Pneumetic Bending Machine

1
PROJECT REPORT
ON
PNEUMETIC BENDING MACHINE
B.S. PATEL POLYTECHNIC, KHERVA
PROJECT GROUP:-
(1) PRIYANK B. PATEL. (126440319023)
(2) PARTH S. PATEL. (126440319025)
(3) AMIT J. KARAMKAR. (126440319028)
(4) JAY B. MODI. (126440319041)
(5) JAYMIN S. PANCHAL. (126440319043)
(6) KUNAL R. PATEL. (126440319053)
INTERNAL GUIDE:-
MR. HARDIK P. PATEL
EXTERNAL GUIDE:-
MR. KAMLESH M.PATEL
PNEUMATIC BENDING MACHINE

2
-:CERTIFICATE:-
This is to certify thatMR. KUNAL R. PATELhaving Enrollment No:

126440319053has completed Part-I UDP Project workhavingtitlePNUMETIK
BENDING MACHINE. He has undergone the process of shodhyatra,
literature survey and problem definition. He is supposed to carry out the residue
UDP Part-II work on same problem during Semester-VI for the final fulfillment
of the UDP work which is prerequisite to complete Diploma Engineering.
Prof. H.P.Patel Prof. K.P.Patel

(Project Guide) (Head of Department)
Mechanical Department Mechanical Department
B.S.Patel Polytechnic B.S.Patel Polytechnic
Kherva, Mehsana Kherva, Mehsana

3
-:CERTIFICATE:-
This is to certify that MR. PARTH S. PATELhaving Enrollment No:



4
-:CERTIFICATE:-
This is to certify that MR. AMIT J.KARAMKARhaving Enrollment No:

Prof. H.P.Patel Prof.

K.P.Patel(Project Guide) (Head of
Department) Mechanical Department Mechanical
Department

5
-:CERTIFICATE:-
This is to certify that MR. JAIMIN S. PANCHALhaving Enrollment No:



6
-:CERTIFICATE:-
This is to certify that MR. JAY B. MODIhaving Enrollment No:

126440319041has completed Part-I IDP Project workhavingtitlePNUMETIK
IDP Part-II work on same problem during Semester-VI for the final fulfillment
of the IDP work which is prerequisite to complete Diploma Engineering.


7
-:CERTIFICATE:-
This is to certify that MR. PRIYANK B. PATELhaving Enrollment No:



8
-:ACKNOWLEDGMENTS:-
1) With due pleasure I would like to express my gratitude to those who

have played an integral role in making this project a success.
2) First of all whole heartedly I would thank Mr. Hardik P. Patel

(SR.lecturer) for allowing me to undertake this project work under his
awe-inspiring guidance.
3) I would like to express my sincere gratitude to my guide Prof.

H.P.Patel (Prof, Mechanical Engineering) who helps me to
understand the subject, stimulating suggestions, encouragement. I am
sincerely thankful for this valuable guidance and help to enhance my
presentation skills.
4) I am thankful to my industry guide Mr. Kamlesh M. Patel (Technical

Officer, GLMD/MESA, SAC/ISRO). In spite of having busy schedule,
he was always ready to help me, whenever required. I am thankful for
his guidance and interest he has shown for this project.
5) My sincere and heartfelt appreciation goes to my family for their

endless and unconditional support and encouragement has consistently
boost up my zeal to make this work up to its final destiny.
6) I am also vary greatly thankful to all my college colleagues who have

been directly or indirectly associated with my endeavor.

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-:ABSTRACT:-
The bending machine is one of the most important machine tool in

sheet metal work shop. It is primarily designed for bending. The
bend has been made with the help of punch which exerts large force
on the work clamped on the die. The bending machine is designed in
such a way that, it works automatically. The automation strategy,
when implemented is believed to result in reduced cycle time, costs
and improved product quality. Other possible advantages are
repeatability, increased productivity, reduced labor and integration of
business systems. Automation is achieved with the help of Electro
pneumatic system.

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USERDEFINED PROBLEM/PROJECT (UDP)

-: STATEMENT FORM:-
STUDENT PARTICULARS-1
FIRST
KUNAL
NAME
LAST NAME PATEL
MOBILE
1 8511337485 2 9662101273
NO.
EMAIL kunalpatel116@ymail.com
COLLEGE
B.S.PATEL POLYTECNIC, GANPAT UNIVERSITY.
NAME
Mandirvalifali,naroda gam,
ADDRESS Opposite ranchodji temple,
Naroda, Ahmedabad.
BRANCH MECHANICAL ENGINEERING

SEMESTER 5th SEM. YEAR 2014-2015
TEAM
G-7
NAME
SIGNATURE
OF K.R.PATEL
STUDENT

11
FIRST
PARTH
NAME
LAST NAME PATEL
MOBILE
1 9998986171 2 9824542906
NO.
EMAIL parth.s.patel111@gmail.com
COLLEGE
NAME
G-303/Raj Recidency-2,
ADDRESS Near Santaram city,
Nanikadi road, Kadi-382715.
TEAM G-7
NAME
SIGNATURE
OF
STUDENT

12
FIRST
AMIT
NAME
LAST NAME KARAMKAR
MOBILE
1 7383904726 2 8866822320
NO.
EMAIL amit.karamkar.7@gmail.com
COLLEGE
NAME
51/396 G.H.B
ADDRESS Sarvodaynagar
Ahemedabad-380026
TEAM
NAME G-7
SIGNATURE
OF
STUDENT

13
FIRST
JAIMIN
NAME
LAST NAME PANCHAL
MOBILE
1 9099226142 2 9979962892
NO.
EMAIL j.panchall9094@gmail.com
COLLEGE
NAME
D/330, Parshwanath township,
ADDRESS Krushnanagar, Nava Naroda,
Ahmedabad-382346
TEAM G-7
NAME
SIGNATURE
OF
STUDENT

