Pneumatic Paper Plate Making Machine - MECHANICAL ENGINEERING PROJECT REPORT

 

CHAPTER-1

INTRODUCTION

 

            The pneumatic paper making press is used to different shapes of plate in faster production rate. The principle of operation is the same as the conventional simple press.  The difference is only in the type of drive and the type of fixtures used

        

The following points reveals why we have to make use of this type of press

• Pneumatic paper making press reduces the manual work.
• This type of machine reduces working time.

 

            By using this machine the bearings can be inserted in the various lengths of shat (up to 600mm

 

Title: Fabrication of Pneumatic Paper Plate Making Machine

 

CHAPTER-2

LITERATURE REVIEW

 

 

1. Design and Fabrication of Pneumatically Operated Paper Plate Making Machine Author: Vignesh K, Porkalan S, Pradhap Kumar M, Prasanna Venkatesh S, Packiyaraj M. In this paper they compared Pneumatic system versus hydraulic system and mechanical system in terms of maintenance, cost and accuracy. Their scope of the project was making the cost of the paper plate making machine as low as possible and increasing its efficiency.

 

2. Design for manufacture and assembly of a paper plate making machine in a developing nation Author: Kudakwashe N. Masengere, Tawanda Mushiri . This paper is on the layout for manufacture and meeting of a paper plate making machine for a growing financial system which can be regionally synthetic within an earnings and expenditure that fits to maximum small to medium corporations. A deeper know-how of the paper plate making system changed into carried out with the aid of the internet, scholarly journals and commercial visits to local businesses.

 

3. Fabrication of pneumatically operated paper plate and dish making machine Author: Ashwini Masurkar, Rushikesh Kolape, Sneha More, Yogesh Mane, prof. Dinesh Pargunde. This paper is based totally on the manufacture and assembly of an air-cooled paper plate and a dishwasher. Paper plates particularly contain plastics. And plastic is the maximum risky substance inside the surroundings. With the assist of this mechanical machine paper plates are made from any kind of paper and the leaves are also used to make plates. After learning how the modern gadget makes paper plates, we got here up with an inexpensive solution for making paper plates and bowls. This length of paper plate making device is free to healthy anywhere and could be very cost-effective as properly. On this system we use the most primary techniques to improve the performance of our undertaking

CHAPTER-3

PROBLEM STATEMENT

 

 

            The problem addressed in this project is the need for an efficient and cost-effective pneumatic paper plate making machine. Traditional paper plate making methods are often labor-intensive and time-consuming. Therefore, there is a requirement to develop an automated system that can produce paper plates quickly and with minimal human intervention.

 

3.1 Existing System:

            The existing paper plate making machines available in the market are mostly mechanical or semi-automatic. They require manual feeding of paper, folding, and sealing operations, which can be time-consuming and prone to errors. These machines may lack the precision, speed, and efficiency needed for large-scale plate production.

 

3.2 Proposed System:

            The proposed system aims to overcome the limitations of the existing systems by developing a fully automated pneumatic paper plate making machine. This machine will utilize pneumatic actuators and sensors to automate the feeding, folding, sealing, and ejecting processes. It will incorporate intelligent control mechanisms to ensure accurate plate dimensions and high production efficiency.

CHAPTER-4

OBJECTIVES

 

• Design and fabricate a pneumatic paper plate making machine capable of producing plates of various sizes.
• Develop an automated feeding mechanism for continuous paper feeding.
• Implement a folding mechanism to fold the paper into plate shapes.
• Integrate a sealing mechanism to securely seal the plates.
• Incorporate an ejection system to release the finished plates.
• Design an intelligent control system for precise plate dimensions and production speed control.
• Ensure the machine's safety and reliability during operation.

 

CHAPTER-5

METHODOLOGY

 

The project will follow these steps:

            We followed a series of steps that will guide us to solve the problems and fulfill the project objectives.

