A PROJECT REPORT ON

DESIGN AND ANALYSIS OF SEMI-AUTOMATIC SHEET

EMBOSSER MACHINE

Submitted by

A SAI KUMAR (17751A0301)

M NITHISH KUMAR (17751A0329)

P HAREESH (17751A0336)

SYED MOHAMMED RAMZAN ALI (17751A0349)

In partial fulfillment for the award of the degree of

BACHELOR OF TECHNOLOGY

In

MECHANICAL ENGINEERING

SREENIVASA INSTITUTE OF TECHNOLOGY AND MANAGEMENT

STUDIES, CHITTOOR-517127, A.P.
(Autonomous-NAAC &NBA Accredited)
(Approved by AICTE, New Delhi & Affiliated to JNTU, Ananthapuramu)
DEPARTMENT OF MECHANICAL ENGINEERING
(2020-2021)
 ACKNOWLEDGEMENT

It is our great pleasure in presenting the project work undergo neat BHARAT
HEAVY ELECTRICALS LIMITED.

Predominately our thanks to Late Sri D.K. AUDIKESAVULU Garu, Founder,

SITAMS and Late Smt. D.A. SATYAPRABHA Garu, Chair person, for her
encouragement and support.

Further we would like to express our profound gratitude to our principal

Dr. P.RAMESH KUMAR, M.E., Ph.D., for providing all possible facilities through-
out the completion of project work.

We express our sincere thanks to our Head of Department, (Mechanical

Engg.) and Guide Dr. S. RAJESH, M.E., Ph.D., for his cooperation and valuable
suggestions towards the completion of this project work.

We express our sincere gratitude and thanks to Mr. PONSJANKAR,

DM/HRDC & Mr. KALYANA SUNDHARAM, Deputy Engineer, HRDC,
B.H.E.L/ Ranipet.

Our sincere gratitude and thanks to our External guide Mr.ANISH K S,Senior
Engineer, B.H.E.L/Ranipet.

Our sincere thanks to all the staff members of our department for their
encouragement and guidance.
COURSE OUTCOMES FOR PROJECT WORK

On Completion of project work we will be able to,

CO1.Demonstrate in–depth knowledge on the “Design and selection of Restriction

orifice.
CO2.Identify, analyse and formulate complex problem chosen for design and
selection to attain substained conclusions.
CO3.Design solutions to the restriction orifice and select restriction orifice to kill the
pressure.
CO4.Undertake investigation of restirction orifice plate to fix in right place to
decrease the volume of pressure.
CO5.Use the appropriate techniques, resources and modern engineering tools
necessary for design and selection of restriction orifice.
CO6.Apply upgraduation of manual design of the restriction orifice with the selection
of orifice for decrease the pressure in pipe.
CO7.Understand the impact can be helpful in fix the orifice with certain suitable
place to kill the pressure.
CO8.Understand professional and ethical responsibilities while executing the design
and selection of restriction orifice.
CO9.Function effectively as individual and a member in the project team.
CO10.Develop communication skills,both oral and written for preparing and
presenting project report.
C011.Demonstrate Knowledge and understanding of cost and time analysis required
for carrying out the project.
CO12.Engage in lifelong learning to improve knowledge and competence in the
chosen area of the project.
 ABSTRACT

The main aim of our project is to design and analysis of semi automatic
sheet embosser machine. At present identification codes of the products are
punched manually, our aim is to fabricate a machine for automatic punching
using pneumatics to reduce the man works and increase the safety of labors.

The pneumatic system has gained a large amount of importance in last

few decades. This importance is due to its accuracy and cost. This convenience

in operating the pneumatic system has made us to design and fabricate this unit
as our project. This unit, as we hope that it can be operated easily with semi
skilled operators.