14
FIRST
JAY
NAME
LAST NAME MODI
MOBILE
1 9510010537 2 9824613450
NO.
EMAIL Jaymodi9197@gmail.com
COLLEGE
NAME
Panjrapolsopping center,
ADDRESS Near kapasiya bazar
Mahesana 384001
TEAM G-7
NAME
SIGNATURE
OF
STUDENT

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FIRST
PRIYANK
NAME
LAST NAME PATEL
MOBILE
1 7802078383 2 7698019403
NO.
EMAIL Priyank78039@gmail.com
COLLEGE
NAME
Margi apartment
ADDRESS Near deri ,
Mahesana -2
TEAM
NAME G-7
SIGNATURE
OF
STUDENT

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-: INDEX :-
Sr Topic Name Page

No. No.
1. Certificates 2
2. Acknowledgments 8
3. Abstract 9
4. Students Particulars 10
5. Introduction 17
6. Press:- 18
-Definition
-Types of Press
-Types of Operations
7. Parts of Machines:- 23
-Pneumatic Cylinder
-Compressor
-Direction Control Valve
-Pressure Gauge
-Die
-Air Supply Pipe
8. 2D & 3D Modeling:- 51
-Pneumatic Cylinder
-Die
9. Conclusion 53
10. References 53

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-:INTRODUCTION :-
Now a day in industries especially in automobile and other industries the

automatic plate bending machines are widely used. Earlier the bending
machines where operated manually. So the output of machine was very less.
Because the movement of ram was done manually by rotating the screw.
Now the technique of bending operation of the component is changed.
Once the plate is loaded the operator should not only use once push button to
start the machine. But he has operated two push buttons so that both the hands
of the operator are engaged. This arrangement is made in order to avoid injuries
to operators.
The main aim of this project is to have the complete know how of
pneumatic devices, sensors etc. by which the manually operated press or any
machine can be converted into a semi or fully automatic unit. In this project the
bending machine is a semi-automatic bending machine, in which the loading
and unloading of the component is done manually and the bending of the plate
is done automatically

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Definition of press:-
A general definition of the word Press, as used for the purposes with
which we are concerned in this treatise, might be written as follows: A
machine in which a bed or anvil is approached by a ram or hammer, having a
reciprocating motion in a line approximately at right angles to said bed, and
the said ram being suitably guided in the frame work of the machine so that it
may always move in the same path. It will thus be seen that the two
important members in any ordinary press are the bed and the ram, and that
they are only a more highly specialized form of the Black Smiths anvil and
hammer or of the still more primitive large stone and small stone used by the
predecessors.
Overview of Conventional Press:-
(Fig.1- Conventional press)

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Types of presses :-
The presses are broadly classified into the following two groups according
to the source of power.
1. Manually operated: Hand press, Ball press or fly press.
2. Power Press: Mechanical press, Hydraulicpress.
Tools of press :-
1. Punch
2. Die
Operations performed by the press

a. Shearing
b. Bending
c. Drawing
d. Squeezing
General Concepts on Design and Development of

Pneumatic Systems:-
Development of PneumaticSystem:-
The solution to a control problem is worked out according to a system with
documentation playing an important role in communicating the final result. The
circuit diagrams are drawn using standard symbols and labeling.
Comprehensive documentation is required including most of the following
The methodical design of a circuit diagram in accordance with
prescribed rules and instructions.
(Fig. 2 Functional Diagram)

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In majority of the pneumatic applications more than one cylinder is used.

The movement of these cylinders is coordinated as per the required
sequence. The activation of the limit switches of different cylinders will
provide set or reset signal to the final control valves for further controlling
the movement of various cylinders.
The limit switches have to be arranged in the proper location with the
help of motion diagram. In order to develop control circuitry for multi
cylinder applications, it is necessary to draw the motion diagram to
understand the sequence of actuation of various signal input switches-
limit switches and sensors. Multi cylinder applications with three
cylinders A, B and C. The status of the cylinder displacement and
actuation of set and reset signals at double piloted directional control
value is shown by functional diagram.
Sequence of Operation: -
StoppingClamping Punching
Z1 Z2 Z3
(Sequenceof Operation)

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Sequential motion of cylinders :-

1 minute 4 fishplates are produced. In one hour 240 units, therefore in one day
2400 units are It is possible to have the following produced (total machining time
taken in a day is sequence of operation with three cylinder 10 hours). To know the
productivity of both the machines it can be understood from the graph.
A+ B C Clamping
A+ B+ C Clamping,bending
A+ B C + clamping, retracting, bending
A B C retracting anclamping
A B C -> Reset condition
Operational and Analysis :-
A Cost Analysis Of Manual And Automated

Production Machine Press: :-
Depending upon the size of the machine the cost varies. Let us
consider a minimum size of the machine and do the analysis. The machine
taken is the press (bending). For manually operated press the cost of the
minimum size machine for bending is approximately around Rs. 2,00,00/-. For
automatically operated press the cost of a minimum machine for bending is
approximately around Rs. 6, 00, 00/-. Lets us consider a flash plate of a sheet
metal with a minimum thickness (1.5mm). In which the two projected parts are
to be bent.

