A PROJECT REPORT ON:

PNEUMATIC VICE
SUBMITTED BY:

AMITKUMAR S. PRASAD A. PATIL ROHIT YADAV SANDEEP BHARTI.

THIS MACHINE IS DESIGNED AND MANUFACTURED UNDER THE GUIDANCE OF:

PROJECT GUIDE: Prof S.G.MATE

H.O.D.: Prof J.S.THOMBRE

THE DEPARTMENT OF: MECHANICAL ENGINEERING PARSHVANATH CHARITABLE TRUSTS M. M. J. SHAH POLYTECHNIC THANE (WEST) YEAR 2010-11

PARSHWANATH CHARITABLE TRUSTS

This is to certify that this report is submitted by . .

Enrollment No.

Seat No.

Third Year Diploma in Mechanical Engineering has satisfactorily completed the Project work of STUDY OF PNEUMATIC VICE in academic year 2010-2011 as prescribed in the curriculum of Maharashtra State Board of Technical Education.

PROJECT GUIDE

H.O.D.

PRINCIPAL

EXAMINER

PARSHWANATH CHARITABLE TRUSTS

I Mr.

, Roll No.

Seat No.

A student of THIRD YEAR of course MECHANICAL ENGINEERING humbly submit that I have completed from time to time the project work as described in this report by my own skills and study between the period from 2010-2011 as per the instruction / guidance of Prof. S.G. MATE And the following students were associated with me for this work. However, the teacher has approved quantum of my contribution

AMITKUMAR S. ROHIT YADAV

PRASAD A. PATIL SANDEEP BHARTI

Date: -

(Signature of the student)

ACKNOWLEDGEMENT
NO PROJECT COULD BE CONSIDERED COMPLETE, WITHOUT A WORD OF APPRECIATION FOR ALL THOSE WHO CONTRIBUTED TO THE PROJECT.

WE ARE DEEPLY INDEBTED TO OUR GUIDE, PROF. S. G. MATE, WITHOUT WHOM, IT WOULD NOT BE POSSIBLE TO COMPLETE THE PROJECT. WE ARE ALSO THANKFUL TO THE IDEAS AND ENCOURAGEMENT GIVEN TO US BY HIM.

WE ALSO GREATLY THANK TO SHIEKH SIR, FROM THE WOKSHOP DEPARTMENT; FOR HELPING US IN FABRICATION OF THE SELF-DESIGNED FRAME.

SPECIAL THANKS TO RESPECTED PRINCIPLE, PROF. S. M. SILASKAR, FOR HIS KINDLY SUPPORT.

WE WOULD ALSO THANK OUR ENTIRE STAFF & WORKSHOP MEMBERS FOR THEIR APPRECIATION AND SUGGESTIONS.

CONTENTS
1) IMPORTANCE OF PNEUMATICS. 2) INTRODUCTION TO PNEUMATIC VICE. 3) TYPES OF PNEUMATIC VICE. 4) WORKING PRINCIPLE OF PNEUMATIC VICE. 5) DESIGN PROCEDURE. 6) DETAILS OF COMPONENTS. 7) DRAWINGS OF COMPONENTS. 8) ASSEMBLY & MANUFACTURING. 9) PLANNING PROJECT. 10) APPLICATION. 11) LIMITATION. 12) MODIFICATION. 13) COST ESTIMATION. 14) BIBLIOGRAPHY. 15) CONCLUSION.

IMPORTANCE

Importance of Pneumatics
MECHANIZATION is broadly defined as replacement of manual effort by mechanical power. In all degree of mechanization, the operator remains an essential part of the system, all though with changing demands on physical inputs as the degree mechanization is incased. 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 installed, and manual machines can be mechanized with only moderate capital expenditure. Where the compressed air service are extended however additional compressors may have to be meet the demand for alternative system.

