all the figures i have done that are from "Product design" by Kevin Otto and Kristin Wood. I have conducted all sorts of engineering analysis and done the project.

1. FABRICATION OF
PNEUMATIC SHEET CUTTER
5/19/2016
Ansita Mohanty
Jyoti Panda
Basundhara Pradhan
Shubhendu Verma
Rohit Ranjan
Smurtipiyush Sahoo
1

2. Mission Statement
• Use of pneumatically controlled Sheet metal cutter in an efficient way.
• Fabrication of pneumatic sheet cutting machine with minimization of cost as
well as size.
• Making the machine automatic and user friendly so that it will be easier for
operation.
• Determine the maximum out put from our model and make it satisfactory to
the customer as well.
• Finally gain experience through individual and team performance.
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3. Introduction
What is a Sheet metal
• Sheet metal is simply a metal formed into thin
and flat pieces. The thickness of sheet is called
its gauge. The thickness above 6mm falls in
Plate category.
• There are many metals that can be made into
sheet metal like Aluminum, Brass, copper, steel,
tin etc. For decorative uses sheet metals of
Silver, gold, platinum are also used.
• Sheet metals are used in Car bodies, medical
tables, roofs for buildings etc. Use of sheet
metal are now days in furniture, shelves or
cupboards.
5/19/2016
Schematic
representation
3

4. How Sheet Metal is cut:
• The cutting process is done by applying Shear Force
• Due to application of shear Force, the stress in the
material will exceed the ultimate shear strength
and the material will fail and separate at the cut
location.
• Shearing force is applied by 2 blades one above and
one below the sheet.
• The upper blade delivers a quick downward blow to the
sheet metal that rests on the lower blade.
• The upper tool penetrates on the sheet causing the
shearing and material failure.
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5. Customer Need Statement and Importance Ranking
5/19/2016
CUSTOMER NEEDS No. Of Occurrences (Out of 20) Weightage
Efficient Cutting 16 0.8
Reduce Human effort 14 0.7
Occupy Less space 15 0.75
Low Cost 13 0.65
Less Maintenance 10 0.5
Automatic Operation 11 0.55
Reduce Power Consumption 7 0.35
Safety During Machining 10 0.5
Portability 15 0.75
More thickness of Sheet 9 0.45
5

6. SMOOTH
OPERATION
TRANSMIT
MECHANICAL
ENERGY
PRODUCE CUTTING
FORCE
PISTON CYLINDER
COMPRESS IT
PNEUMATICALLY
LUBRICATIONDAMP VIBRATIONS
TRANSMIT FORCE
TO CUTTING BLADE
ALIGNMENT OF
WORK PIECE
LOCOMOTION OF
CUTTING BLADE
OVER SHEET METAL
CUT THE
SHEET
PROVIDE
AIR
GENERATE NOISE
HOW? WHY?
REDUCE NOISE
ELIMINATE
LEAKAGE
FAST Method
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PORTABILITY
LINEAR SMOOTH
OPERATION

7. Function Structure
5/19/2016 7
Open System
Close System Support
Cutting blades
Execute
Cutting
Store the split sheetRaw Metal
sheet
Pressure force
Air
Sheet uncut
Cutting force
Release air
Sheared
metal sheet
Provide elect. to
compressor
Generation of
compressed air
Stores
compressed air
Flow of air to FRL
unit
Compression &
storage
Release into
pneumatic cylinder
Cut the sheet
FRL Unit
Expansion of air
inside cylinder
Motion of
connecting rod to
movement of
blade
Shearing over the
sheet
Electrical
energy
Compressed
air pressure
Air
Uncut Sheet
Sheared
metal
K.E of blade
Cutting of
metal as
required
Desired cut