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Manually operated press:-

The time needed to produce (bend) one fishplate on a manually
operated press is about 1 minute or 60 seconds. In 1 hour 60 units are produced
.therefore in one day 600 units are produced (total machining time taken in a
day is 10 hours).
Automated Press: -
The time needed to produce one fishplate on an automatic operated
press is about 15 seconds.
Graph shows the productivity of two machines:-
As seen from the graph the rate of production is very high

in case of the automated press as compared with the manually operated
machine. Hence the productivity is high on the automatic machines.
A Development of Pneumatic System :-

The solution to a control problem is worked out according to a system with
documentation playing an important role in communicating the final result. The
circuit diagrams are drawn using standard symbols and labeling.
Comprehensive d

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-:PARTS OF MACHINE:-
1. Pneumatic Cylinder:-
Key points:-
Pneumatic cylinders come in many basic versions.
All cylinders can be tweaked to better fit an application.
Custom designs can perform better and save money when standard cylinders
dont fit the job.

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Resources:-
Pneumatic cylinders are widely used to generate force and motion on a vast
range of OEM equipment. They can move products directly or indirectly by
pushing, pulling, lifting, lowering, or rotating, and can keep them from moving
by clamping them in place.
Wide acceptance comes in large part because cylinders are simple, economical,
durable, and easy to install. They can produce thousands of pounds of force
over a broad range of velocities; cycle at high speeds without overheating; and
stall without internal damage. And they readily tolerate tough conditions such as
high humidity, dusty environments, and repetitive high-pressure wash downs.
Pneumatic actuators come in literally thousands of styles, sizes, and

configurations. This variety makes more innovative-equipment possible, but
sorting out the best cylinder for an application can be a bit overwhelming. Here
are some key considerations.
Cylinder design:-
The basic, rod-style industrial cylinder consists of a tube sealed by end caps. A
rod attached to an internal piston extends through a sealed opening in one of the
ends. The cylinder mounts to a machine and the piston rod acts upon the load.
A port at one end of the cylinder supplies compressed air to one side of the
piston, causing it (and the piston rod) to move. The port at the other end lets air
on the opposite side of the piston escape usually to atmosphere. Reversing
the roles of the two ports makes the piston and rod stroke in the opposite
direction. Rod-style cylinders function in two ways:
Double-acting cylinders use compressed air to power both the extend and
retract strokes, moving the rod back and forth. This arrangement makes them
ideal for pushing and pulling loads. Controlling the rate at which air exhausts
determines rod speed.
Single-acting cylinders have compressed air supplied to only one side of the
piston; the other side vents to atmosphere. Depending on whether air is routed
to the cap or rod end determines whether the rod extends or retracts.

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-:Rod-style cylinders come in various designs:-
Repairable cylinders can be disassembled to replace seals and other internal

components. This extends a cylinders life. These durable cylinders are
generally used in rugged, heavy-duty applications.
Sealed-for-life or disposable cylinders have end caps mechanically crimped to

the tube. Internal components are preluded prior to assembly. Although they are
less expensive to manufacture than comparable repairable cylinders, they cannot
be taken apart to repair without destroying the housing. These cylinders are
usually used in lighter-duty applications and must be replaced when they fail.
Compact:-
Cylinders fit into smaller spaces where only a short stroke is required. They are
used in lighter-duty applications due to the small bearing surface on which the
rod slides. They mainly come in single-acting versions, but double-acting styles
also are available.
Guided :-
Cylinders have guide rods and guide blocks mounted parallel to the piston rod,
or dual piston rods. They prevent the piston from rotating and provide precise,
controlled linear motion especially when the unit is subject to high side
loads. In such cases, the guides reduce rod and piston bending and uneven seal
wear. They are recommended in applications with sizeable offset loads or
require that the load be guided, for example, down a conveyor.

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Rack-and-pinion:-
Units convert a cylinders linear motion to angular rotation that can exceed
360. The rotary actuators with the rack mounted on the rod are often
used in process industries to operate quarter-turn valves.In addition to rod-type
cylinders, other designs included.
Bellows:-
Are durable, single-acting actuators with flexible, reinforced-elastomeric walls
and metal end plates. They extend when inflated and can generate high forces,
thanks to their large diameters. A cylindrical shape lets them bend in any
direction, making them useful where load direction might curve. Note that
external restraints should be used to limit maximum extension and compression.
Unrestrained extension can blow off the end plate, and exhaust without restraint
can let the load crush the sidewalls.
Rodless cylinders, as the name implies, have no rod extending through the end
caps. Instead, an external carriage slides back and forth on the tube. The load
mounts on this carriage. In many designs, an internal piston is mechanically
connected to the carriage through a sealed longitudinal slot in the cylinder wall.
Long sealing strips inside and outside the cylinder tube prevent air leaks and
dust and dirt ingression. Other variations include cable-and-pulley arrangements
and magnetically coupled pistons and carriages.

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2. Compressor:-
According to the design and principle of operation:-

1. Rotary screw compressor
2. Turbo compressor

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Positive displacement:-
Positive-displacement compressors work by forcing air into a chamber whose
volume is decreased to compress the air. Common types of positive
displacement compressors are:-
Piston-type air compressors use this principle by pumping air into an air
chamber through the use of the constant motion of pistons. They use one-
way valves to guide air into a cylinder chamber, where the air is compressed.
Rotary screw compressors use positive-displacement compression by
matching two helical screws that, when turned, guide air into a chamber,
whose volume is decreased as the screws turn.
Vane compressors use a slotted rotor with varied blade placement to guide
air into a chamber and compress the volume. A type of compressor that
delivers a fixed volume of air at high pressures.
Negative displacement:-
Negative-displacement air compressors include centrifugal compressors. These
use centrifugal force generated by a spinning impeller to accelerate and then
decelerate captured air, which pressurizes it.
Cooling:-
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)[3] and the atmospheric changes also considered during
cooling of compressors.
Applications:-
To supply high-pressure clean air to fill gas cylinders

To supply moderate-pressure clean air to a submerged surface supplied diver
To supply moderate-pressure clean air for driving some office and school
building pneumatic HVAC control system valves
To supply a large amount of moderate-pressure air to power pneumatic
tools, such as jackhammers
For filling tires
To produce large volumes of moderate-pressure air for large-scale industrial
processes (such as oxidation for petroleum coking or cement plant bag house
purge systems).

