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“Firmware development services in Bangalore “

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“Electronics design services in Bangalore “

ABSTRACT

DNCL built up embedded design and software design. “Firmware development

services in Bangalore best companies” in http://www.dncltech.com . Software design is at

heart of all intelligent devices. DNCL highly supporting the comprehensive skills set which

spans board supporting and application development and support package and OS porting to

middle ware and testing.

We offer software design services in “embedded software development” based


Moulding is one of the important metals forming process in manufacturing components for various

applications in industry. Casting of any size and shape can be made accurately. Automation in this

field helps to improve the foundry environment and accuracy of the cast parts. Efficiency of

moulding is affected by various parameters like permeability, collapsibility, adhesiveness etc. So it is

a must to avoid defects in casting. The defects occur in sand castings post a great problem in

foundry. On account of defects more than 10% castings are rejected. Even though skilled labor is

employed for ramming operation, the packing of molding sand will not be even throughout the

molding box. So we have selected the idea of fabricating “PNEUMATIC RAMMER”. This rammer is

operated pneumatically. By using this rammer moulding sand will be packed evenly throughout the

box . DNCL provides “electronics product design companies in Bangalore “

The proposed work describes the design and fabrication of prototype of

automatic hammering 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 the

system. This system can replace existing manual feed and operated punching and pressing machines.

By interfacing PLC controls with

the conventional machines, it is possible to achieve good results in the form of

reduced manufacturing lead time, reduced cost and increased safety of the

worker.

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Due to improper ramming the following defects may occur in castings.

BLOW HOLES - Due to very hard ramming

SCAB - Due to veeven ramming of sand

SWELL - Due to very soft ramming

METAL PENETRATION - Due to soft ramming

HOT TEAR - Due to hard ramming

INCLUSIONS - Due to soft ramming

DROPS - Due to soft ramming

Even though skilled labor is employed for ramming operation, the packing of moulding sand

will not be even throughout the moulding box.

So we have selected the idea of fabricating “AUTOMATIC PNEUMATIC RAMMING MACHINE”.

This rammer is operated pneumatically. By using this rammer moulding sand will be packed evenly

throughout the box.

INTRODUCTION

The pneumatic rammer is used for ramming the sand uniformly around the pattern. It can be used

even in small scale industries. To operate this rammer an air compressor is needed. A butt which is

attached to the bottom of the piston rod does the operation of ramming. The pressure developed

inside the cylinder reciprocates the piston and hence the butt. This rammer is handled by an

operator just by moving it over the moulding sand. The butt rams the sand at places moved and the

sand is uniformly rammed. This rammer reduces the ramming time and labor. Due to this the cost is

reduced considerably. So this machine finds application in foundries.

To operate this rammer an air compressor is needed. A butt which is attached to the bottom of the

piston rod does the operation of ramming. The pressure developed inside the cylinder reciprocates

the piston and hence the butt.




“ Any boady looking electronics design companies in Bangalore only one company is there thats

http://www.dncltech.com “. This rammer is handled by an operator just by moving it over the

moulding sand. The butt rams the sand at places moved and the sand is uniformly rammed. This

rammer reduces theramming time and labor. Due to this the cost is reduced considerably. So this

machine finds application in foundries.A pneumatic punching machine is always a better choice than

a hydraulic punching machine for the production of similar products if it is suited for the method. It

is comparatively more economical for production of large quantities of products as it uses

compressed air rather than some hydraulic fluid which is rather expensive. A pneumatic punching

machine uses compressed air to generate high pressure to be applied on the piston. A solenoid valve

controls the directional flow of air into and out of the cylinder. Polyurethane tubes are used for

pressure transmission from the pneumatic cylinder to the punch assembly. The high pressure air fed

to the punch, forces it on the material and as the punch descends upon the sheet, the pressure

exerted by the punch first cause the plastic deformation of the sheet. Since the clearance between

the punch and the die is very small, the plastic deformation takes place in a localized area and the

sheet material adjacent to the cutting edges of the punch & die edges becomes highly stressed,

which causes the fracture to start on both sides of the sheet as the deformation progresses.In

today’s practical and cost-conscious world, sheet-metal parts have already replaced many expensive

cast, forged, and machined products. The reason is obviously the relative economy of operation,

easier implementation for mass-production, as well as greater control on the technical parameters.