The pneumatic press tool has an advantage of working in low pressure,

that is even a pressure of 6 bar is enough for operating the unit. The pressurized
air passing through the tubes to the cylinder, forces the piston out whose power
through the linkage is transmitted to the punch. The work piece thus got is for
required dimensions and the piece can be collected through the land clearance
provided in the die. The die used in this is fixed such that the die of required
shape can be used according to the requirement. This enables us to use different
type punch dies resulting in a wide range of products. Different types of punch
as requirement can be thus got. According to the work material the operating
pressure can be varied.
 INDEX

CHAPTER TITLE PAGE

NO. NO.
1. BHARATHEAVYELECTRICALSLIMITED-AN 1-2
OVERVIEW
1.1 COMPANY PROFILE 1
1.2 MAIN MANUFACTURING FACILITIES 2
1.3 PRODUCTS 2

2. INDUSTRIALFANS 4
2.1 ABOUT FANS 4
2.2 AXIAL FANS 4
2.3 RADIAL FANS 4
3 APPLICATIONS 5
3.1 FORCED DRAFT FANS 5
3.2 INDUCED DRAFT FANS 5
3.3 PRIMARY AIR FANS 5
3.4 GAS RECIRCULATION FANS 5
3.5 MAIN PARTS OF AXIAL PROFILE FAN 5

4 INTRODUCTION TO PNEUMATICS 6-14

4.1 INTRODUCTION 6
4.2 GENERAL DESCRIPTION 6
4.2.1 PRODUCTION OF AIR COMPRESSOR 6
4.2.2 PRINCIPLE OF OPERATION OF PRESS 7
4.2.3 MECHANICAL ADVANTAGE 8
4.3 COMPONENTS AND DESCRIPTION 8
4.3.1 PNEUMATIC CONTROL COMPONENTS 8
4.3.2 SOLENOID VALVE 9
WORKING OF 5/2 AND 3/2 SOLENOID VALVE
4.4 DESIGN CALCULATION WORKING PRESSURE 11
4.5 UNIT DESCRIPTION(CONSTRUCTION) 12
4.5.1 CYLINDER 12
4.5.2 PUNCH AND DIE 13
4.5.3 COMPRESSOR 14
4.5.4 DIRECTION CONTROL VALVES 14
4.5.5 WORKING PRINCIPLE 14

5 EXISTING METHOD 16
6 NEW METHOD 17
7 COMPONENT DESCRIPTION 18
8 DESIGN OF PART DIAGRAM 19-28
 ASSEMBLY 19
A - BED 20
B - WORK BENCH 21
C - DIE HOLDER 22
D - PNEUMATIC CYLINDER 23
E - PISTON 24
F - DIE AND SHAFT 25
RACK AND PINION 27
SIMULATION 28
9 CALCULATION 29
10 ADVANTAGES 35
11 COST ESTIMATION 36
12 CONCLUSION 37
13 BIBLIOGRAPHY 38
 CHAPTER -1
1. BHARAT HEAVY ELECTRICALS LIMITED- AN OVERVIEW
1.1 COMPANY PROFILE:
The first plant of what is today know as BHEL was established nearly 40
years ago at Bhopal and was the genesis of the heavy electrical equipment industry in
India. BHEL is today the largest engineering enterprises of its kind in India, with
well-recognized sales turnover of Rs.5755crores with a profit of Rs.864crores in
1996-1997.
BHEL is the largest engineering and manufacturing enterprise in India in the
energy-related/infrastructure sector, today. BHEL was established more than 40 years
ago, ushering in the indigenous Heavy Electrical Equipment Industry in India-dream
that has been more than realized with a well-recognized tract record of performance.
The company has been earning profits continuously since 1971-72 and paying
dividends since 1976-77. BHEL manufactures over 180 products under 30 major
products groups and caters to core sectors of the Indian Economy viz., Power
Generation &Transmission, Industry, Transportation, Telecommunication, Renewable
Energy, etc. The wide network of BHEL 14 manufacturing divisions, 4 power sector
regional centers over 100 project sites, 8 service centers and 18 regional offices,
enables the company to promptly serve its customers and provide them with suitable
products, system and services-efficiently and at competitive prices.
The high level of quality & reliability of its products is due to the emphasis on
design, engineering and manufacturing to international standards by acquiring and
adapting some of the best technologies from leading technologies from leading
companies in the world, together with technologies developed in its own R&D
centers.
BHEL has acquired certifications to Quality Management Systems (ISO
9001), Environment Management Systems (ISO 14001) and occupational Health &
Safety Management Systems (OHSAS 18001) and is also well on its journey towards
Total Quality Management.

BHEL has
1. Installed equipment for over 90,000 MW of power generation- for utilities,
captive and industrial users.

