hi am jeshua i would like to get details on the methodology of pneumatic sheet metals cutting machine for my research proposal
i would really appreciate it if you could give a the details thank you in advance

We are using scissors for simple sheet metal cutting. It
is a manual method so that sheet metals are to be
wasted sometime because of mistakes happened such
as wrong dimensions etc., and also even a simple
cutting may take long time.Hydraulic machines are
also available for sheet metal cutting. But this method
is used for only heavy metal cutting and its cost is very
high.We are using a pneumatic system for sheet metal
cutting in a easy way. It is operated by a pneumatic
hand lever of two ways control valve.Control valve is
operated by a compressor.
I.INTRODUCTION:
The formation of any business begins with someone
producing the initial idea for the project. The
continued success of an established business depends
upon the number and quality of the ideas fed into it.
Without a continual flow of new ideas, a business
cannot function profitably or expand successfully and
must, therefore eventually fade into total obscurity.
Figure 1: Concept Image for Project
Ideas for a new business project, a new product, a
means of reducing manufacturing costs or for solving
industrial labor problems, begin in the human mind.
Most people conceive their ideas unconsciously, and
because they are unaware of the mental mechanics that
caused the ‘idea’ to be produced, they cannot repeat
the ideation process to produce further profitable ideas
at will.Fortunately, there are available established
creative techniques which, when used correctly, do
enable a person to produce a large number of firstclass
ideas at will. One such creative technique, and
probably the most widely used in American industry,
is ’brainstorming’.
II.LITERATURE SURVEY:
In shearing or cutting operation as or blade descends
upon the metal, the pressure exerted by the blade first
cause the plastic deformation of the metal. Since the
clearance between the two blades is very small, the
plastic deformation takes place in a localized area and
the metal adjacent to the cutting edges of the blade
edges becomes highly stressed, which causes the
fracture to start on both sides of the sheet as the
deformation progresses and the sheet is sheared. In
dentistry applications, pneumatic drills are lighter,
faster and simpler than an electric drill of the same
power rating, because the prime mover, the
compressor, is separate from the drill and pumped air
is capable of rotating the drill bit at extremely high
rpm. Pneumatic transfer systems are employed in
many industries to move powders and pellets.
III.SHEET METAL:
Sheet metal is simply a metal formed into thin and flat
pieces. It is one of the fundamental forms used in
metal working and can be cut and bent into a variety of
different shapes. Countless everyday objects are
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constructed of the material. Thicknesses can vary
significantly, although extremely thin thicknesses are
considered foil or leaf, and pieces thicker than 6 mm
(0.25 in) are considered plate.Sheet metal is available
in flat pieces or as a coiled strip. The coils are formed
by running a continuous sheet of metal through a roll
slitter.The thickness of the sheet metal is called its
gauge. Commonly used steel sheet metal ranges from
30 gauges to about 8 gauge. The larger the gauge
number, the thinner the metal. Gauge is measured in
ferrous (iron based) metals while nonferrous metals
such as aluminum or copper are designated differently;
i.e., Copper is measured in thickness by Ounce.
There are many different metals that can be made into
sheet metal, such as aluminum, brass, and copper,
steel, tin, nickel and titanium. For decorative uses,
important sheet metals include silver, gold and
platinum (platinum sheet metal is also utilized as a
catalyst.)Sheet metal also has applications in car
bodies, airplane wings, medical tables, roofs for
buildings (Architectural) and many other things. Sheet
metal of iron and other materials with high magnetic
permeability, also known as laminated steel cores, has
applications in transformers and electric machines.
Historically, an important use of sheet metal was in
plate armor worn by cavalry, and sheet metal continues
to have many decorative uses, including in horse tack.
Sheet metal workers are also known as "Tin
Bashers",("Tin Knockers") which is derived from the
hammering of panel seams when installing tin roofs.
There are three primary procedures in Layout
1. Parallel
2. Radial
3. Triangulation
SHEET METAL CUTTING:
Cutting processes are those in which a piece of sheet
metal is separated by applying a great enough force to
cause the material to fail.The most common cutting
processes are performed by applying a shear force, and
are therefore sometimes referred to as shearing
processes.When a great enough shearing force is
applied, the shear stress in the material will exceed the
ultimate shear strength and the material will fail and
separate at the cut location.This shearing force is
applied by two tools, one above and one below the
sheet. Whether these tools are a punch and die or upper
and lower blades, the tool above the sheet delivers a
quick downward blow to the sheet metal that rests over
the lower tool.A small clearance is present between the
edges of the upper and lower tools, which facilitates
the fracture of the material. The size of this clearance
is typically 2-10% of the material thickness and
depends upon several factors, such as the specific
shearing process, material, and sheet thickness.The
effects of shearing on the material change as the cut
progresses and are visible on the edge of the sheared
material. When the punch or blade impacts the sheet,
the clearance between the tools allows the sheet to
plastically deform and “rollover” the edge. As the tool
penetrates the sheet further, the shearing results in a
vertical burnished zone of material, finally, the shear
stress is too great and the material fractures at an angle
with a small burr formed at the edge. The height of
these portions of the cut depends on several factors,
including the sharpness of the tools and the clearance
between the tools.
IV.CONSTRUCTION
Raw Material Used-
1. Mild Steel bars for base frame.
2. 35C8 material for shearing blades.
3. Cylinder fittings like fork end, base plates, support
links.
4. Angle section for blade fitting.
5. Connecting link.
6. Blade link.
Ready Items Used-
1. Pneumatic double acting cylinder.
2. Direction & flow control valves.
3. Pneumatic pipe & pipe fittings.
4. Bolts & nuts.
5. Antirust coat & paint.
Machines & Tools Used-
1. Cutting Machine.
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2. Hacksaw Cutting Machine.
3. Sensitive Drilling Machine.
4. Horizontal Milling Machine.
5. Electric Arc Welding Machine.
6. Table Grinder.
7. Hand Grinder.
8. Surface Grinding Machine.
9. Tap & Tap Holder.
Specifications
1. Pneumatic CylinderQuantity:
1
Total Length: 375mm
Bore: 40mm
Stroke: 200mm
Piston Rod Diameter: 20mm
Max Working Pressure: 8 bar
Weight: 3kg
2. DC ValveQuantity:
1
Operation: Manual
Type: Hand Lever, Detent Type
Number of Ports: 5
Number of Positions: 3
Construction: Sliding spool type
3. Pneumatic PipeQuantity:
3000mm
Diameter: 8mm
Thickness: 1mm
4. Fork End NutQuantity:
2
Length: 16mm
Size: M16
5. Cylinder Base Plate BoltsQuantity:
4
Length: 32mm
Size: M6
6. Blade Fixing BoltsQuantity:
3
Length: 25mm
Size: M10
V.PARTS OF MACHINE
1. Pneumatic Cylinder:-
Fig: Schematic diagram of 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 don’t fit the job.
Resources:
Fig: cross sectional view of Pneumatic Cylinder
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
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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 highpressure
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. 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 andretract 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 thepiston; 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.
Rod-style cylinders come in various designs:-
Repairable cylinders can be disassembled to replace
seals and other internal components. This extends a
cylinder’s 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.CompactCylinders 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.GuidedCylinders 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.
Rack-and-pinion:
Units convert a cylinder’s 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.
BellowsAre 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.Rod-less 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 prevents air leaks and dust and dirt
ingression. Other variations include cable-and-pulley
arrangements and magnetically coupled pistons and
carriages.