• Firstly we concentrated on designing the dimensions of the various components such as the punch, die and the frame.
• We further analysed the loading conditions required for the manufacturing of paper (leaf) plate using the pneumatic system as the main operating
• We also tried to find out the different ways in which the pneumatic plates are made in today’s industry.
• By taking a survey on the internet we found that the plate making industries have equipments which are much more expensive and are not affordable to the small scale industries and thus they are not able to make profit.
• We further took a look at the die manufacturers as well as the frame manufacturers and the pneumatic cylinder supplying dealers.
• We then further collected all the components and we went on towards the assembling of the components.
• We faced many difficulties while assembling, as there were many issues regarding the fittings of the components.
• After facing many difficulties, we finally were able to complete our project successfully with the help of our guide Prof. Mr. Vishwas Palve sir

CHAPTER-6

WORKING PRINCIPLE AND BLOCK DIAGRAM

 

             In this paper plate making machine there is a double acting cylinder which is a pneumatic device a punch, die, screw rod, top plate, bottom plate, direction control valve, flow control valve, connectors and hoses. A compressor supplies high pressure air to the cylinder, whose flow is controlled by a flow control valve. The air passes through a direction control valve. This is used to actuate the piston and to specify its direction of movement. The piston is connected to a ram.

 

            At the end of the ram punch is fastened. The die in the ram can be replaced. The piston, ram and punch are the moving parts in this machine. The die is fixed on the base of the machine by screw rods.   The height of the base can be adjusted by rotating the screw rod. The whole unit is fixed on the column. When the air flows through the flow control valve, its volume is restricted to the specified amount. Then the direction control valves control the part of cylinder which it should ocplatey.

 

            When it ocplateies part A of the cylinder, it moves the ram downwards along with the punch. The punch, punches the paper kept over the die. The paper will be wet. To recover the wetness and make the shape stable a heating coil is placed in the die.   Next, direction control valves are actuated which makes the air to flow in part B of cylinder. Due to air in part A is released to the atmosphere by a valve. This makes the punch to move upwards. The plate can be taken out and the next paper can be placed over the die for the next cycle.

PNEUMATICS

 

Pneumatic Cylinder

 

            The word ‘pneumatic’ comes from Greek and means breather wind. The word pneumatics is the study of air movement and its phenomena is derived from the word pneuma. Today pneumatics is mainly understood to means the application of air as a working medium in industry especially the driving and controlling of machines and equipment.

 

             Pneumatics has for some considerable time between used for carrying out the simplest mechanical tasks in more recent times has played a more important role in the development of pneumatic technology for automation.

 

            Pneumatic systems operate on a supply of compressed air which must be made available in sufficient quantity and at a pressure to suit the capacity of the system. When the pneumatic system is being adopted for the first time, however it wills indeed the necessary to deal with the question of compressed air supply.

The key part of any facility for supply of compressed air is by means using reciprocating compressor. A compressor is a machine that takes in air, gas at a certain pressure and delivered the air at a high pressure.

 

          Compressor capacity is the actual quantity of air compressed and delivered and the volume expressed is that of the air at intake conditions namely at atmosphere pressure and normal ambient temperature.

 

            The compressibility of the air was first investigated by Robert Boyle in 1962 and that found that the product of pressure and volume of a particular quantity of gas.

 

The usual written as

            PV = C    (or) Pı Vı = P2 V2

 

           In this equation the pressure is the absolute pressured which for free is about 14.7 Psi and is of courage capable of maintaining a column of mercury, nearly 30 inches high in an ordinary barometer. Any gas can be used in pneumatic system but air is the mostly used system now a days.

 

SELECTION OF PNEUMATICS:

          Mechanization is broadly defined as the replacement of manual effort by mechanical power.  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, which is capable of providing both the power or energy requirements and the control system (although equally pneumatic control systems may be economic and can be advantageously applied to other forms of power).

 

            The main advantages of an all-pneumatic system are usually economy and simplicity, the latter reducing maintenance to a low level.  It can also have out of standing advantages in terms of safety.

 

PRODUCTION OF COMPRESSED AIR

 

Air Compressor

 

            Pneumatic systems operate on a supply of compressed air, which must be made available, in sufficient quantity and at a pressure to suit the capacity of the system. When pneumatic system is being adopted for the first time, however it wills indeed the necessary to deal with the question of compressed air supply.

 

         The key part of any facility for supply of compressed air is by means using reciprocating compressor. A compressor is a machine that takes in air, gas at a certain pressure and delivered the air at a high pressure.

 

         Compressor capacity is the actual quantity of air compressed and delivered and the volume expressed is that of the air at intake conditions namely at atmosphere pressure and normal ambient temperature.