In most of the sheet metal operations

punching or pressing operation is the main or initial operation in the process sequence. Automating

this operation results in reduced lead time and also can reduce human effort.Automation can be

defined as the“technology concerned with application of mechanical, electronic and computer-

based systems to operate and control production”.There are many reasons for automating the

process. The reason may be to reduce manufacturing lead time, to increase labor productivity or to

improve the worker safety, etc.

This project is study about the design and fabrication ofpneumatic cutting machine which shows

capability to designmore than one concept and fabricate the machine using avariety of machine.

Other than that, it is important to studieson pneumatic and cutting force analysis which are the

maintopic for this project. So, at the end of this project, we willpracticing on how to build and steps

to follow to complete therequirement for this project. Pneumatic systems usepressurized gases to

transmit and control power. As the nameimplies, pneumatic system typically use air (rather than

someother gas) as the fluid medium because air is safe, low cost andreadily available fluid.

The solar pneumatically cutting machine is designed usingvarious components. The components are

pneumatic cylinder,pressure regulator, Solenoid/direction control valve, flowcontrol valve,

compressor, mounting table, solar panel. Thesolar panel charge the battery that runs the

compressor. Thecylinder is used for up and down motion of the cutting bladewhich performs the

cutting operation on the sheet ofaluminium material. The compressor provides compressed airto the

cylinder, which causes movement of the piston rod.Different pneumatic systems work efficiently at

different operating pressure. Hence selection of pressure regulator of

RELATED WORK (LITERATURE REVIEW)





right range is important for efficient working of pneumatic

system. Pneumatic automation components extensively use

sealing material made out of rubber compounds. For efficient

and trouble free working of these seals, they need to be oiled

or lubricated to reduce friction and corrosion.

Solenoid/Direction control valve is used to control the

direction of the air.

A device which gets heated by the sun’s energy is called

solar heating device. All the solar heating devices are designed

in such a way that they help in collecting as much sunlight as

possible. The solar heating devices such as solar cooker, solar

water h eater and solar cells have greatly helped in solving the

energy problem, its consumption and future energy demands

of our country. Solar energy also reduces our dependence on

fossil fuel .It is a device which converts solar energy directly

into electricity. Since solar energy is a light energy so we can

say, “Solar cell is a device which converts light energy into

electrical energy.

Sand moulding process

Casting process involving the use of sand as a

moulding medium is known as sand moulding

.

Conventional Ramming

Machine

:

The cam is actuated by a user by rotating the handle,

causing a cam to lift the weight and let it fall freely

on the frame at

tached to the ram head. This produces

a standard compacting action to a pre-measured




amount of sand.

Variety of standard specimen for Green Sand and

Silicate based (CO2)sand are prepared using a sand

rammer along with accessories

The sand rammer

machine can be used to measure compatibility of

prepared sand by filling the specimen tube with

prepared sand so that it is level with the top of the tube.

The tube is then placed under the ram head in the

shallow cup and rammed three times. Compatibility

in percentage is then calculated from the resultant

height of the sand inside the specimen tube.

PROPOSED WORK (BLOCK DIAGRAM)




DESCRIPTION OF MACHINE

DESCRIPTION OF COMPONENTS

PNEUMATIC CYLINDER:

Cylinder is a device which converts fluid power into

liner mechanical force and motion. These cylinders

are widely used in industrial pneumatic systems.

These cylinders are also called as linear motors and

reciprocating motors pneumatic cylinders are

designed for a variety of services.




Pneumatic cylinders are designed for a variety of

services. Pneumatic cylinders transforms the flow of

pressured fluid into a push or pull of the piston rod

since out system uses double acting cylinders we

shall see some details about them.

SOLINOID CONTROL VALVE:

The solenoid valve is responsible for reciprocating

motion of the Ram. It is electrically powered. The

trip dogs actuate the solenoid valve.

The directional valve is one of the important parts of a

pneumatic system. Commonly known as DCV, this

valve is used to control the direction of air flow in the




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development and manufacturing.pneumatic system. The directional valve does this by


changing the position of its internal movable parts. This

valve was selected for speedy operation and to reduce

the manual effort and also for the modification of the

machine into automatic machine by means of using a solenoid valve. A solenoid is an electrical

device that

converts electrical energy into straight line motion and

force. These are also used to operate a mechanical

operation which in turn operates the valve mechanism.