INTRODUCTION

Introduction to Pneumatic Vice

The Vice machine is one of the most important machine tool in the workshop. As regards it is important it is second only to the lathe. Although its primarily designed to hold the work piece. It can perform a number of similar operations. In vice machine the work piece is held tightly. Energy efficiency of Pneumatic circuits is far too often sacrificed to cost and design convenience. In the past, the pneumatics industry has approached energy considerations primarily from the point of view of improving the efficiency of components. For example, considerable effort has been devoted to improving the efficiency of the pump to the extent that one can now obtain units with volumetric efficiencies of 98%.

Types Of Vice
Pneumatic vice are made in different types & size, each designed to handle a class of work or specified job to the best advantage of machine. The different types of Pneumatic vice are: 1. DRILL VICE.

2. BENCH VICE.

3. MILLING VICE.

WORKING PRINCIPLE

Working Principle
This is a product has been producing by orcan, manufacturer of rear jaw sliding bench vices since 1978. The pneumatic machine vice provide highest clamping force at the minimal effort, hence decreasing the operatos fatigue and enhances the work ability dramatically. Also, its accuracy ground top and bottom faces ensures full stability. Key benefits: in-built sophisticated piston mechanism; clamping power of 4500 n at 7 bar [100 psi] air pressure; ground and hardened tool steel jaws for perfect parallelism; thread rolled screw with lock nut to clamp various length jobs; and steel moving jaw to eliminate pressure drop and slightest of air leakage. This vice is available in

100 mm jaw width.

The 4-way spool valve can be controlled by using two operators, one on each end or by a spring return and a single operator. The flow path when actuated at the 14 end of the valve is from port 1 to port 4 and from port 2 to port 3. Port 5 is blocked. When the valve is actuated from the 1 2 end, the flow path is from port 1 to port 2 and from port 4 to port 5. Port 3 is blocked. Each cylinder port has a separate exhaust port.

Specification of Pneumatic Vice

Maximum holding capacity Pneumatic Shaft Cylinder 30-40cm

5cm

Pneumatic Power Kg/cm2 Overall Height Weight Table Size

5 kg/cm2 5 Inch 26 Kg 720mm*350mm

Assembly and Manufacturing

A Pneumatic operated machine is low cost automation today, there is vast competition in the industry.

There should be low input and high output i.e. reduction in price at increase in efficiency of Pneumatic Vice. Expertise of worker is not required as it is manufactured and design for any layman to operate basic media of pneumatic is air which is supplied by compressor in about 90 % of the industries have a compressor which are the basic media of compressor.

Manufacturing Assembly
First start the manufacturing of the sliding assembly. For Sliding table downtail mechanism is

used. For upper sliding plate make angular slot of depth as shown. Lower plate make size of part which is easily slide with upper table. At right side make thorough hole of lower Plate. Assemble the piston rod of double acting cylinder with thorough hole by using screw joint. Assembly of table and cylinder is fixed to machine through lock nut. The assembly of Double acting cylinder, which is used to give horizontal motion. Cylinder is fixed to motor body by screw joint and vice is fixed to table by nut.

DETAILS OF COMPONENTS

Reciprocating Air Compressors

Reciprocating air compressors are positive displacement machines, meaning that they increase the pressure of the air by reducing its volume.They are available in great variety This means they are taking in successive volumes of air which is confined within a closed space and elevating this air to a higher pressure. The reciprocating air compressor accomplishes this by a piston within a cylinder as the compressing and displacing element. Single-stage and two-stage reciprocating compressors are commercially available.

Single-stage compressors are generally used for pressures in the range of 70 psig to 100 psig.

Two-stage compressors are generally used for higher pressures in the range of 100 psig to 250 psig.

Note that

1 HP ~ 4 CFM at 100 psi

and that 1 to 50 HP are typically for reciprocating units. Compressors 100 hp and above are typically Rotary Screw or Centrifugal Compressors. The reciprocating air compressor is single acting when the compressing is accomplished using only one side of the piston. A compressor using both sides of the piston is considered double acting.

Load reduction is achieved by unloading individual cylinders. Typically this is accomplished by throttling the suction pressure to the cylinder or bypassing air either within or outside the compressor. Capacity control is achieved by varying speed in engine-driven units through fuel flow control.