 

         Clean condition of the suction air is one of the factors, which decides the life of a compressor. Warm and moist suction air will result in increased precipitation of condense from the compressed air. Compressor may be classified in two general types.

 

Positive displacement compressor

Turbo compressor

 

            Positive displacement compressors are most frequently employed for compressed air plant and have proved highly successful and supply air for pneumatic control application.

 

The types of positive compressor

Reciprocating type compressor

Rotary type compressor

            Turbo compressors are employed where large capacity of air required at low discharge pressures. They cannot attain pressure necessary for pneumatic control application unless built in multistage designs and are seldom encountered in pneumatic service.

 

AIR PIPE

 

Air Pipe

 

            A pipe is a tubular section or hollow cylinder, usually but not necessarily of circularcross 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. A pipe is a tubular section or hollow cylinder, usually but not necessarily of circularcross 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.

PNEUMATIC CIRCUIT:

            PNEUMATIC CONTROL SYSTEMS can be designed in the form of pneumatic circuits. A pneumatic circuit is formed by various pneumatic components, such as cylinders, directional control valves, flow control valves, etc. Pneumatic circuits have the following functions:

• To control the injection and release of compressed air in the cylinders.
• To use one valve to control another valve

 

PNEUMATIC CIRCUIT DIAGRAM:

            A pneumatic circuit diagram uses pneumatic symbols to describe its design. Some basic rules must be followed when drawing pneumatic diagrams. i) A pneumatic circuit diagram represents the circuit in static form and assumes there is no supply of pressure. The placement of the pneumatic components on the circuit also follows this assumption. ii) The pneumatic symbol of a directional control valve is formed by one or more squares. The inlet and exhaust are drawn underneath the square, while the outlet is drawn on the top. Each function of the valve (the position of the valve) shall be represented by a square. If there are two or more functions, the squares should be arranged horizontally Fig: 1

CONSTRUCTION AND DESIGN

            For this model we are used pneumatic cylinder which have 100mm internal diameter and 50 mm stroke. For body we used mild steel material.

Further information given as follow:

 

Dimension of Model:

 

 

Fig. Front View and Side View of C Frame body

 

Top view and Front View of Ram

 

Machine Die

 

CALCULATION RELATED TO PNEUMATIC CYLINDER:

DIMENSION

• Cylinder type – double acting
• Internal diameter; D – 100 mm
• Stroke – 50 mm
• Piston rod diameter; d – 20 mm
• Maximum working pressure; P – 100 psi ( 7bar )

SPECIFICATION OF PNEUMATIC CYLINDER

• Cylinder thrust in forward stroke F = F = F = 549.77 550 kg
• Cylinder thrust in return stroke F = F = F = 351.85 kg
• Theoretical air consumption calculation

 

Free air consumption in liters for forward stroke

            C = 3.141 liters

 

Free air consumption in liters for forward stroke; C

C = C =

C = 2.0106 liters

            Hence for one complete one cycle of operation for this cylinder, the free air consumption will be (3.141 + 2.106 = 5.1516 liters)

 

MOUNTING TYPES

• Front plate mounting
• Rear plate mounting
• Double trunion mounting
• Centretrunion mounting
• Neck mounting
• Leg mounting
• Hinge mounting

            But we are select “Front type mounting” because it‟s suitable for our project construction

 

SAFETY MEASURES WHEN USING PNEUMATIC CONTROL SYSTEMS

• Compressed air can cause serious damage to the human body if they enter the body through ducts like the oral cavity or ears.
• Never spray compressed air onto anyone.
• Under high temperature, compressed air can pass through human skin.
• Compressed air released from the exhaust contains particles and oil droplets, which can cause damage to eyes.
• Even though the pressure of compressed air in pipes and reservoirs is relatively low, when the container loses its entirety, fierce explosions may still occur.
• Before switching on a compressed air supply unit, one should thoroughly inspect the whole circuit to see if there are any loose parts, abnormal pressure or damaged pipes.
• A loose pipe may shake violently due to the high pressure built up inside it. Therefore, each time before the system pressure is increased; thorough inspection of the entire circuit is required to prevent accidents.
• As the force produced by pneumatic cylinders is relatively large, and the action is usually very fast, you may suffer serious injuries if you get hit by a cylinder.
• Switches should be installed on the compressed air supply unit to allow easy and speedy control of air flow.
• In case of a leakage, the compressed air supply unit should be turned off immediately.
• The compressed air supply unit must be turned off before changes can be made to the system.
• Stay clear of the moving parts of the system. Never try to move the driving parts in the mechanical operation valve with your hand.