8. Bill Of Material Form
5/19/2016 8
Project Name: Design and fabrication of Pneumatic Sheet cutter
Engineers ANSITA MOHANTY, JYOTI PANDA, BASUNDHARA PRADHAN, SHUBHENDU VERMA, ROHIT RANJAN, SMRUTIPIYUSH
SAHOO
Date 04.03.2016
Part
No
Name Qty Functional Analysis DFM Cost Analysis
Function Flows in Flows out Manuf.
Process
Manuf.
Cost
(In Rupees)
Dimensions Mass Material Finish
1 Shearing
Blades
assembly
2 Cut the Sheet Metal
sheet
Sheared
sheet
Machining 320 L=200 mm,
B=55 mm,
t=12mm
2kg High
Speed
Steel
Smooth
2 Pneumati
c cylinder
assembly
1 Provide force to
the blades
Compres
sed air
Expanded
air
Available
in market
2449 Stroke=200mm,
D=50mm,
Pr.=10bar
2.5kg High
Carbon
Steel
Smooth
3 Base
frame
assembly
1 Support the
blades and
cylinder
Sheet
metal
Sheet
metal
Wood
cutting
NA As required 2kg Wood Rough
4 Nuts and
bolts
As
require
d
Tightening ------- -------- 80 As required Mild steel Rough

9. Efficient cutting 1
Reduce human effort 2
Less space to occupy 3
Portability 4
Low cost 5
3 5 1 3 4
N cm2 kg bar Rs
562 1500 10 8 3000
570 1500 NA 10.3 4200
566 1350 NA 8 3500
Max.cutting
Force
Areaofbase
Weighttocarry
Max.Air
pressure
Equipmentcost
Technical Difficulty
Measurement Unit
Object Target Value
Objective
Measures
FIBER 500
Reference model
Strong Relationship
Medium Relationship
Weak Relationship
House of Quality
5/19/2016 9
4 3
4 3
3 4
4 4
3 3
FIBER
500
Referencemodel

10. Sheet Metal Cutting
Human
Cutter
alignment
Use of
removable
cutter
Use of single type of metal
sheet cutter
Expectation
Well
trained
Analogies
Use of FRL unit
Use of solenoid
Use of regulating
switch
Material
alignment
Use of single
variant of sheet
metal
Thickness within
the limit
Manual
application
Replacement
of effort
application
method
Hydraulic
application
Pneumatic
application
Mind Map Function
5/19/2016 10

11. PUGH CHART
Weightage
Concepts
Option # 1 Option #2 Option #3 Option #4 Option
#5
Use of
Pneumatic
Cylinder
Use of shear
blades
instead of
scissor
blades
Electronic
sensor for
air flow
regulation
FRL
regulating
switch for air
flow
Use less base
area for sheet
cutting
CRITERIA
Efficient Cutting 4 1 1 S S S
Reduced Human effort 3 S S 1 1 1
Less space to occupy 3 S S 1 S 1
Portability 4 S S S S 1
Low cost 3 1 -1 -1 1 S
∑+ 2 1 2 2 3
∑- 0 -1 -1 0 0
∑ 2 0 1 2 3
5/19/2016 11

12. Part Models
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13. Assembly
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14. Mathematical Equations and numerical calculation for
Sheet metal cutter
For Aluminum Sheet of Thickness “1mm”
Thickness = 1 mm
Length of cut = 30mm
Maximum Shear Strength of Aluminum = 30 N/mm2
Force Calculation:
Force required to cut the sheet =
This is the force required to cut the sheet. However,
initially the force required will be 140-150 % of calculated
value.
(We have taken this from reference)
Hence, required force
The Compressor pressure should be max 10 bar.
But our Base structure is made up of wood, so it can’t
withstand such pressure when applied continuously.
So we have taken iterations of 8 bar, 6 bar and 4 bar
respectively. Out of which 8 bar pressure gives us
the cylinder diameter of minimum size.
Design of cylinder:
Since max force required to cut the sheet= 1350N
Applied Max pressure= 10bar, we will let the pressure at
8 bar.
Converting the unit 1 bar= 10−1
𝑁/𝑚𝑚2
So, Force applied by the cylinder,
Therefore, diameter of the cylinder is ~50mm (This is
taken basing upon the dimensions available in the
market)
5/19/2016 14
max tL
30130 F
N900
1350%150900  mmd
d
35.46
108
4
1350 12

 
PdF  2
4

1260%140900 

15. Solid Works Simulation
Fixtures and Load
5/19/2016 15
Fixture name Fixture Image Fixture Details
Fixed-1
Entities:3 face(s)
Type:Fixed Geometry
Resultant Forces
Components X Y Z Resultant
Reaction force(N) -0.490486 5.69331 1.44239 5.89362
Reaction
Moment(N.m)
0 0 0
0
Load
name
Load Image Load Details
Force-1
Entities:1 face(s)
Type: Apply normal
force
Value: 675 N