1
2. Supplied over 2,25,000 MVA transformer capacities and other equipment
operating in transmission & Distribution network up to 400kv(AC & DC)
3. Supplied over 25,000 Motors with drive control system to power projects,
petrochemicals, refineries, steel, Aluminium, Fertilizers, Cement plants, etc
4. Supplied traction electrics and AC/DC locos to over 12,000 Kms Railway
network.
5. Supplied over one million valves to power plants and other industries.

BHEL’s operations are organized around three business sector namely Power,
Industry- including Transmission, Transportation, and Telecommunication &
renewable Energy- and Overseas Business. This enables BHEL to have a strong
customer- orientation, to be sensitive to his needs and respond quickly to the changes
in the market.
BHEL’s vision is to become a world-class engineering enterprise, committed
to enhancing stakeholder value. The company is striving to give its aspiration and
fulfill the expectations of the country to become a global player.
The greatest strength of BHEL is its highly skilled and committed 42,600
employees. Continuous training and retraining, career plannlng, positive work culture
and participative style of management have endangered development of a commited
and motivated workforce new benchmarks in terms of productivity, quality and
responsiveness.
1.2 MAIN MANUFACTURING FACILITIES:
• Bhopal (Madhya Pradesh)
• Bharat Heavy Electricals Limited, Ranipur, Haridwar (Uttarakhand)
• Hyderabad (Andhra Pradesh)
• Jhansi (Uttar Pradesh)
• Tiruchirapalli (Tamil Nadu)
• Ranipet(Tamil Nadu)
• Bangalore (Karnataka)
• Jagdishpur (Uttar Pradesh)
• Goindwal (Punjab)

1.3. PRODUCTS:
• Steam turbine
• Gas turbine
• Steam generators
• HRSG-Heat recovery steam generator

2
• Locomotives
• Circuit breakers Motors
• Pumps
• Generators
• ESP-Electrostatic precipitator
• Oil field equipments
• Valves

Besides manufacturing these products BHEL also takes up the onsite erection,
commissioning and testing of these equipments. By the end of 2009 it will have a total
capacity of 15000MW.Type public Founded 1962.
Head quarters New Delhi
Key people Mr.B.P.Rao(CMD)
Industry electrical Power Industry
Revenue Rs.214.97 billion (2009)
Employees 4,43,305

3
 CHAPTER - 2
INDUSTRIAL FANS

2.1 ABOUT FANS:

Fans may be defined as rotating machines with blades impeller, which
maintains the continuous flow of air or gas. In fans, blower, compressor, pumps, etc.
The energy transfer occurs from the machine to the fluid. They may be classified as
Axial and Radial Flow Fans.

2.2 AXIAL FANS:

In axial profile fans the main flow is para11e1 to the axis of the rotation of the
fan both at entry and exit. Axial profile may be classified further into impulse and
reaction type fans.
In the impulse type fans, most of the energy coming out of the impeller is
kinetic energy. It is converted into pressure energy at the outlet blades. Hence these
fans are called as impulse fans.
In the reaction type of axial fan, most of the energy coming out of the impeller
is in the form of pressure energy. It is converted into kinetic energy. Hence these fans
are called as reaction fans.

2.3 RADIAL FANS:

In radial flow fans, the flow is axial entry and radial discharge. It is
suitable for harsh operating condition and it is main advantage is it can operate high
pressure and higher efficiencies the radial fans are classified into three categories
namely, Backward curved, forward curved and radial bladed impeller.

4
 CHAPTER-3
APPLICATIONS

3.1 FORCED DRAFT FAN:

Supplies secondary air to the furnace during combustion

3.2 INDUCED DRAFT FAN:

Creates a negative pressure inside the combustion chamber

3.3 PRIMARY AIR FAN:

Supplies air to carry the fuels from the mills, to the burner and to dry to the coal

3.4 GAS-RECIRCULATION FANS:

Suck the fuel gas from the boiler second pass and it deliver to the bottom of
the furnace, helping steam temperature control in an oil-fired boiler
For 110MW units axial fan will be recommended for FD & PA application. ID
will be of radial fan type. For FD & ID it is preferable to give axial fans because of
lower weight, better efficiency and hence better power consumption, smaller size,
smaller foundation easy maintenance, etc.