 

 

INTRODUCTION TO WELDING PROCESS

INTRODUCTION

            Welding is a process in which two or more parts are joined permanently at their touching surfaces by a suitable application of heat and/or pressure. Often a filler material is added to facilitate coalescence. The assembled parts that are joined by welding are called a weldment. Welding is primarily used in metal parts and their alloys.

 

WELDING PROCESSES ARE CLASSIFIED INTO TWO MAJOR GROUPS:

1. Fusion welding: In this process, base metal is melted by means of heat. Often, in fusion welding operations, a filler metal is added to the molten pool to facilitate the process and provide bulk and strength to the joint. Commonly used fusion welding processes are: arc welding, resistance welding, oxy fuel welding, electron beam welding and laser beam welding.
2. Solid-state welding: In this process, joining of parts takes place by application of pressure alone or a combination of heat and pressure. No filler metal is used. Commonly used solid-state welding processes are: diffusion welding, friction welding, ultrasonic welding.

 

            Arc welding and similar processes Arc welding is a method of permanently joining two or more metal parts. It consists of combination of different welding processes wherein coalescence is produced by heating with an electric arc, (mostly without the application of pressure) and with or without the use of filler metals depending upon the base plate thickness. A homogeneous joint is achieved by melting and fusing the adjacent portions of the separate parts. The final welded joint has unit strength approximately equal to that of the base material. The arc temperature is maintained approximately 4400°C. A flux material is used to prevent oxidation, which decomposes under the heat of welding and releases a gas that shields the arc and the hot metal. The second basic method employs an inert or nearly inert gas to form a protective envelope around the arc and the weld. Helium, argon, and carbon dioxide are the most commonly used gases.

 

SHIELDED-METAL ARC (SMAW) OR STICK WELDING

            This is an arc welding process wherein coalescence is produced by heating the work piece with an electric arc setup between a flux-coated electrode and the work piece. The electrode is in a rod form coated with flux. Figure M6.1.1 illustrates the process.

 

Shielded-Metal Arc (SMAW)

 

SUBMERGED ARC WELDING (SAW)

            This is another type of arc welding process, in which coalescence is produced by heating the work piece with an electric arc setup between the bare electrode and the work piece. Molten pool remains completely hidden under a blanket of granular material called flux. The electrode is in a wire form and is continuously fed from a reel. Movement of the weld gun, dispensing of the flux and picking up of surplus flux granules behind the gun are usually automatic. Flux-Cored Arc Welding (FCAW)

 

FLUX-CORED ARC WELDING (FCAW)

            This process is similar to the shielded-arc stick welding process with the main difference being the flux is inside the welding rod. Tubular, coiled and continuously fed electrode containing flux inside the electrode is used, thereby, saving the cost of changing the welding. Sometimes, externally supplied gas is used to assist in shielding the arc.

GAS-METAL ARC WELDING (GMAW)

            In this process an inert gas such as argon, helium, carbon dioxide or a mixture of them are used to prevent atmospheric contamination of the weld. The shielding gas is allowed to flow through the weld gun. The electrode used here is in a wire form, fed continuously at a fixed rate. The wire is consumed during the process and thereby provides filler metal. This process is illustrated in Figure M6.1.2

 

Gas-Metal Arc Welding

 

GAS-TUNGSTEN ARC WELDING (GTAW)

            This process is also known as tungsten–inert gas (TIG) welding. This is similar to the Gas Metal Arc Welding process. Difference being the electrode is non consumable and does not provide filler metal in this case. A gas shield (usually inert gas) is used as in the GMAW process. If the filler metal is required, an auxiliary rod is used

 

Plasma Arc Welding (PAW)

PLASMA ARC WELDING (PAW)

            This process is similar to TIG. A non-consumable electrode is used in this process. Arc plasma is a temporary state of gas. The gas gets ionized after the passage of electric current and becomes a conductor of electricity. The plasma consists of free electrons, positive ions, and neutral particles. Plasma arc welding differs from GTAW welding in the amount ofionized gas which is greatly increased in plasma arc welding, and it is this ionized gas that provides the heat of welding. This process has been illustrated in Figure M6.1.3.