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Compressors - Saving Energy
Most air compressors either are reciprocating piston type, rotary vane or rotary
screw. Centrifugal compressors are common in very large applications. There
are two main types of air compressor's pumps: oil-lubed and oil-less. The oil-
less system has more technical development, but is more expensive, louder and
lasts for less time than oil-lubed pumps. The oil-less system also delivers air of
better quality.
Compressor saving energy:-

Reduce run time turn off when not needed
Lower system pressure to lowest possible level
Repair leaks
Recover waste heat
Additional system volume (load/unload only)
Reduce use of pneumatic tools

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3. Direction Control Valve:-
Directional control valve:-
Directional control valves are one of the most fundamental parts in hydraulic
machinery as well and pneumatic machinery. They allow fluid flow into
different paths from one or more sources. They usually consist of a spool inside
a cylinder which is mechanically or electrically controlled. The movement of
the spool restricts or permits the flow, thus it controls the fluid flow.
Nomenclature:-
The spool (sliding type) consists of lands and grooves.The lands block oil flow
through the valve body. The grooves allow oil or gas to flow around the spool
and through the valve body. There are two fundamental positions of directional
control valve namely normal positionwhere valve returns on removal of
actuating force and other is working position which is position of a valve when
actuating force is applied. There is another class of valves with 3 or more
position that can be spring centered with 2 working position and a normal
position.

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Classification:-
Directional control valves can be classified according to-
number of ports
number of positions
actuating methods
Type of spool.
Example: A 5/2 directional control valve would have five ports and two spool
positions.
Number of Ports:-
According to total number of entries or exits connected to the valve through
which fluid can enter the valve or leave the valve there are types like two
way,threeway,four way valves.
Number of Positions:-
Including the normal and working positions which a valve spool can take there
are types like two position, three position and proportional valves.
-:Actuating Methods:-
Manually Operated:-
Manually operated valves work with simple levers or paddles where the
operator applies force to operate the valve. Spring force is sometimes used to
recover the position of valve. Some manual valves utilize either a lever or an
external pneumatic or hydraulic signal to return the spool.
Mechanically Operated:-
Mechanically operated valves apply forces by using cams, wheels, rollers, etc.,
hence these valves are subjected to wear.
Hydraulically Operated:-
A hydraulically operated DCV works at much higher pressures than its
pneumatic equivalent. They must therefore be far more robust in nature so are
precision machined from higher quality and strength materials.

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Solenoid Operated:-
They are widely used in the hydraulics industry. These valves make use of
electromechanical solenoids for sliding of the spool. Because simple application
of electrical power provides control, these valves are used extensively.
However, electrical solenoids cannot generate large forces unless supplied with
large amounts of electrical power. Heat generation poses a threat to extended
use of these valves when energized over time. Many have a limited duty cycle.
This makes their direct acting use commonly limited to low actuating forces.
Often a low power solenoid valve is used to operate a small hydraulic valve
(called the pilot) that starts a flow of fluid that drives a larger hydraulic valve
that requires more force.
A bi-stable pneumatic valve is typically a pilot valve that is a 3 ported 2
position detected valve. The valve retains its position during loss of power,
hence the bi-stable name.
Bi-stability can be accomplished with a mechanical detent and 2 opposing
solenoids or a "magna-latch" magnetic latch with a polarity sensitive coil.
Positive opens and negative closes or vice-versa. The coil is held in position
magnetically when actuated.
Type of Spool:-
Spool is of two types namely sliding and rotary. Sliding spool is cylindrical in
cross section, and the lands and grooves are also cylindrical. Rotary valves have
sphere-like lands and grooves in the form of holes drilled through the spheres.
Specification:-
They are generally specified using the number of ports and the number of
switching positions. It can be represented in general form asn p /n s , where n p is
the number of ports connected to the direction control valve and n s the number
of switching positions.
In addition, the method of actuation and the return method can also be specified.
A hypothetical valve could 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. In this example, one port is called the pressure port which is connected to
the pump; one port is the tank port and is connected to the tank (or reservoir);
and the two remaining ports are called working ports and are connected to
the actuator. Apart from characteristics of valve the fluid suitable for
valve,working temperature and viscosity also thought upon before selecting a
particular type of valve.

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Symbolic representation:-
While working with layouts of hydraulic machinery it is cumbersome to draw
actual picture of every valve and other components.instead of pictures symbols
are used for variety of components in the hydraulic system to highlight the
functional aspects. Symbol for directional control valve is made of number of
square boxes adjacent to each other depending on the number of
positions.Connections to the valve are shown on these squares by capital
letters.Usually they are named only in their normal position and not repeated in
other positions.Actuation system of the valve is also designated in its symbol.
-:Two way two position directional control valve:-
Gate valve is example of 2W/2P directional control valve which

either turns on or off the flow in normal or working position depending on need
of application. Here arrow indicates that fluid flow is taking place whereas other
position shows cut-off position.

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-:Four way two position directional control valve:-
4 way 2 position valve has four connections to it and two valve positions. One
of them is normally open.

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4. Pressure Gauge:-
Location:-
Wheneverpossible,gaugesshouldbelocatedtominimizetheeffectsofvibration,extre
meambienttem-peraturesandmoisture.Drylocationswayfromveryhigh
thermalsources (ovens, boilersetc.)are preferred. Ifthe
mechanicalvibrationliveLisextreme,thegaugeshouldberemotelylocated
(usuallyonawall)andconnectedtothe pressuresourcevia flexibletubing.