3.5 MAIN PARTS OF AXIAL PROFILE FANS:

l. Casing
2. Impeller
3. Shaft with bearing assembly

5
 CHAPTER – 4

INTRODUCTION TO PNEUMATICS

4.1 INTRODUCTION:

The press is the punching and riveting machine tool designed to punch letter
or rivet metal by applying mechanical force or pressure. The metal is punched or
riveted to the desired requirement. The presses are exclusively intended for mass
production and they represent the fastest and more efficient way to form a metal into a
finished punched or riveted product.

Press tools are used to form and cut thin metals. Press tools operation can be
simplified to a few simple operations involving a punch a die. There are Nemours
types of Presses in engineering field, which are used to fulfill the requirements.
We are interested to introduce pneumatic system in presses. The main function of
pneumatic press is to form or cut thin sheet metals or non metals using pneumatic
power. In this project we have used to punching process and riveting process for
Simple application.
4.2 GENERAL DESCRIPTION:

4.2.1 PRODUCTION OF COMPRESSED AIR

Pneumatic systems operate on a supply compressed air, which must be made

available insufficient quantity end at a pressure to suit the Capacity of the system.

When a pneumatic system is being adopted for the time, however it will indeed the
necessary to deal with the question of compressed air supply.

The key part of any facility for supply of compressed air is the compressor. A
compressor is a machine that takes in air, gas or vapours at any certain pressure and
delivers the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and delivered and the
volume expressed is that of the air at intake conditions, namely at atmosphere
pressure and normal ambient temperature.

6
 The key part of any facility for supply of compressed air is the compressor. A
compressor is a machine that takes in air, gas or vapor sat any certain pressure and
delivers the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and delivered and the
volume expressed is that of the air at intake conditions, namely at atmosphere
pressure and normal ambient temperature.

Clean condition of the suction air is one of the factors, which decides the life of the
compressors. Warm and moist air will result in Compressors may be classified into
two types, namely

1. Positive displacement compressors.

2. Turbo compressors.

Positive displacement compressors are most frequently employ for compressed air
plants and have proved highly successful to supply for pneumatic control application.

The types of positive compressors are:

a. Reciprocating type compressors.

b. Rotary type compressors.

Turbo compressors are employed where large capacity of air is required at low
discharge pressures. They cannot attain pressure necessary for pneumatic control
applications unless built in multi stage designs are seldom en counted in pneumatic
service.

4.2.2 PRINCIPLE OF OPERATION OF A PRESS:

Every press has got certain basic units. They are bed frame, sliding ram, drive for

the ram and power source.

Base or bed is the lower part of the press frame. A thick plate called bolster

plate is placed on the top of the bed. A die is fitted on the top of the bolster plate.

The driving mechanism is mounted on the frame. The frame has got guide ways for

7
the sliding movement of the ram. The driving mechanism is connected to the ram.

The punch is fitted at the bottom of the ram. The die and punch are correctly aligned.

The work piece is in the form of sheet metal. It is fed over the die. When the ram

comes down, the punch presses the sheet metal. The required operation is carried out.

As said earlier the force from the press is used to do a particular operation.

This is done by two main parts die and punch.

4.2.3 MECHANICAL ADVANTAGE

Mechanical advantage can be defined as the ratio or the load lifted to the power or
the effort applied in the system to overcome the load successfully.

4.3 COMPONENTS AND DESCRIPTION:

4.3.1 PNEUMATIC CONTROL COMPONENTS

Selection of Pneumatics

Mechanization is broadly defined as the replacement of manual effort by

mechanical power. Pneumatics is an attractive medium for low cost mechanization

particularly for sequential or repetitive operations. Many factories and plants already

have a compressed air system, which is capable of providing both the power or energy

requirements and the control system (although equally pneumatic control systems may

be economic and can be advantageously applied to other forms of power).

The main advantages of all-pneumatic system are usually economy and

simplicity, the latter reducing maintenance to a low level. It can also have outstanding

advantages in terms of safety. The pneumatic punching and riveting machine consists

of the following Components to fulfill the requirement s of complete operation of the

machine.

8
  Pneumatic cylinder
 Solenoid valve
 Flow control value
 Connectors and
 Hoses

4.3.2 Solenoid valve:

5/2 Double Acting Solenoid Valve:

The directional valve is one of the important parts of a pneumatic

system. Commonly known as DCV, this valve is used to control the direction of

air flow in the pneumatic system. The directional valve does this by changing the

position of its internal movable parts.