Reciprocating air compressors are available either as air-cooled or water-cooled in lubricated and non-lubricated configurations and provide a wide range of pressure and capacity selections. A reciprocating compressor uses the reciprocating action of a piston inside a cylinder to compress refrigerant. As the piston moves downward, a vacuum is created inside the cylinder. Because the pressure above the intake valve is greater than the pressure below it, the intake valve is forced open and refrigerant is sucked into the cylinder. After the piston reaches its bottom position it begins to move upward. The intake valve closes, trapping the refrigerant inside the cylinder. As the piston continues to move upward it compresses the refrigerant, increasing its pressure. At a certain point the pressure exerted by the refrigerant forces the exhaust valve to open and the compressed refrigerant flows out of the cylinder. Once the piston reaches it top-most position, it starts moving downward again and the cycle is repeated.

Construction of Compressor
The costruction of reciprocating compressor is similar to that of internal combustion engine Consisting of a cast iron or alluminium body with an oil tank the base, piston with piston rings, valves, bearings, etc. As the Piston is drawn in air is sucked through the suction valve via filter and its compressed in return stroke. Various external parts of a reciprocating type air compressor as shown in fig. Parts of reciprocating air compressor : 1) 2) 3) 4) 5) 6) 7) 8) Water outlet valve Air outlet valve Safety valve Pressure gauge Pressure switch Air receiver or tank Base for electric motor Safety guard

9) Intake filter 10) Compressor stand 11) Oil reservoir

Double Acting Cylinder

Rod Design
Due to the forces acting on the cylinder, the piston rod is the most stressed component and has to be designed to withstand high amounts of bending, tensile and compressive forces. Depending on how long the piston rod is, stresses can be calculated differently. If the rods length is less than 10 times the diameter, then it may be treated a a rigid body which has compressive or tensile forces acting on it. In which case the relationship is: F = A()

Where: F is the compressive or tensile force A is the cross-sectional area of the piston rod is the stress However, if the length of the rod exceeds the 10 times the value of the diameter, than the rod needs to be treat and a column and bucking needs to be calculated as well.[7] [edit]Instroke and Outstoke Although the diameter of the piston and the force exerted by a cylinder are related, they are not directly proportional to one another. Additionally, the typical mathematical relationship between the two assumes that the air supply does not become saturated. Due to the effective cross sectional area reduced by the area of the piston rod, the instroke force is less than the outstroke force when both are powered pneumatically and by same supply of compressed gas.

The relationship, between force on outstroke, pressure and radius, is as follows: With the same symbolic notation of variables as above, but also A represents the effective cross sectional area. On instroke, the same relationship between force exerted, pressure and effective cross sectional area applies as discussed above for outstroke. However, since the cross sectional area is less than the piston area the relationship between force, pressure and radius is different. The calculation isn't more complicated though, since the effective cross sectional area is merely that of the piston less that of the piston rod. For instroke, therefore, the relationship between force exerted, pressure, radius of the piston, and radius of the piston rod, is as follows: Where:

F represents the force exerted r1 represents the radius of the piston r2 represents the radius of the piston rod is pi, approximately equal to 3.14159.

FLOW CONTROL VALVE

Features:

Elbow Meter-in , meter-out and in-line pneumatic flow valve configurations Inch and metric flow control valve sizes available NPT and BSPT (R) threads available Tough thermoplastic bodies, stainless steel tube gripping claws, nickel-plated threads with preapplied Teflon sealant (O-ring on #10-32 and M5 threads) Air control valve bodies can be rotated after installation

Release rings are color coded to differentiate between meter-in and meter-out For use with air pneumatics only. Working pressure: -29.5 Hg to 150 psi. Working Temperature 32 to 140F (0 to 60C)
Serial number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Name Valve body Pin Washer Valve body O-ring Valve element Valve body O-ring Y-ring seal Bearing Front piston rod C-ring seal Wear ring Piston Middloe cover Tube O-ring Head cover Tie rodnut Bolt Head pistun rod Tie rod Rod cylinder tube Head cylinder tube

Inner construction

22

Rod cover

This valve is double-position flow adjustable type. When the air come into the bore P2, this valve is closed. This valve is totally opened when the air come into the bore P1 and P3.When the air come into bore P4,this valve is hale-opened. That rate is half-diminished also means the flowing. Att: When this kind of valve is working, make sure the inlet Airs pressure of P3 and P4 is 0.1Mpa bigger than P1and P2.Otherwise,the valve-element cant keep balance.