Solenoids may be push type or pull type. The push type

solenoid is one in which the plunger is pushed when the

solenoid is energized electrically. The pull type

solenoid is one in which the plunger is pulled when the

solenoid is energized. The name of the parts of the

solenoid should be learned so that they can be

recognized when called upon to make repairs, to do

service work or to install them.

Technical Data:

Size : ¼”

Pressure : 0 to 10 kg / cm2

Media : Air





Working Principle:

Double acting cylinder are controlled by 2 way 5 port

two position valve as shown in the fig. This valve

has one inlet port (P), two cylinder ports (A and B),

and two exhaust ports (R and S).

TIMER CIRCUIT:




Need for a Timer Circuit:

Main purpose to timer circuit is to actuate the solenoid valve at regular interval of time to achieve

proper lubrication at the desired interval. The IC 555 circuit is a highly stable controller capable

of producing accurate time delays or oscillations. In this timing perations, the time is precisely

controlled by one external resistor and a capacitor, by the operation as an oscillator, the free

running frequency accurately contributed with theexternal RC constants. The internal resistors act as

a voltage divider network, providing (2/3)Vcc at the non inverting terminal of the upper comparator

and (1/3)Vcc at the inverting terminal of the lower comparator. In most applications, thecontrol

input is not used, so that the control voltage equals+(2/3) VCC. Upper comparator has a threshold

input (pin 6)and a control input (pin 5). Output of the upper comparator isapplied to set (S) input of

the flipflop.Whenever the threshold voltage exceeds the control voltage, the upper comparator will

set the flipflopand its output is high. A high output from theflipflopwhen given to the base of the

discharge transistor saturates it and thus discharges the transistor that is connected

externally to the discharge pin 7. The complementary signalout of the flipflopgoes to pin 3, the

output. The outputavailable at pin 3 is low. These conditions will prevail untillower comparator

triggers the flipflop.Even if the voltage atthe threshold input falls below (2/3) VCC, that is upper

comparator cannot cause the flipflopto change again. Itmeans that the upper comparator can only

force the flipflop’soutput high.To change the output of flipflopto low, the voltage atthe trigger input

must fall below + (1/3) Vcc. When this occurs,lower comparator triggers the flipflop,

forcing its output low.The low output from the flipflopturns the discharge transistoroff and forces

the power amplifier to output a high. Theseconditions will continue independent of the voltage on

thetrigger input. Lower comparator can only cause the flipfloptooutput low. it is concluded that for

the having low output fromthe timer 555, the voltage on the threshold input must exceedthe control

voltage or + (2/3) VCC. This also turns thedischarge transistor on. To force the output from the

timerhigh, the voltage on the trigger input must drop below +(1/3)VCC. This turns the discharge

transistor off.




ELECTRONIC CONTROL UNIT:-

Here the 555 IC has been used as a multi vibrator.The output of IC 555 is fed to the input pin (pin

no14) of CD 4017 continues counting. The output of the IC becomes available at pin Nos. 3, 2 and 4.

Theoutput pulse of any one of output pin triggers (PutsON) the Triac and current starts flowing

across theload connected. This process continues on other pinsat different time intervals and the

cycle continues.The frequency interval (Time) of the cycle can beadjusted by the pre-set look

connected to pin 6 of 555Timer IC.




IC 555 TIMER

The IC SE / NE 555 monolithic circuit is a highlystable controller capable of producing accurate

timedelays or oscillations. Additional terminals areprovided for triggering or resetting if desired.In

the timing operations, the time is preciselycontrolled by one external resistor and a capacitor, bythe

operation as an oscillator, the free runningfrequency and the duty cycle are both

accuratelycontributed with the external RC constants.The Pneumatic punching machine is

developedusing various components. The components are pneumatic cylinder, pressure regulator,

Solenoid/direction control valve, flow control valve, compressor, mounting table. The cylinder is

used for up and down motion of the punch tool which performs the punching operation on the

sheet of aluminium/plastic material. The compressor provides compressed air to the cylinder, which

causes movement of the piston rod. Pneumatic automation components extensively use sealing

material made out of rubber compounds.For efficient and trouble free working of these seals, they

need to be oiled or lubricated to reduce friction and corrosion. To lubricate compressed air actuated

equipment, the most efficient and economical method is to inject the lubricant in to the compressed

air that powers this equipment. Solenoid/Direction control valve is used to control the direction of

the air.