This valve was selected for speedy operation and to reduce the Manual effort

and also the modification of the machine into automatic machine by means of using

a solenoid valve.

A solenoid is an electrical device that converts electrical energy into straight line

motion and force. These are also used to operate a mechanical operation which in turn

operates the valve mechanism. Solenoids may be push type or pull type. The push

type solenoid is one in which the plunger is pushed when the solenoid is energized

electrically.

The pull type solenoid is one which the plunger is pulled when the solenoid is

9
energized. The name of the parts of the solenoid should be learned so that they can be

recognized when called upon to make repairs, to do see ice work or to install them.

Technical Data

Size : 1/4”

Pressure : 0 TO 10 Kg/cm2

Media : Air

Working of 3/2 Solenoid Valve

It has 2 position and three ports on the valve block and it has two interior

flow paths. The two ports are on one side of block are exhaust (T)and inlet (A) ports

and one port on other side of block is outlet port(P) and these ports are separated by a

actuated plunger which can be through manual or single solenoid on one end and

return its position through spring on the other end. It is used generally for low

pressure fluid applications like pneumatic lines with single acting cylinder. When the

plunger actuated through any mechanism the inlet (A) and outlet (P) are connected

and when the actuation is off the outlet (P) and exhaust port (T) are connected and air

released into the atmosphere or any fluid to the tank.

10
SPECIFICATION

Supply Voltage (Vcc) = 4.5 to l5V Supply

Current(VGG=5V/2) = 3 to 6 mA

Supply Current = 10 to l5mA

Output Current = 200mA

Power dissipation = 600mw

4.4. DESIGN CALCULATIONS WORKING PRESSURE:

8 bar to 10 bars

Operating Force = Pressure x Cylinder area

F = (8 x 100) x (3.14/4) (D * D)

Where, D is the diameter of the cylinder in mm.

Operating force= 6 x 9.5 l x 104 x 0.785 x 0.057 x 0.057

OPERATING FORCE = 1501.96 N

11
 YIELD STRESS OF THE WORK MATERIAL FROM DATA BOOK FOR

ASTIIETIC FIBRE = 40 N/mm2

Cutting Force = Yield stress x Shearing area

Yield stress = Fy

Shearing area = (3.14 x d X t)

Factor of safety is to be decided based upon the operating force and cutting force.

CUTTING FORCE REQIRED FOR THE WORK MATERIAL

CUT TING FORCE FOR ASTHETIC FIBRE = 40 x 117.74 = 1256 N

MECHANICAL ADVANTAGE W x Ll = P x L2

W/p = Mechanical Advantage = L2/LI = Leverage, L2 / Ll is 2:1

Hence applied force is doubled due to the leverage. Operating force is greater

than cutting force,

Hence the design is safe and the material is cut.

4.5 UNIT DESCRIPTION (CONSTRUCTION):

4.5.1 CYLINDER

An (pneumatic) air cylinder is an operative device in which the state

input energy of compressed air; (i.e.) pneumatic power is converted into mechanical

output power, by reducing the pressure of the air to that of the atmosphere. The bore

of the cylinder has very smooth finishing reduces friction and losses. There are two

angle plates welded in3 the cylinder as fitting means.

12
DOUBLE ACTING CYLINDER

A double acting cylinder is employed in a control system with a full

pneumatic cushioning and it is essential when the cylinders itself is required heavy

masses. The normal escape of air is out by ‘cushioning piston’.

4.5.2 PUNCH AND DIE

Die and punch are known as ‘press tools’. Die is the lower part of

press tool. It is clamped on the bolster plate of the press. It remains stationary

during the operation. The die has a cavity to receive the punch. The cavity may be

with clearance or without clearance.

Punch is the upper part of the press tool. It is attached to the lower end

of the ram of the press. It sheds with the ram during the operation and is forced

into the die cavity. Die and punch must be in prefect alignment for proper

operation.

Die and punches are always used together. Dies are classified

according to either the type of construction or operation to be performed. High

speed steel, satellite or cemented carbide is the materials used for making dies

and, punches. The die materials selected depend on the type of production,

operation, sheet metal thickness and accuracy.