Selection of Pipeline for Pneumatic System

In most of the plants the air compressor is positioned at a distance away from the main shop and installation area , i.e. from the actual point of consumption due to reason related to machine safety and other operational problems like transmission of vibrations to other equipments The compressed air is stored in air receiver from which the air is drawninto the consumer point by means of pipeline. While laying out the pneumatic pipeline system, should take sufficient

take and pay due attention so that pressure does not drop from generating point to point of consumption remains as low as possible. The following factors are taken into account while selecting pneumatic pipes and other air line installation :1) Pressure of compressed air in the line. 2) Total nflow rate per unit time through the line. 3) Permissible pressure drop in the line. 4) Type of tube material and type of line fittings. 5) Length and dia. Of tube or other pipelines. 6) Working environment etc.

Pipe Materials :Galvanized iron pipes Cast iron pipes Copper tubes

Aluminium tubes Rubber hose Plastic and nylon hose High strength steel pipes Brass tubes Reinforced rubber or plastic hose3 etc.

DESIGN PROCEDURE

Design Procedure
List of parts to be designed: 1. 2. Frame. Double acting cylinder.

Design of pillars:

Material selection for pillars are angle bars Materials make M. S. Specification: Carbon percentage 8% Specific weight 0.0785 N/cm Melting point - 1510C Modulus of elasticity 2.080 * 10 N/mm Tensile stress (t) 120 Mpa Compressive stress (c) 140 Mpa Shear stress ( ) 70Mpa Ultimate stress 810 to 870 Mpa Brinell hardness 137 For design of pillars, we must consider the weight of cylinder, mountings, tank, impact load, etc. Hence, Weight of cylinder 6.44Kg

Design procedure piston rod of double acting cylinder.

Max load= Applied pressure x bore area W = P (kg/mm2) x /4 (dia. of bore)2 W = 0.05 x /4(40)2 W = 63.2N

Due to load W piston of vice moves in forward and reverse direction holding the work piece.

Piston rod of this cylinder may be failed due to compression failure.

W = /4 x dc2 x fc induced. 63.2 = /4 x 10 x fc induced. fc induced = 8 N/mm2 <fc permissible =70N/mm2

Sr No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Component Used Main Body Pneumatic Cylinder Body Stroke Shaft Pneumatic cylinder fitting plate Alignment Bush Jaw Pneumatic Shaft End Pneumatic Cylinder Lock Nut PU Tube Hand Operated Valve

Material CI Al SS MS Gun Metal Hardened Ms Plate MS SS Plastic Al, Plastic, Fibre, Rubber, SS MS MS Wood

11. 12. 13.

Fitting Bolts And Nuts Angle Frame Wooden Frame

APPLICATION

Application

 It can hold the material like aluminium, gold , Silver,wood, plastic etc. It can hold size of workpiece dia 5-6 cm.

Unless and until we first clamp the workpiece any operation wont start even if any other clamping is pressed. Less fatigue, compact, and easy to handle. Very reliable and instantaneous in action.

Hold the workpiece of accurate position.

LIMITATION

Limitation
Hold Work piece having dia. Greater than 6 cm cant be hold. Large workpiece cant be hold due to small jaw size.

Harder material like Copper, Ag, Gold cannot be hold. As the compressed air is normally saturated with water vapour it leads to corrosion.

 Lubrication is continuously from the system when its working.(exhausted to atmosphere)

MODIFICATION

Modification
We can use fixture instead of workpiece to be hold. The jaw of the vice change from concave to flat.

We can use magnatic table for holding.

 We have designed

COST

ESTIMATION

Cost Estimation
Cost Estimation Aspect :A cost estimate is an attempt to forecast the expenses that may be incurred to the manufacture a product.