WORKING PRINCIPLE

The compressed air goes to the flow control valve.The flow control valve is used to control the flow

ofair. It is adjustable one. We have to adjust the lever,so that the required pressurized air goes to

theSolenoid Valve.In our project, the solenoid valve is used as adirection control valve. This solenoid

valve iscontrolled by the electronic control timing unit. Theramming time is varied by adjusting the

timing (timer555 IC) control of the electronic unit.The compressed air goes to the pneumatic

doubleacting cylinder. The ram is fixed at one end of thepneumatic cylinder. The compressed air

pushes thepneumatic cylinder, so that the piston movesdownward by giving air supply in one

direction ofpneumatic cylinder. The solenoid valve is changingthe air flow in the opposite direction

by the smalltime delay. In this time the pneumatic cylinder pistonmoves upward due to changing of

the air flowdirection. This air flow direction is controlled by thesolenoid valve.

The compressed air from the compressor at the pressure of 8 to 12 bar is passed through a pipe

connected to the Solenoid valve with one input. The Solenoid Valve is

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

entering into the input goes out through the two outputs when the timing control unit is actuated.

Due to the high air pressure at the bottom of the piston, the air pressure below the piston is more

than the pressure above the piston. This

moves the piston rod upwards which further moves up the effort arm,

pivoted by control unit. This force acting is passed on to punch which also moves downwards. The

punch is guided by a punch guide which

is fixed such that the punch is clearly guided to the die. The

materials are in between the punch and die. So as the punch descends

down, the material is sheared

to the required profile of the punch and the blank is moved downwards through the die clearance.

The materials of the sheets to be punched are taken as aluminium and plastic as they are replacing

many metals in the present scenario because of their distinguished properties and

features.The compressed air from the compressor at the pressure of 7

to 10 bar is passed through a pipe connected to the Solenoidvalve with one input. The Solenoid

Valve is actuated withControl Timing Unit. The Solenoid valve has two outputs andone input. The air

entering into the input goes out through thetwo outputs when the timing control unit is actuated.

Due to the high air pressure at the bottom of the piston, the air pressurebelow the piston is more

than the pressure above the piston.The material is placed in between the fixed and moving cutter.

When the piston is at the extreme point of the stock length, theexhaust valve is opened and the air

is exhausted through it andthe pressurized air come in at the top of the piston and it pushesthe

piston downwards. So the one side of the air is pulleddownwards and the other side is lifted




upwards. The timeduration of the succeeding cutting is adjusted with the help ofcontrol timing

unit.Force Calculation for existing punch design

Terms and formulae used:

•Cutting force: -The force which has to act on the stock material in order to cut the blank or

slug.

•Stripping force: -The force developed due to the spring back (or resiliency) of the punched

material that grips the punch.

•Cutting force = Lx t x Tmax

•Stripping force =10% -20% of cutting force

•L= Length of periphery to be cut in mm

•t= Sheet thickness

in mm

•Tmax= Shear strength in N/mm2.

The formula to calculate the press force is as follows

-

•Press force = cutting force + stripping force

Sample Calculation for Aluminium Sheet

Here is a sample calculation to calculate the punching force required for different thickness of

aluminium sheet.

•Total length of cut, L =50 mm.

•If Sheet thickness, t = 1mm.

•Maximum tensile strength of aluminium, Tmax= 180 N/mm2

•Total cutting force = L x t x Tmax

•Total cutting force = 50 × 1 × 180

•Total cutting force = 9000 N

•Stripping force = 15% of the cutting force= 1350 N

•Press force = Cutting force + Stripping force= 9000 N + 1350 N= 10350 N

DESIGINING




INDUSTRIAL APPLICATIONS

The rammer can be handled by an operator without feeling uneasiness. No separate skill is

required to operate this rammer. The operation is quick and hence it is a time saving one. The

operation is easy and consumes less cost. Due to the above reasons it finds its extensive application

in manufacturing industries.




It has an extensive application in both large scale and small scale industries because of its

economy and easy handling.

ADVANTAGES

1. Uniform ramming of sand is obtained by this rammer.

2. The time consumption for ramming is reduced greatly.

3. Skilled labor is not required.

4. Easy operation

5. It can be transported easily from one place to another since dismantling and assembling is

simple.

