many different materials.

Applications mostly use nylon,  polyurethane,  polyethylene, PVC, or
synthetic or natural rubbers, based on the environment and pressure
rating needed.
● In recent years, hoses can also be manufactured from special grades
of polyethylene (LDPE and especially LLDPE). Other hose materials
include PTFE  (Teflon), stainless steel and other metals
● To achieve a better pressure resistance hoses can be reinforced with
fibers or steel cord. Commonly used reinforcement methods are
braiding, spiralling, knitting and wrapping of fabric plies.
● The reinfocement increases the pressure resistance but also the stiffness.
To obtain flexibility corrugations or bellows are used. Usually
circumferential or helical reinforcement rings are applied to maintain
these corrugated or bellowed structures under internal pressure
● It transmitts the high pressure air from compressor to the dirction
control valve and also transmitts the air from the valve to the pneumatic
cylinder.

5.STRUCTURE

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Structural steel is steel construction material, a profile, formed with a specific
shape or cross section and certain standards of chemical composition and strength.
Structural steel shape, size, composition, strength, storage, etc, is regulated in most
industrialized countries.Structural steel members, such as I-beams, have high
second moments of area, which allow them to be very stiff in respect to their cross-
sectional area.

A steel I-beam, in this case used to support wood beams in a house.

Structural steel in construction: A primed steel beam is holding up the floor above,
which consists of a metal deck (Q-Deck), upon which a concrete slab has been
poured.

Steel beam through-penetration with incomplete fireproofing.

Metal deck and OWSJ (Open Web Steel Joist), receiving first coat of spray
fireproofing plaster, made of polystyrene leavened gypsum. Contents

1 Common structural shapes

2 Standards

2.1 Standard structural steels

2.2 Standard structural steels

2.2.1 Carbon steels

2.2.2 High strength low alloy steels

2.2.3 Corrosion resistant high strength low alloy steels

2.2.4 Quenched and tempered alloy steels

3 Steel vs. concrete

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4 Thermal properties

5 Fireproofing of structural steel

COMMON STRUCTURAL SHAPES

In most developed countries, the shapes available are set out in published
standards, although a number of specialist and proprietary cross sections are also
available.

I-beam (I-shaped cross-section - in Britain these include Universal Beams (UB)

and Universal Columns (UC); in Europe it includes the IPE, HE, HL, HD and other
sections; in the US it includes Wide Flange (WF) and H sections)

Z-Shape (half a flange in opposite directions)

HSS-Shape (Hollow structural section also known as SHS (structural hollow

section) and including square, rectangular, circular (pipe) and elliptical cross
sections)

Angle (L-shaped cross-section)

Channel ( [-shaped cross-section)

Tee (T-shaped cross-section)

Rail profile (asymmetrical I-beam)

Railway rail

Vignoles rail

Flanged T rail

Grooved rail
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Bar a piece of metal, rectangular cross sectioned (flat) and long, but not so wide so
as to be called a sheet.Rod, a round or square and long piece of metal or wood, see
also rebar and dowel.Plate, sheet metal thicker than 6 mm or 1/4 in.

Open web steel joist

While many sections are made by hot or cold rolling, others are made by welding
together flat or bent plates (for example, the largest circular hollow sections are
made from flat plate bent into a circle and seam-welded).

6. CUTTING TOOL

Various attachments and blades have come on the market giving these machines a
wide variety of uses. The blades can be separated into 5 main categories: cutting,
tile, grout & masonry, sanding, scraping and polishing.Cutting blades are standard
saw blades with various tooth configurations for cutting different material. They
are either straight blades with the teeth on the end, allowing the user to 'plunge cut'
directly into the material they are cutting or circular blades. Bi-metal blades offer
smaller hardened teeth that allow the user to cut soft metals and the popular Japan
tooth blades have large teeth that cut wood quickly but cannot cut metal

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 7. WORKING PRINCIPLE

The hacksaw frame is fastened with the piston rod provided in the pneumatic
cylinder .the compressor provides highly pressurized air to the cylinder. The power
will be transmitted to the piston rod and hacksaw frame is actuated. Here the air
passed through the solenoid valve and it will pass through the pneumatic cylinder.
The pneumatic cylinder is double acting cylinder in which the air is paased through
the two sides of the cylinder. The hacksaw frame is fixed in the pneumatic cylinder
rod end.

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 8. DESIGN FOR PNEUMATIC CYLINDER

● The force exerted on in stroke can be expressed as :

F = p π (d12 - d22) / 4

Where,

P = Initial pressure ( N\m² )

d1 = full bore piston diameter (m)

d2 = piston rod diameter (m)

For Example:

P = 6 bar

π = 3.14

d1 = 0.05m

d2 = 0.015m

F = p π (d12 - d22) / 4

F = 6x105x3.14x (0.052 – 0.0152) / 4

F = 1884955.592x2.275x10-3 / 4

F = 1072.06 N

● The following formula is used to calculate the required area of a cylinder

Piston:
A=F/P

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Where,

F = force

P=pressure
A = area of the cylinder piston

For Example:

F = 1072.06 N

P = 6 bar

A=F/P

A = 1072.06 / 6x105

A = 1.786x10-3 m2

DESIGN OF CYLINDER TICKNESS

T = pd/2 fc

Where,

fc = Circumferential stress of hoop-stress and Is also called maximum

allowable stress

= 98.1 Newton/mm²

P = Intensity of internal pressure

= 1.2599 N/mm²

D = Diameter of the shell

= 60 mm
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 Thickness of the cylinder (t)

= 1.2599 x (60/2) x 98.1

= 0.3853 mm

Thickness of the cylinder take as = 1 mm.

PART DIAGRAM – 1

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PART DIAGRAM – 2

40
 9. ADVANTAGES& DIS ADVANTAGES

ADVANTAGES

 Quick process
 Saves time
 Easy to operate.

DISADVANTAGES

 Its need separate compressor.

APPLICATION

 It can be used in switch board cutting processes.

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 10. LINE DIAGRAM

PNEUMATIC SWITCH BOARD CUTTER

11. COST OF ESTIMATION

COMPONENTS NAME QTY RATE AMOUNT

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 Mechanical structure& 1 1500 1500
Controlassembly 1 2500 800
Pneumatic cylinder 2 900 1800
D.c valve 1 700 700
Tool - 300
Fabrication cost 1200
Total 6300

12. CONCLUSION

This report deals with the design and fabrication of Pneumatic

operated switch board cutter and it is attached with the line diagram . However
some of the various industrial applications is various profile cutting straight cutting
throughout the project period we gained knowledge on all type of machining

43
Process of board cutting and pneumatic system system is controlled. We have
done to our ability and skill making maximum use of available facilities.

13. BIBLOGRAPHY

 GUPTA J.K and KHURUMI R.S (1981) “Text book of Machine Design”,
S.Chand & comp and.

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 Parr. ANDREW (2003) ‘Hydraulic & Pneumatics’ Butterworth Heimann
Ltd

 Dr.D.K.AGGARVAL & Dr.P.C SHARMA(2004) “machine design”,

S.K.Kataria and sons

 MAJUMDAR.S.R “Pneumatic systems”, Tata mcgraw-hills company ltd.

 SRINIVASAN.R(2004) “Hydraulic & pneumatic controls”, vijay Nicole

imprints private ltd.

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