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Gauge re use:-
ASMEB40.100recommendsthat gaugesnotbemovedin discriminatelyfrom
oneapplication to another.The cumulativenumberof pressurecycleson an
In-serviceor previousloused gaugeisgenerallyunknown,so itisgenerallysafer to
installnewgaugewheneverand whereverpossible.Thiswill
alsominimizethepossibilityof a reactionwithpreviousmedia.
Tighteningofgauge:-
Torquesholdneverbe applied tothegaugecase.Instead,anopenendor adjustable
wrenchshouldalwaysbe used on the wrenchflatsofthe
gaugesockettotightenthegaugeintothefittingorpipe.
NPTthreadrequiretheuseofasuitablethreadsealant,
Suchsippedoperateflontape,andmustbetightenedvery
securelytoensurealeaktightseal.Torqueappliedtoadiaphragmsealorits
attachedgauge,thattendstoloosenonerelativetothe
other,cancauselossoffillandsubsequentinaccurate read-
ings.Alwaysupplytorqueonlytothewrenchflatsonthe
lowersealhousingwheninstallingfilled,diaphragmseal
assembliesorremovingsamefromprocesslines.
Processisolation:-
Asyut-offvalveshouldbeinstalled
betweenthegaugeandtheprocessinordertobeableto
isolatethegaugeforinspectionoreplacementwithoutshut- tingdowitherprocess.
Surface mounting:-
Alsoknownaswall mounting.Gaugesshouldbekeptfreeofpipingstrains.
Thegaugecase mountingfeet, fipplecable, willensureclearancebetweenthe
pressurerelievingbackandthemoutingsurface.
Flushmounting:-
Alsoknownaspanelmounting.The applicable panel mounting cutout dimensions
can be4.0OPERATION

37
Frequencyofinspection:-
Thisisquitesubjectiveand dependsupontheseverityoftheserviceandhowcriticalthe
accuracyoftheindicatedpressureis.Forexample,amonthlyinspectionfrequencymay
beinorderforcritical,severe
serviceapplications.Annualinspections,orevenlessfree- quantsschedules,
aerofenemployedinn on criticalApplica- tons.
In-serviceinspection:-
Iftheaccuracyofthegauge cannotbecheckedin place,theusercanat leastlookfor (a)
erraticorrandumpintimation;(b) readingsthataresus- pact
especiallyindicationsofpressurewhentheuser
believesthetruepressureis0psig.Anygaugewhichis
obviouslynotworkingorindictatingerroneoussully,shouldbe immediatelyvalued
offorremovedfromservicetoavoidpossiblepressureboundaryfailure.
Whentocheckaccuracy:-
Anysuspicion usbehaviorof
thegaugepointerwarrantsthatafullaccuracycheckbeeper-
formed.Evenifthegaugeisnotshowinganysymptomsof
abnormalperformance,theuser
maywantestablishedfrequencyofbenchtypeinspection.
Whentorecalibrate:-
Thisdependsonthecriticalityof theapplication.Iftheaccuracyofa3-2-
3%commercialtype gaugeisonly0.5%beyondspecification,theusermust
decidewhet heritsworththetimeandexpensetobringthe
gaugebackintospecification .Converselyiftheaccuracyof
a0.25%testgaugeisfoundtobe0.1%outofspecificationthen the gauge should be
recalibrated.

38
5. Die :-
Die forming:-
(Progressive die with scrap strip and stampings)

39
Forming dies are typically made by tool and die makers and put into production
after mounting into a press. The die is a metal block that is used for forming
materials like sheet metal and plastic. For the vacuum forming of plastic sheet
only a single form is used, typically to form transparent plastic containers
(called blister) for merchandise. Vacuum forming is considered a simple molding
thermoforming process but uses the same principles as die forming. For the
forming of sheet metal, such as automobile body parts, two parts may be used:
one, called the punch, performs the stretching, bending, and/or blanking
operation, while another part, called the die block, securely clamps the work
piece and provides similar stretching, bending, and/or blanking operation. The
work piece may pass through several stages using different tools or operations
to obtain the final form. In the case of an automotive component there will
usually be a shearing operation after the main forming is done and then
additional crimping or rolling operations to ensure that all sharp edges are
hidden and to add rigidity to the panel.
Die components:-
The main components for die toolsets are:
Die block - This is the main part that all the other parts are attached to.
Punch plate - This part holds and supports the different punches in place.
Blank punch - This part along with the blank die produces the blanked part.
Pierce punch - This part along with the pierce die removes parts from the
blanked finished part.
Stripper plate - This is used to hold the material down on the blank/pierce
die and strip the material off the punches.
Pilot - This is used to keep the material being worked on in position.
Guide, back gage, or finger stop - These parts are all used to make sure that
the material being worked on always goes in the same position, within the
die, as the last one.
Setting (stop) block - This part is used to control the depth that the punch
goes into the die.
Blanking dies - See blanking punch
Pierce die - See pierce punch.
Shank - used to hold in the presses. it should be aligned and situated at the
center of gravity of the plate.

40
-:Processes:-
Blanking:-
A blanking die produces a flat piece of material by cutting the desired shape in
one operation. The finish part is referred to as a blank. Generally a blanking die
may only cut the outside contour of a part, often used for parts with no internal
features.
Three benefits to die blanking are:
1. Accuracy. A properly sharpened die, with the correct amount of clearance

between the punch and die, will produce a part that holds close
dimensional tolerances in relationship to the parts edges.
2. Appearance. Since the part is blanked in one operation, the finish edges
of the part produces a uniform appearance as opposed to varying degrees
of burnishing from multiple operations.
3. Flatness. Due to the even compression of the blanking process, the end
result is a flat part that may retain a specific level of flatness for
additional manufacturing operations.
Broaching:-
The process of removing material through the use of multiple cutting teeth,
with each tooth cutting behind the other. A broaching die is often used to
remove material from parts that are too thick for shaving.
Bulging: -
A bulging die expands the closed end of tube through the use of two types of
bulging dies. Similar to the way a chefs hat bulges out at the top from the
cylindrical band around the chefs head.
1. Bulging fluid dies: Uses water or oil as a vehicle to expand the part.