13
4.5.3 COMPRESSOR

The Compressor forms the main part the pneumatic system by

producing the compressed air. Compressor capacity is the actual quantity of air

compressed and delivered and the volume expressed is that of the air intake

conduction, namely at atmospheric pressure and normal ambient temperature. The

clear conduction of the suction air one of the factors which decide the life of a

compressor. Compressor is generally classified two types, namely

1. Positive displacement compressor

2. Turbo compressor

4.5.4 DIRECTION CONTROL VALVES

Direction control valves control the way the air passes and used controlling the

commencements, termination and direction of air flow. Depending on the number of

paths the air is allowed to pass, directional valves termed two way, three way, and

four way or multi way valves.

The different number of rays by means the number of controlled connection of

the valve. Inlet connection to the compressed air supplies outlet connections the air

consumer and exhaust connection to the atmosphere The solenoid valve is used to

control the air fl0W direction. This is the direction control valve in our project.

4.5.5 WORKING PRINCIPLE

Compressed air from a compressor is used to press the work by means of the

piston and piston rod, cylinder through a lever. The high pressurized air striking

again5t the piston tends to push it downwards. This force is transmitted to a punch

14
by means of a lever by its mechanical advantage. The punch forced downward

pierces the work material. This is the main principle of the unit.

WORKING

The compressed air from the compressor at the pressure of 5 to 6bar is passed

through a pipe connected to the Solenoid valve with one input. The Solenoid Valve

is actuated with Control Timing Unit. The Solenoid valve has two outputs and one

input. The air entering into the input goes out through the two outputs when the

timing control unit is actuated.

When the trigger is pressed the valve is actuated the air flows inside the cylinder

and moves the piston downwards. The die attached with piston hits the object

which as to be punched.

15
 CHAPTER -5

EXISTING METHOD :

As in many industries still they are using the old technology by punching the die

using the hammering in hand. Which leads to un safety for the employees, as the

same time there is a lack of products due to delay of punching. This is happened

because the employee needs more time to do this punching.

16
 CHAPTER-6

NEW METHOD:

In the new method of letter punching we arranged a double acting

pneumatic cylinder to hold the designed die in it, which is operated with
pneumatic control valve. It is easy to operate and no skilled Labours are needed to
operate it. At the same time it can create a work station so that the lack of products
for punching can be totally avoided.

17
 CHAPTER 7

COMPONENT DESCRIPTION

COMPONENT DESCRIPTION

PNEUMATIC CYLINDER SINGLE ACTING, SPRING RETURN

DIE HARDENED STEEL

PNEUMATIC VALVE 3/2 VALVE

GEAR USED IN STAND RACK AND PINION

18
 CHAPTER – 8

DESIGN PART DIAGRAMS

ASSEMBLY

19
A - Bed
B - work Bench
C - Die Holder
D - Pneumatic Cylinder
E - Piston
F - Die and shaft
G,H - Adjusting Screw
I - Locking Screw
A-BED

20
DESCRIPTION

Weight: 25kg

Material Used: Cast Iron

Mechanism: RACK AND PINION

The Bed is the base part which carries the entire machine on it.

Especially the work bench moves on the bed with the help of Rack and Pinion

mechanism by holding work piece. It also holds Die holder which moves

transversely.

B- Work Bench

21
 DES

CRIPTION

Weight: 17kg

Material Used: Cast Iron

Mechanism: RACK AND PINION

Movement: LONGITUDINAL DIRECTION

The work of Work bench is to hold the work piece firmly while the

machining process is going on. It locks the work piece by means of magnet.

C- DIE HOLDER

22
DESCRIPTION

Weight: 9.5 kg

Material Used: Cast Iron

Mechanism: RACK AND PINION

Movement: TRANSVERSE DIRECTION

The Die Holder’s main task is to hold the Die and the movement of the
die holder is in Transverse direction. It has the Magnetic lock to lock the die as per
ourrequirement.

23
D- PNEUMATIC CYLINDER

DESCRIPTION

Weight: 4 kg

Material Used: Stainless Steel

Mechanism:

The Double acting Pneumatic cylinder is firmly attached to the Die

holder on the top. This cylinder holds a piston with die.

24
E- PISTON

DESCRIPTION

Weight: 2.3 kg

Material Used: Stainless Steel

Movement: linear

The piston reciprocates in the cylinder with the help of force exerted
by pneumatics

25
F- DIE

DESCRIPTION

Weight : 4 kgs

Material Used : Hardened steel

26
No. of Alphabets : 26

No. of digits : 10

No. of Faces : 36

With the help of the piston the Die punches on the Work piece as per
our requirement.