 

OXYFUEL GAS WELDING (OFW)

            This process is also known as oxy-acetylene welding. Heat is supplied by the combustion of acetylene in a stream of oxygen. Both gases are supplied to the torch through flexible hoses. Heat from this torch is lower and far less concentrated than that from an electric arc.

 

RESISTANCE WELDING

            Resistance welding is a group of welding process in which coalescence is produced by the heat obtained from the resistance of the work to the flow of electric current in a circuit of which the work is a part and by the application of pressure. No filler metal is needed in this process.

 

ELECTRON-BEAM WELDING

            (EBW) Electron beam welding is defined as a fusion welding process wherein coalescence is produced by the heat obtained from a concentrated beam of high velocity electron. When high velocity electrons strike the workpiece, kinetic energy is transformed into thermal energy causing localized heating and melting of the weld metal. The electron beam generation takes place in a vacuum, and the process works best whenthe entire operation and the workpiece are also in a high vacuum of 10-4torr or lower. However, radiations nameray, infrared and ultraviolet radiation generates and the welding operator must be protected

 

LASER BEAM WELDING (LBW)

            Laser beam welding is defined as a fusion welding process and coalescence is achieved by utilizing the heat obtained from a concentrated coherent light beam and impinging upon the surface to be joined. This process uses the energy in an extremely concentrated beam of coherent, mono-chromatic light to melt the weld metal. This process is illustrated in Figure M6.1.4

 

Laser Beam Welding

 

CHAPTER-7

APPLICATIONS

 

• This product is an alternative for plastic plates and plates.
• Easily decomposing product.
• Cheaper and easily available material is used.
• Eco friendly product.
• The pneumatic arm is more efficient in the technical field.
• Quick response is achieved
• Simple in construction.
• Easy to maintain and repair.
• Cost of the unit is less.
• No fire hazard problem due to over loading.
• Comparatively the operation cost is less.
• Continuous operation is possible without stopping.
• It reduces the manual work.
• It reduces the production time.
• Ocplateies less floor space.
• Less skilled operator is sufficient.

 

CHAPTER-8

CONCLUSION

 

            This paper plate and dish making machine gives desire shapes of plate and dish as approximate efficiency of 80%. It is clearly seen that the project is economically possible in all aspect, and paper recycling unit has a potential to generate employment for many worker and can also act as an environment friendly initiative for the world.

REFERENCES

 

[1]        Sanchit Gaikwad, Amol Kalokhe, “Automatic paper plate making machine”, International Journal for Research in Engineering Applications and Management , ISSN:2494-9150 , vol02 , pp.1-5 , (2016).

[2]       Mohanraj K S, Vijayakumar P, Senthikumar R, GokulKarthik A “design and analysis of semi automatic paper cum arecanut plate making machine”, IRJET, e-ISSN: 2395-0056, p-ISSN: 2395-0072, vol-04, pp.3546-3550, (2017).

[3]       Vinesh K. ,Pradhap Kumar M. , PrasannaVenkatesh S. , Packiyaraj M. “Design and fabrication of pneumatically operated paper plate making machine”, International Journal for Scientific Research and Development, vol-6, pp.314-315, (2018).

[4]       M. A. Olutoye, “Design of manually operated paper recycling machine”, Leonardo Electronic Journal of Practices and Technologies, ISSN: 1583- 1078, pp.49-54, (2005)

[5]       Saurabh rathod, Nitin H Wankhede, “Design of manually operated portable paper recycling machine”, ISSN:2321-8169 , (2015)

[6]       U.P.Singh, “Design study of the geometry of a punching vol-33”, pp.331-345, (1992).

[7]       P. Goyal , G. Srivastava , R. Singh , N. Singh , “Review on pneumatic punching machine and modification in punch tool to reduce punching force requirement.”, International Journal of Engineering Technology Science and Research , vol-2 , ISSN:2394-3386 , pp.129-135 , (2015).