41
2. Bulging rubber dies: Uses a rubber pad or block under pressure to move
the wall of a workpiece.
Coining:-
Coining is similar to forming with the main difference being that a coining
die may form completely different features on either face of the blank, these
features being transferred from the face of the punch or die respectively. The
coining die and punch flow the metal by squeezing the blank within a
confined area, instead of bending the blank. For example: an Olympic medal
that was formed from a coining die may have a flat surface on the back and a
raised feature on the front. If the medal was formed (or embossed), the
surface on the back would be the reverse image of the front.
Compound operations:-
Compound dies perform multiple operations on the part. The compound
operation is the act of implementing more than one operation during
the press cycle.
Compound die:-
A type of die that has the die block (matrix) mounted on a punch plate with
perforators in the upper die with the inner punch mounted in the lower die
set. An inverted type of blanking die that punches upwards, leaving the part
sitting on the lower punch (after being shed from the upper matrix on the
press return stroke) instead of blanking the part through. A compound die
allows the cutting of internal and external part features on a single press
stroke.
Curling:-
The curling operation is used to roll the material into a curved shape. A door
hinge is an example of a part created by a curling die.
Cut off:-

42
Cut off dies are used to cut off excess material from a finished end of a part
or to cut off a predetermined length of material strip for additional
operations.
Drawing:-
The drawing operation is very similar to the forming operation except that
the drawing operation undergoes severe plastic deformation and the material
of the part extends around the sides. A metal cup with a detailed feature at
the bottom is an example of the difference between formed and drawn. The
bottom of the cup was formed while the sides were drawn.
Extruding:-
Extruding is the act of severely deforming blanks of metal called slugs into
finished parts such as an aluminum I-beam. Extrusion dies use extremely
high pressure from the punch to squeeze the metal out into the desired form.
The difference between cold forming and extrusion is extruded parts do not
take shape of the punch.
-:Forming:-
Forming dies bend the blank along a curved surface. An example of a part
that has been formed would be the positive end (+) of an AA battery.
a. Cold forming (cold heading):-

Cold forming is similar to extruding in that it squeezes the blank material but
cold forming uses the punch and the die to create the desired form, extruding
does not.

43
(Roll Forming Stand)
b. Roll forming:-
a continuous bending operation in which sheet or strip metal is gradually
formed in tandem sets of rollers until the desired cross-sectional
configuration is obtained. Roll forming is ideal for producing parts with long
lengths or in large quantities.
Horning:-
A horning die provides an arbor or horn which the parts are place for
secondary operations.
Hydroforming:-
Forming of tubular part from simpler tubes with high water pressure.
Pancake die:-
A Pancake die is a simple type of manufacturing die that performs blanking
and/or piercing. While many dies perform complex procedures
simultaneously, a pancake die may only perform one simple procedure with
the finished product being removed by hand.
Piercing:-
The piercing operation is used to pierce holes in stampings.
Transfer die:-

44
Transfer dies provide different stations for operations to be performed. A

common practice is to move the material through the die so it is
progressively modified at each station until the final operation ejects a
finished part.
Progressive die:-
The sheet metal is fed through as a coil strip, and a different operation (such
as punching, blanking, and notching) is performed at the same station of the
machine with each stroke of a series of punches.
Shaving:-
The shaving operation removes a small amount of material from the edges
of the part to improve the edges finish or part accuracy. (Compare
to Trimming).
Side cam die:-

Side cams transform vertical motion from the press ram into horizontal or
angular motion.
Sub press operation:-

Sub-press dies blank and/or form small watch, clock, and instrument parts.
Swaging:-
Swaging (necking) is the process of "necking down" a feature on a part.
Swaging is the opposite of bulging as it reduces the size of the part. The end
of a shell casing that captures the bullet is an example of swaging.

45
Trimming:-
Trimming dies cut away excess or unwanted irregular features from a part,
they are usually the last operation performed.
Pillar set:-
Pillar set are used for alignment of dies in press movement.
6. Air Supply Pipe:-
A pipe is a tubular section or hollow cylinder, usually but not

necessarily of circular cross-section, used mainly to convey
substances which can flow liquids and gases (fluids), slurries,
powders, masses of small solids. It can also be used for structural
applications; hollow pipe is far stiffer per unit weight than solid
members.
In common usage the words pipe and tube are usually
interchangeable, but in industry and engineering, the terms are
uniquely defined. Depending on the applicable standard to which it is
manufactured, pipe is generally specified by a nominal diameter with
a constant outside diameter (OD) and a schedule that defines the
thickness. Tube is most often specified by the OD and wall thickness,

46
but may be specified by any two of OD, inside diameter (ID), and
wall thickness. Pipe is generally manufactured to one of several
international and national industrial standards. While similar
standards exist for specific industry application tubing, tube is often
made to custom sizes and a broader range of diameters and tolerances.
Many industrial and government standards exist for the production of
pipe and tubing. The term "tube" is also commonly applied to non-
cylindrical sections, i.e., square or rectangular tubing. In general,
"pipe" is the more common term in most of the world, whereas "tube"
is more widely used in the United States.
Both "pipe" and "tube" imply a level of rigidity and permanence,

whereas a hose (or hosepipe) is usually portable and flexible. Pipe
assemblies are almost always constructed with the use of fittings such
as elbows, tees, and so on, while tube may be formed or bent into
custom configurations. For materials that are inflexible, cannot be
formed, or where construction is governed by codes or standards, tube
assemblies are also constructed with the use of tube fittings.
Uses:-
Pipe installation on a street in Belo Horizonte, Brazil
Plumbing
Tap water
Pipelines transporting gas or liquid over long distances
Scaffolding
Structural steel
As components in mechanical systems such as:
Rollers in conveyor belts
Compactors (E.g.: steam rollers)
Bearing casing
Casing for concrete pilings used in construction projects
High temperature or pressure manufacturing processes
The petroleum industry:
Oil well casing