Estimation of manufacturing cost for a part of project may be considered as judgement after careful considerations of all factors by calculation to determine amount of labours, material and factory services required to produce the parts. Definations Related To Cost Estimation :Cost :- It is defined as the amount of expenditure incurred in building up the project on or attributable to a given thing. Accounting :It is defined as the art and science of recording business transactions in a methodological manner to show. The deficiency or surplus for a specific period of time. True state of affairs of a business at a particular instance of time.

Cost Accounting Involves : Classifying, recording an appropriate allocation of the expenditure for determination of the cost of products or services. Relation of this cost to sales value. Ascertaining profitability. Basically Cost Estimation Is Of Two Types : Material cost. Matching cost.

Material Cost Estimation :The material cost estimation gives the amount required to get the raw materials, which has to be processed and manufactured to get various components of the machines to be manufactured. The material is divided into two broad categories:-

 Standard purchased items. Material for fabrication components. Standard Purchased items :This includes all the parts, which are able to be included and are brought remanufactured i.e. Standard Parts e.g. Nuts, bolts, Pins, etc. Material For Fabrication Components :This list includes the material, which is obtained raw and is machined and manufactured into components or parts of the machine. Procedure For Calculation Of Material Cost :The general procedure for calculation of material cost estimates is :-

1) After designing the project all the components are listed into two categories the fabricated components and the standard parts. 2) The rates of the standard parts taken and added up. 3) The fabricated components are all taken added,then dimension of the compound are noted and the volume of the material is calculated which is multiplied with the specific gravity of the material to give the weight of the compound. 4) The weight of the components is multiplied to the rate per kg of the material to give material cost of each component. 5) The summarization of all the cost of standard brought components and the cost of all components gives the material cost estimation of the project. Machining Cost Estimation :-

The machining cost estimation gives the time required by machine to construct the component. The estimate of how much time will be required to hire the machine constitute the parts of the machine being manufactured. Procedure For Calculation Of Machining Cost :The procedure followed for the calculation of the machining components time cost is as follows :1) After the machining time has been calculated including allowance for components, each component has different operations and hence rates of machines are different. 2) The machining cost is calculated using standard machine working rates. 3) The time required to do machining on machine is multiplied by the machine rate given to machinery cost. 4) The estimation of all the machining cost of the components gives the machining cost estimation, machining time of components are

essential in order to know the manufacturing cost of components. The total time includes the basic and the various other factors which are taken into considerations.

MATERIAL COST

Material Cost
SR COMPONENTS COST(Rs)

NO. 1. Frame(MS) 2. Frame(Wood) 3. Pneumatic Cylinder 4. Vice 5. PU Tube 6. Flow Control Valve 7. Pneumatic Cylinder Fitting Plate(MS) 8. 9. 10. Fasteners Machining and Labour Painting TOTAL COST =

2000 500 6000 2800 500 1500 200 80 700 200 14,480 Rs

CONLUSION

Conclusion
We realized that this aspect of scientific base yearly pattern is very beneficial and helpful as regard to improve the knowledge and approach of students. The industrial project has helped us to relate the knowledge and practical field, which will surely prove very useful in our near future. The main advantage of industrial project is exposure to the technical environment, which cannot be simulated in the polytechnic. Here we become familiar with various working processes, which are easily and economically adopted by the industries.

We have gained a major knowledge through this project experience. Involvement in the project work also gave us the idea of preparing and presenting the project report. We also developed the skill of communicating and interacting with other people as well as in searching the information from the number of sources. We are thankful to our supervisors to have been given us the opportunity to come across various project field and are confident that it has indeed proved very advantageous. Lastly we would say that we have acquired great practical knowledge, this knowledge gave us valuable technical experience.

REFRENCES

Refrences
1)Elements of workshop technology(volume 1) Hajra choudhary. 2)Elements of workshop technology(volume 2) Hajra choudhary. 3)Course in workshop technologyB.S.Raghu 4)Machine Design N.D.Bhatt. 5)Pneumatic Systems S.R.Majumdar

THE END