International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Index Copernicus Value (2015): 78.96 | Impact Factor (2015): 6.391
Design and Manufacturing of Pneumatic Burr
Removing Machine
Kakde D V1, Lokawar V L2
1
B.E. (Mechanical), Lecturer, MGM’s Polytechnic Aurangabad, Kakde
2
B.E. (Mechanical), Lecturer, MGM’s Polytechnic Aurangabad
Abstract: Many machines today are using of electrical, hydraulic and pneumatic component as a source of system. So, to gain skills
and knowledge on how to develop machine, this paper are recommend. With the title of “Design and Manufacturing of Pneumatic Burr
Removing Machine”, there are many requirements to know such as function of pneumatic component the purpose of this paper is
making Burr removing machine for application of wheel clutch. The greatest advantage of Pneumatic punches is their speed. Pneumatic
punches are approximate 10 times faster than hydraulic punches and they can perform many jobs faster and more efficiently. They can
also be stopped at any time by opening the valves to release the air. Pneumatic punches are extremely flexible, that they can be placed in
a factory in any required position, even upside down. The objective of this paper is to manufacture a pneumatic punching machine
which is necessary for removing the burrs present in the holes of any casting product which saving the manufacturing lead time in the
process and also system is worker safety, By using this system the productivity is also increases
Keywords: Pneumatic, Burr, Flexible, Manufacturing, Design, Clutch, Productivity
1. Introduction uses a punch press to force a tool, called a punch, through
the work piece to create a hole via shearing. The punch often
Pneumatic systems operate on a supply of compressed air. passes through the work into a die. A scrap slug from the
Compressed air must be made available in sufficient hole is deposited into the die in the process. Depending on
quantity and at a pressure to suit the capacity of the system. the material being punched this burr may be recycled and
When the pneumatic system is being adopted for the first reused or discarded. Punching is often the cheapest method
time, however it wills indeed the necessary to deal with the for creating holes in sheet metal in medium to high
question of compressed air supply. The key part of any production volumes. When a specially shaped punch is used
facility for supply of compressed air is by means using to create multiple usable parts from a sheet of material the
reciprocating compressor. A compressor is a machine that process is known as blanking. In forging applications the
takes in air, gas at a certain pressure and compresses the air work is often punched while hot, and this is called hot
& delivered the air at a high pressure. punching.
This project is study about the design and fabricates of Punch tooling (punch and die) is often made of hardened
pneumatic burr removal tool which shows capability to steel or tungsten carbide. A die is located on the opposite
design more than one concept and fabricate the machine side of the work piece and supports the material around the
using a variety of machine. Other than that, it is important to perimeter of the hole and helps to localize the shearing
studies on pneumatic and die for punching tool which are the forces for a cleaner edge. There is a small amount of
main topic for this project. So, at the end of this project, we clearance between the punch and the die to prevent the
will practicing on how to build and steps to follow to punch from sticking in the die and so less force is needed to
complete the requirement for this project. make the hole. The amount of clearance needed depends on
the thickness, with thicker materials requiring more
This project are also provided to familiarize to us about the clearance, but the clearance is always less than the thickness
technology on sheet metal forming which is used pneumatic of the work piece. The clearance is also dependent on the
concept yet has rapidly grown especially in the automotive hardness of the work piece. The punch press forces the
and electrical industry. Furthermore, the strong concern is to punch through a work piece, producing a hole that has a
obtain better product quality with lower cost. Then, cutting diameter equivalent to the punch or slightly smaller after the
and punching are two important processes in the sheet metal punch is removed. All ductile materials stretch to some
industry; the former is flexible in processing while the latter extent during punching which often causes the punch to
is effective in production. To combine the advantages of stick in the work piece. In this case, the punch must be
both, the so-called combination machines that combine the physically pulled back out of the hole while the work is
cutting and punching processes are used in sheet metal supported from the punch side, and this process is known as
processing. Using pneumatic systems is economical and stripping. The whole walls will show burnished area,
environmentally friendly, as air is inexpensive, plentiful and rollover, and die break and must often be further processed.
easily compressed and stored in tanks. The slug from the hole falls through the die into some sort of
container to either dispose of the slug or recycle it.
In this project we use the pneumatic punching principle,
there is we use burr removing tool instead of punches, and
remove the burr. Punching is a metal forming process that
Volume 6 Issue 4, April 2017
www.ijsr.net
Licensed Under Creative Commons Attribution CC BY
Paper ID: ART20172609 1757
International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Index Copernicus Value (2015): 78.96 | Impact Factor (2015): 6.391
2. Literature Survey 4. Model and Specification of Components:
1) According to A.S. Adityapolapragada, K. Sri varsha sthe Cad Design:
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
2) Arun S, sreerajendra and vijayavithalbongalestated
thatThe proposed work describes the design and fabrication
of prototype of automatic punching machine controlled by
PLC and shedding light on the working principle and the
hardware structure of the system. Punching or pressing
process is one of the most important and necessary
processing step in sheet metal industry. By automating this
process one can have a greater control over the process.