47
Oil refinery equipment

Delivery of fluids, either gaseous or liquid, in a process plant from
one point to another point in the process
Delivery of bulk solids, in a food or process plant from one point
to another point in the process
The construction of high pressure storage vessels (note that
large pressure vessels are constructed from plate, not pipe owing to
their wall thickness and size).
Manufacture:-
There are three processes for metallic pipe manufacture. Centrifugal
casting of hot alloyed metal is one of the most prominent
process.Ductile pipes are generally manufactured in such a
fashion. Seamless (SMLS) pipe is formed by drawing a
solid billet over a piercing rod to create the hollow shell. As the
manufacturing process does not include any welding, seamless pipes
are perceived to be stronger and more reliable. Historically seamless
pipe was regarded as withstanding pressure better than other types,
and was often more easily available than welded pipe.
Advances since the 1970s in materials, process control and non-
destructive testing allow correctly specified welded pipe to replace
seamless in many applications. Welded (also Electric Resistance
Welded ("ERW"), and Electric Fusion Welded ("EFW")) pipe is
formed by rolling plate and welding the seam. The weld flash can be
removed from the outside or inside surfaces using a scarfing blade.
The weld zone can also be heat treated to make the seam less visible.
Welded pipe often has tighter dimensional tolerances than seamless,
and can be cheaper if manufactured in the same quantities.
There are a number of processes that may be used to produce ERW
pipes. Each of these processes leads to coalescence or merging of
steel components into pipes. Electric current is passed through the
surfaces that have to be welded together; as the components being
welded together resist the electric current, heat is generated which

48
forms the weld. Pools of molten metal are formed where the two
surfaces are being connected as strong electric current is passed
through the metal; these pools of molten metal form the weld that
binds the two connected components.
ERW pipes are manufactured from the longitudinal welding of steel.
The welding process for ERW pipes is continuous as opposed to
welding of distinct sections at intervals. ERW process uses steel coil
as feedstock.
The High Frequency Induction Technology (HFI) welding process is

used for manufacturing ERW pipes. In this process the current to
weld the pipe is applied by means of an induction coil around the
tube.
Large-diameter pipe (25 centimeters (10 in) or greater) may be ERW,

EFW or Submerged Arc Welded ("SAW") pipe. There are two
technologies that can be used to manufacture steel pipes of sizes
larger than the steel pipes that can be produced by seamless and ERW
processes. The two types of pipes produced through these
technologies are Longitudinal submerged arc welded (LSAW) and
Spiral submerged arc welded (SSAW) pipes. LSAW are made by
bending and welding wide steel plates and most commonly used in oil
and gas industry applications. Due to their high cost, LSAW pipes are
seldom used in lower value non-energy applications such as water
pipelines. SSAW pipes are produced by spiral (helicoidally) welding
of steel coil and have a cost advantage over LSAW pipes as the
process uses coils rather than steel plates. As such, in applications
where spiral-weld is acceptable, SSAW pipes may be preferred over
LSAW pipes. Both LSAW pipes and SSAW pipes compete against
ERW pipes and seamless pipes in the diameter ranges of 16-24.
Tubing for flow, either metal or plastic, is generally extruded.

49
Typically metallic piping is made of steel or iron, such as unfinished,

black (lacquer) steel, carbon steel,stainless steel or galvanized
steel, brass, and ductile iron. Iron based piping is subject to corrosion
in highly oxygenated water stream.[2] Aluminum pipe or tubing may
be utilized where iron is incompatible with the service fluid or where
weight is a concern; aluminum is also used for heat transfer tubing
such as in refrigerant systems. Copper tubing is popular for domestic
water (potable) plumbing systems; copper may be used where heat
transfer is desirable (i.e. radiators or heat
exchangers). Inconel, chrome moly, and titaniumsteel alloys are used
in high temperature and pressure piping in process and power

facilities. When specifying alloys for new processes, the known issues
of creep and sensitization effect must be taken into account.
Lead piping is still found in old domestic and other water

distribution systems, but it is no longer permitted for new potable
water piping installations due to its toxicity.
Plastic tubing is widely used for its light weight, chemical resistance,
non-corrosive properties, and ease of making connections. Plastic
materials include polyvinyl chloride (PVC),[4] chlorinated polyvinyl
chloride (CPVC), fiber reinforced plastic (FRP),[5] reinforced polymer
mortar (RPMP),[5] polypropylene (PP), polyethylene (PE), cross-
linked high-density polyethylene (PEX), polybutylene (PB),
and acrylonitrile butadiene styrene (ABS), for example. In many
countries, PVC pipes account for most pipe materials used in buried
municipal applications for drinking water distribution and wastewater
mains. Market researchers are forecasting total global revenues of
more than US$80 billion in 2019. In Europe, market value will
amount to approx. 12.7 billion in 2020