27
F- SHAFT

DESCRIPTION

Weight: 0.5kg

Material Used: Cast Iron

Movement:

This Shaft holds the piston and Die so that Die can move along the
Piston.

28
RACK AND PINION

RACK:

Number of Teeth: 79

Root Fillet: 0.20 mm

(b) Face Width: 10.00 mm

Linear Speed: 1.000 cm/s

Tangential Force: 27000.000 mN

PINION:

Number of Teeth: 21

Root Fillet: 0.20 mm

(DM) Mounting Hole Diameter: 10.00 mm

(b) Face Width: 10.00 mm

29
SIMULATION

30
 CHAPTER -9

CALCULATION

PNEUMATIC CYLINDER

Design of piston rod:

Load due to air pressure.

Diameter of the piston(d) = 40mm
Pressure acting (p) = 6 Kgf/cm2
Material used for rod = c 45
Yield stress(sy) = 36 kgf / mm2
Assuming factor of safety = Pressure x Area
Force acting on the rod(P) =px(pd2I4)
=6 x{(p x42)I4}

P =73.36Kgf

Design stress(sy) = sy/FOS

=36/2
=18kgf/mm
=p/(πd2/4)
=v(4p/p[sy])
=v(4*75.36/{p*l8})
=v(5..33)=2.3

Minimum diameter of the rod required for the load=2.3mm

We assume diameter of the rod =15mm

DESIGN OF PISTON ROD:

Diameter of the piston rod(P) = pressure* area = p*π/4d2 36/2

= 6*(π/4)*42
= 73.36 Kgf
Also, Force on the piton rod(P) =(π/4)*(dp)2*ft
P =(π/4)*(dp)2*625 73.36
=(π/4)*(dp)2*625
= dp2 =73.36*(4/π)*(1/625)

31
 = 0.15
dp =0.38 cm = 3.8 mm
By standardizing dp = 15mm

LENGTH OF THE PISTON ROD:

Approach Stroke = 160 mm
Length of thread =2*20= 40 mm
Extra length due to front cover = 12 mm

Extra Length of Accommodate Head =20 mm

Tptal length of the piston rod =160+40+12+20= 232 mm

By standardizing, the length of the piston rod =230 mm

Solid Edge Engineering Reference

Design And Calculation Report

Rack and Pinion Gears Designer

STRENGTH VALIDATION: Pass

Standard: ISO

INPUT DESIGN CONDITIONS

-------------------------------------------------------------

DESIGN INPUT PARAMETERS

GEARING PARAMETERS

(al) Pressure Angle: 20.00 °

32
Module: 2.00 mm

Application Factor: 1.2

Gear Accuracy: 4

Efficiency: 0.92

RACK:

Number of Teeth: 79

Root Fillet: 0.20 mm

(b) Face Width: 10.00 mm

Linear Speed: 1.000 cm/s

Tangential Force: 27000.000 mN

PINION:

Number of Teeth: 21

Root Fillet: 0.20 mm

(DM) Mounting Hole Diameter: 10.00 mm

(b) Face Width: 10.00 mm

33
MATERIAL PROPERTIES USED FOR CALCULATIONS

Pinion Material: Struct Steel 42-O

Contact Stress: 270 MPa

Bending Stress: 315 MPa

Rack Material: Struct Steel 42-O

Contact Stress: 270 MPa

Bending Stress: 315 MPa

CALCULATE RESULTS

OUTPUT DESIGN PARAMETERS

GENERAL RESULTS

Module: 2.00 mm

Contact Ratio: 1.775

Base Circular Pitch: 5.90 mm

Design Power: 0.293 W

Total Unit Correction: 0

Operating Pressure Angle: 20.00 °

Pinion:

Speed: 27.284 deg/s

Torque: 0.616 N-m

Number of Teeth: 21

Pinion Revolutions: 3.762

34
STRENGTH VALIDATION
Rack:

Allowable Bending Stress: 543.970 MegaPa

Safety Factor in Bending: 24.4

Allowable Pitting Stress: 331.210 MegaPa

Safety Factor in Pitting: 1.26

Pinion:

Allowable Bending Stress: 531.180 MegaPa

Safety Factor in Bending: 24.5

Allowable Pitting Stress: 331.210 MegaPa

Safety Factor in Pitting: 1.18

FORCES

Tangential Force: 29347.826 mN

Radial Force: 10681.735 mN

Normal Force: 31231.304 mN

Circumferential Velocity: 1.000 cm/s

Resonance Speed: 2405617.685 deg/s

BASIC DIMENSIONS
Rack:

(S) Tooth Thickness: 4.96 mm

(L) Rectangular Rack Length: 496.37 mm

(r) Corrected Root Fillet: 0.50 mm

(ha) Addendum: 2.00 mm

(hf) Dedendum: 2.50 mm

(h) Tooth Height: 4.50 mm

35
Pinion:

(db) Base Diameter: 39.47 mm

(da) Tip Diameter: 46.00 mm

(d) Pitch Diameter: 42.00 mm

(dr) Root Diameter: 37.00 mm

Working Pitch Diameter: 42.00 mm

(S) Tooth Thickness: 3.54 mm

(pc) Circular Pitch: 6.28 mm

(L) Rectangular Rack Length: -

(r) Corrected Root Fillet: 0.50 mm

FACTOR FOR BENDING

Helix Angle Factor: 1

Contact Ratio Factor: 0.836

Pinion:

Form Factor: 2.926

Stress Correction Factor: 1.642

Life Factor: 1.6

Notch Sensitivity Factor: 1.054

Rack:

Form Factor: 2.926

Stress Correction Factor: 1.691

Life Factor: 1.6

Notch Sensitivity Factor: 1.079

36
 10. ADVANTAGES

 REDUCTION OF MAN POWER

 LESS CHANCE OF ERROR

 SAFETY

 LOCOMOTIVE

 EASE OF OPERATION

 EASILY REPLACABLE

37
 11. COST ESTIMATION

S.NO COMPONENT COST

1. PNEUMATIC PUNCH 8000

4. PNEUMATIC HOSES AND 700

VALVES
TOTAL 31500

38
 12. CONCLUSION

The sheet metal Embossing machine has been successfully completed with

fullest satisfaction. We are optimistic based on the revolution, the machine is

going to make in this field. This machine is easy to operate & relocate. This

project may be further developed into an automatic sheet embosser, with the help

of electronic systems.

39
 CHAPTER-13

BIBLIOGRAPHY

1. A Text Book of Design of material and Press Tools 3rd Edition 2000- .

Jerome Jernix.

2. A Text Book of Engineering Materials and Metallurgy 1st Edition 2005-

R.K.Rajput.

3. A Text Book of Process Planning And Cost Estimation 1" Edition 2000-

R.Kesavan

WEB ADDRESS:

www.google.com

www.bhel.com

www.wikipedia.com

https://nptel.ac.in

40
 DESIGN AND ANALYSIS OF SEMI- AUTOMATIC SHEET EMBOSSER MACHINE

NAME OF THE STUDENT : A. SAI KUMAR (17751A0301)

M. NITHISH KUMAR (17751A0329)

P. HAREESH (17751A0336)

SYED MOHAMMED RAMZAN ALI (17751A0349)

NAME OF THE GUIDE : DR. S. RAJESH, H.O.D., MECHANICAL DEPT.

Table : Out come attained and its justification

PO JUSTIFICATION
The concept knowledge of design and selection of restriction orifice gained through
PO1 project work.
We analyzed the problems of design and also came up with the solutions of overcoming
PO2 the selection of orifice.
PO3 We designed and found solutions to the design and selection of restriction orifice.
PO4 We investigated design and selection to kill the pressure
PO5 We implemented our work with well appropriate techniques, good resources and modern
engineering tools to uplift the project.
PO6 We executed the work by upgrading the restriction orifice for sustainable development of
the society.
PO7 We understanding that the impact can be helpful in design and selection process in the
context of environmental sustainability.
PO8 We understanding the value of professional and ethical responsibility while executing the
restriction orifice taking place of the human workforce.
PO9 We worked in the project function effectively as a member of the project team.
PO10 We tired our best to develop communication skills, while planning, implementing and
executing the entire project till submission of the report.
PO11 We demonstrated our knowledge and understanding of cost and time analysis required for
carrying out the project.
PO12 Facilitated ourselves in lifelong learning to improve technical knowledge and competence
in the chosen area of the project.

41