Programmable Logic Controllers are used for the control of
Specification of Components
the system. This system can replace existing manual feed
and operated punching and pressing machines. By
Sr. Name of Specifications of Material
interfacing PLC controls with the conventional machines, it No. Material
is possible to achieve good results in the form of reduced 1 Pneumatic Cylinder Tube: bore of 80 mm seamless
manufacturing lead time, reduced cost and increased safety cylinder honed & hard chrome plated steel tube is used.
of the worker. Piston Rod: High tensile steel, Ground & hard
chrome plated.
3. Working Stroke: 125 mm
Seals : Buna "N" ( Nitrile elastomer )
When the system starts working, the hold the work piece in End cover & piston: Close grained cast iron.
fixture provide at the bed. Then supply the compressed air to 2 Hand lever Hand lever: 5 x 2 hand lever
the system. When compressed air is supplied the air going Operating on: air
through various sections i.e. from FRL unit, direction control 03 Connectors ID: 12 mm
valve & finally to the actuator. Tube size: 10 mm
4 P-U tube Material: Polyurethane
When the air is supplied from top side of the actuator then ID: 10 mm
the piston start to move in forward or downward direction OD: 13 mm
and hence the punch holder & punches attached to it are 5 M S plate Material: M. S.
Dimensions: 250 mm x 250 mm
moves in that direction automatically, and hence the burr
Thickness: 8 mm
removal process is done in forward motion. 6 Square bar Material: BRIGHT M. S.
Dimensions: 20 mm x 20 mm
Now we have to remove the work piece from the fixture so Thickness: 400 mm
we have to return the piston in upward direction, so we have 07 Round bar Material: BRIGHT M. S.
to supply the compressed air from the bottom side of the (M S bright) Dimensions: 20 mm
cylinder. For this we have to change the position of the length: 250 mm
direction control valve. Then the direction control valve 8 M S plate Material: M. S.
change the flow direction and supply the air to bottom side, (flat) Dimensions: 40 mm x 200 mm
hence the piston start to move in upward direction. Thickness: 8 mm
9 Nut / bolts 8 mm / 10 mm / 12 mm
10 Allen key 3 mm / 4 mm
After that we replace another work piece and done the same
11 Round plate Material: BRIGHT M. S.
procedure.
(M S ) Dimensions: 60 mm
Thickness: 10 mm
From that process the time required for the burr removing is 12 Roller ID: 20 mm
less as compared to the manually burr removing process. bearings OD: 32 mm
And also the operation is very safety to the workers. And 13 Round bar Material: M. S. (bright)
also increases the accuracy and also increases the (M S Bright) Dimensions: 20 mm x 200 mm
productivity.
Volume 6 Issue 4, April 2017
www.ijsr.net
Licensed Under Creative Commons Attribution CC BY
Paper ID: ART20172609 1758
International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Index Copernicus Value (2015): 78.96 | Impact Factor (2015): 6.391
5. Design Calculations
5.1 Force Calculation Of Cylinder
(Reference: Machine design by R S Khurmi& J K Gupta)
…………..[6]
Cutting Force= Area * Shear Stress = ∏*27*0.7*55.2
=3277.56 N
Stripping Force= 10% To 20% Of Cutting Force
F= 491.63 N
Press Force = Cutting Force + Stripping Force
= 3770 N
5.2 Cylinder Design
Working Pressure of the compressor= 7 bar …….[3]
FORCE = AREA * PRESSURE
Hence the Dia. Of cylinder is= 80 mm
PISTON ROD DIA.= 21 mm
Stroke length = 125 mm
cylinder thrust,
For forward stroke = Area* pressure
=3770 N
For return stroke = 2086.84 N
5.3 Punch Specification
The outer punch size is 8mm
The smaller punch size is 5mm
The inner biggest punch size is 29.5mm
6. Conclusion
We have done this project in the MADHURA DIE-
CASTING PVT. LTD. For the removal of burr from the
wheel clutch. By implementing this project we conclude that
the process is become faster & productivity is increases by
1320 pieces, also they have saving the cost of wages which
they have pay to the worker because there is the reduction of
worker, before implementation of project they require 3
workers and after implementation of project require only 1
worker. They saves the cost approx per month Rs. 18000/-
References
[1] A.S. Adityapolapragada, K. Sri varsha-“Pneumatic auto
feed punching and riveting machine”
[2] Arun S, sreerajendra and vijayavithalbongale -
“Automatic punching machine: A low cost approach”
vol-4 (2014)
[3] A. K. Gupta, P. Bharadwaj, S. Sahgal, P. M. Pradhan -
“Experimental investigation and fabrication of pneumatic
punch” Vol-2, issue 6, june 2013.
[4] M.J. Lawrence, D. R. Buckmaster, W. J. Lamont, jr.-“A
pneumatic dibbling machine for plastic mulch”
[5] K. Shanmugasundarama, M. Prakashb- “Study on impact
of cad / cam tools on production of punched cards by
indian silk saree designers for handloom industry”
[6] R S Khurmi& J K Gupta- A text book of “ Machine
design” vol-1.
Volume 6 Issue 4, April 2017
www.ijsr.net
Licensed Under Creative Commons Attribution CC BY
Paper ID: ART20172609 1759