50
Pipe may be made from concrete or ceramic, usually for low-pressure

applications such as gravity flow or drainage. Pipes for sewage are
still predominantly made from concrete or vitrified clay. Reinforced
concrete can be used for large-diameter concrete pipes. This pipe
material can be used in many types of construction, and is often used
in the gravity-flow transport of storm water. Usually such pipe will
have a receiving bell or a stepped fitting, with various sealing
methods applied at installation.
Installation:-
Pipe installation is often more expensive than the
material and a variety of specialized tools, techniques, and parts have
been developed to assist this. Pipe is usually delivered to a customer
or jobsite as either "sticks" or lengths of pipe (typically 20 feet, called
single random length) or they are prefabricated with elbows, tees and
valves into a prefabricated pipe spool [A pipe spool is a piece of pre-
assembled pipe and fittings, usually prepared in a shop so that
installation on the construction site can be more efficient.]. Typically,
pipe smaller than 2.0 inch are not pre-fabricated. The pipe spools are
usually tagged with a bar code and the ends are capped (plastic) for
protection. The pipe and pipe spools are delivered to a warehouse on a
large commercial/industrial job and they may be held indoors or in a

gridded laydown yard. The pipe or pipe spool is retrieved, staged,
rigged, and then lifted into place. On large process jobs the lift is
made using cranes andhoist and other material lifts. They are typically
temporarily supported in the steel structure using beam clamps, straps,
and small hoists until the Pipe Supports are attached or otherwise
secured.

51
An example of a tool used for installation for a small plumbing pipe

(threaded ends) is the pipe wrench. Small pipe is typically not heavy
and can be lifted into place by the installation craft laborer. However,
during a plant outage or shutdown, the small (small bore) pipe may
also be pre-fabricated to expedite installation during the outage. After
the pipe is installed it will be tested for leaks. Before testing it may
need to be cleaned by blowing air or steam or flushing with a liquid.
-:2D&3D Modeling:-
Pneumatic Cylinder:-

52
Die:-

53
Conclusion:-
The manually controlled press is converted into automatic machine by
which maximum operating time will be saved. Thus the output will be
more. In this project the human intervention is for loading and unloading
the plate. It may be called as semiautomatic machine. This machine can
be converted into a fully automatic machine where loading and unloading
of the plate can be done automatically.
To conclude, this project is made keeping in mind that any manually
operated machine can be converted to automatic machines by using
pneumatic, electrical and electronic devices. For these purpose one
should have the full know how of the devices which are being used. By
doing so the existing old machines can be modified and made automatic
by which the initial cost, to procure new automatic machines may be
minimized. Thus there is a lot of scope in this area (automation).
Further in this project the wiring is very much complicated, if any troubleshoot
occurs then the fault cannot be easily found, for this the interface with the PLC
can be used, by which the wiring is minimized and the fault can be easily
detected without waste of time.

54
Hence there is still wide scope in the automation are where lots of improvement
can be made with the help of the latest technology
References:-
www.google.com
www.wikipidiya.com

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PNEUMETIC BENDING MACHINE

B.S. PATEL POLYTECHNIC, KHERVA

PNEUMATIC BENDING MACHINE

This is to certify thatMR. KUNAL R. PATELhaving Enrollment No:

Prof. H.P.Patel Prof. K.P.Patel

PNEUMATIC BENDING MACHINE

This is to certify that MR. PARTH S. PATELhaving Enrollment No:

Prof. H.P.Patel Prof. K.P.Patel

PNEUMATIC BENDING MACHINE

This is to certify that MR. AMIT J.KARAMKARhaving Enrollment No:

Prof. H.P.Patel Prof.

PNEUMATIC BENDING MACHINE

This is to certify that MR. JAIMIN S. PANCHALhaving Enrollment No:

Prof. H.P.Patel Prof. K.P.Patel

PNEUMATIC BENDING MACHINE

This is to certify that MR. JAY B. MODIhaving Enrollment No:

Prof. H.P.Patel Prof. K.P.Patel

PNEUMATIC BENDING MACHINE

This is to certify that MR. PRIYANK B. PATELhaving Enrollment No:

Prof. H.P.Patel Prof. K.P.Patel

PNEUMATIC BENDING MACHINE

1) With due pleasure I would like to express my gratitude to those who

2) First of all whole heartedly I would thank Mr. Hardik P. Patel

3) I would like to express my sincere gratitude to my guide Prof.

4) I am thankful to my industry guide Mr. Kamlesh M. Patel (Technical

5) My sincere and heartfelt appreciation goes to my family for their

6) I am also vary greatly thankful to all my college colleagues who have

PNEUMATIC BENDING MACHINE

The bending machine is one of the most important machine tool in

PNEUMATIC BENDING MACHINE

USERDEFINED PROBLEM/PROJECT (UDP)

BRANCH MECHANICAL ENGINEERING

PNEUMATIC BENDING MACHINE

PNEUMATIC BENDING MACHINE

PNEUMATIC BENDING MACHINE

PNEUMATIC BENDING MACHINE

PNEUMATIC BENDING MACHINE

PNEUMATIC BENDING MACHINE

Sr Topic Name Page

PNEUMATIC BENDING MACHINE

Now a day in industries especially in automobile and other industries the

PNEUMATIC BENDING MACHINE

Overview of Conventional Press:-

(Fig.1- Conventional press)

PNEUMATIC BENDING MACHINE

Operations performed by the press

General Concepts on Design and Development of

(Fig. 2 Functional Diagram)

PNEUMATIC BENDING MACHINE

In majority of the pneumatic applications more than one cylinder is used.

PNEUMATIC BENDING MACHINE

Sequential motion of cylinders :-

Operational and Analysis :-

A Cost Analysis Of Manual And Automated

PNEUMATIC BENDING MACHINE

Manually operated press:-

Graph shows the productivity of two machines:-

As seen from the graph the rate of production is very high

A Development of Pneumatic System :-

PNEUMATIC BENDING MACHINE

PNEUMATIC BENDING MACHINE

Pneumatic actuators come in literally thousands of styles, sizes, and

PNEUMATIC BENDING MACHINE