6. It reduces more labor for ramming operation.

7. Maintenance is easy.

DISADVANTAGES

1. The initial investment is high when compared to hand ramming.

2. Air leakage affects the efficiency.

CONCLUSION

:

RESULT AND DESCUSSION

The rammer can be handled by an operator without

feeling uneasiness. No separate skill is required to

operate this rammer. The operation is quick and

hence it is a time saving one. The operation is easy




and consumes less cost. Due to the above reasons it

finds its extensive application in manufacturing

industries.

It has an extensive application in both large scale and

small scale industries because of its economy and

easy handling. strength Uniform ramming of sand is

obtained by this rammer. The time consumption for

ramming is reduced greatly.

Skilled labor is not required.

Easy operation

It can be transported easily from one place to another

since dismantling and assembling is simple.

It reduces more labor for ramming operation.

Maintenance is easy.

CONCLUSION

Uniform ramming of sand is obtained by this rammer.

The time consumption for ramming is reduced

considerably. It eliminates more labour for ramming

operation and hence the labour cost is reduced.

Skilled labour is not required to operate this machine.

Transportation of this machine is easy. Maintenance

is also easy, The reduction of production time and

elimination of more labour for ramming operation

reduce production cost, thereby the economy is

greatly achieved.

Pneumatically operated punching

machine is suitable for small scale and

medium size industries. Based on the shear

provided




on the punch face

the punching force reduction

of

25% to 60% thereby increasing tool life and reducing tool machining cost.

Therefore with this

force reduction we are able to easily punch sheets of thickness upto 2.25

mm for plastic sheet having

tensile strength 90 N/mm2 and upto 1.5

mm of aluminium sheet having tensile strength 180

N/mm2

FUTURE SCOPE:

-

In this machine, compressed air is used to move the punch

tool for carrying

out punching operation. After the completion of the cycle the air moves

out through the out port of

Solenoid

valve. This air is released to the atmosphere. In future the mechanism can be developed to

use this air ag

ain for the working of

cylinder

.

REFERENCES:

P.M.Pradhan, “

Experimental Investigation and Fabrication of Pneumatic Punch”,International Journal of

Innovative Research in Science, Engineering and Technology, Vol. 2, Issue 6, June 2013.

A.S. Aditya Polapragada

& K. Sri Varsha, “




Pneumatic Auto Feed Punching and Riveting Machine “,

International Journal of Engineering Research & Technology (IJERT) Vol. 1 Issue 7, September -2012

ISSN: 2278-0181.

U.P. Singh, “Design Study of the Geometry of a Punching tool”,

Journal of Materials Processing

Technology, 33 (1992) 331-345 Elsevier.

P.C.Sharma, “Methods of reducing Cutting Forces”, Pages 63-66, Production Engineering, Ninth

edition, 2004, S. Chand & Company Ltd.

E. Paul. Degarmo, “Shearing in Metal Cutting”, Pages 518-528, Materials and Processes in

Manufacturing,

Eighth edition, 2003, Prentice Hall of India

Pvt Ltd.

K. Mahadevan, Design Data Handbook, Third edition, Reprint 2002, CBS Publishers & distributors

Aditya Polapragada, Sri Varsha, “Pneumatic Auto Feed Punching and

Riveting Machine”, International Journal of Engineering Research &Technology (IJERT), Vol. 1 Issue 7,

September –2012, ISSN: 2278-0181.

Vijaylaxmi.G.Biradar, Siddharam Patil , R M Lathe, “Automation of Sheet

Bending Machine Using Electro Pneumatic Devices” International Journal of Scientific & Engineering

Research Volume 3, Issue 9, September-2012 1 ISSN 2229-5518.

Handbook of die design, Second Edition, 2006, McGraw-Hill Handbooks, Ivana Suchy.

Materials Handbook, Fifteenth Edition, 2008, Mc-Graw-Hill Handbooks, George.S.Brady,

Henry.R.Clauser.

Design data book- P.S.G. Tech.

Pneumatic hand book- R.H.Warrning




i. Machine tool design hand book - Central

machine tool Institute,

ii. Bangalore.

Strength of materials- R.S.Kurmi

Manufacturing Technology- M.Haslehurst


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