16. Dynamic Analysis of stress
5/19/2016 16
Name Type Min
Max
Stress1 VON: von Mises Stress at Step No:
100(1 Seconds)
2.20596 N/m^2
Node: 6434
7.90995e+007 N/m^2
Node: 1727
Assembly3-Dynamic 3-Stress-Stress1

17. Displacement analysis
5/19/2016 17
Name Type Min
Max
Displacement1 URES: Resultant Displacement at
Step No: 100(1 Seconds)
0 mm
Node: 1725
0.373107 mm
Node: 10603
Assembly3-Dynamic 3-Displacement-Displacement1

18. FMEA of Sheet metal cutter product
Product Name: Pneumatic sheet
metal cutter
Metal Cutting System
Devel. Team: Ansita, Jyoti, Basundhara, Shubhendu,
Rohit, Smruti
Page No. 1 of 1
Date: 21.03.2016
Part No &
Functions
Potential
Failure Mode
Potential
Effect(s) of
Failure
S
E
V
E
R
E
(S)
Potential Cause(s)/
Mechanism(s) of
Failure
O
C
C
U
R
(O)
Current Design
Controls/ Tests
D
E
T
E
C
T
(D)
Recommended
Actions
RPN
Blade Tool breakage
and edge
breakage
Deteriorated
cutting
operation
8 Incorrect clearance
angle and blade angle
during manufacturing
Misalignment of lower
blade and upper blade
3 Prototype test
and analysis
7 Regular
maintenance and
checking for contact
surface erosion
168
Cylinder Decrease of air
pressure within
the cylinder
Insufficient
cutting force to
the blade
4 Leaks in tubing and
connections
6 Prototype test
and analysis
8 Secure the valves
and check the tubing
regularly
192
Piston Damage in
Piston head
In appropriate
motion
6 Maximum usage and
mfg. defects
5 NA 8 Maintenance service 240
Connecting
Rod
Fracture of
connecting rod
Disengagemen
t of blade w.r.t.
pneumatic
cylinder
9 Failure due to sudden
change in pressure of
inlet air
2 Check for
material
strength during
prototype
simulation
9 To maintain a near
constant pressure
output from the
compressor
162
5/19/2016 18

19. Material selection for pneumatic sheet metal cutter
• Base frame: To choose the material for
the ‘Base frame’ would be ‘Wood’. The
kind of wood available in local area is
mostly Teak.
The Base of the frame would be made
up of ‘Plywood’ as it provides High
strength and it is available in large
sheets.
• Shearing Blade: To choose the material
for ‘Shearing blade’ would be ‘High
speed steel (H 13)’.
This type of hot work steel provides
better Toughness and resistance to
Thermal Fatigue cracking.
• Connecting Link: The material for
‘Connecting Link’ would be ‘Mild steel’.
The connecting link should provide high
strength during to and fro motion of the
connecting rod.
Also the connecting Link needs to be
welded properly with the Upper blade to
make a linkage as shown in the figure.
• Pneumatic cylinder: The material for
‘Pneumatic Cylinder’ would be ‘High
carbon steel’. As we are not
manufacturing this cylinder, we don’t
focus on what material it is based on.
5/19/2016 19

20. Component Manufacturing process
Shearing
blade
(1 )Milling, (2) Hardening
and tempering, (3) Surface
grinding. (4) Drilling, (5)
Welding
Base Frame (1)Ply cutting, (2) Wood
cutting, (3) Fastening, (4)
Drilling
Connecting
Link
(1)Drilling, (2) Filing, (3)
Welding
Manufacturing
Process
 Pneumatic Cylinder-Frame:
Assembled by Drilling.
 Upper Blade and Lower Blade: Bolt
and nut tightening at the hinge point
so that Upper blade can rotate
smoothly.
 Connecting Link-Upper Blade:
They were Joined by welding and
bolt nut tightening.
 Connecting Link-Cylinder: There
was a threading at the end of
Connecting Rod of Cylinder. So The
connecting Link was tightened with
Nuts and Bolts to the Connecting
Rod.
Assembling
Process
5/19/2016 20

21. Our Fabricated Model
5/19/2016 21

22. Merits and Demerits
Hydraulics present certain advantages over
pneumatics, but in a given application,
pneumatic powered equipment is more
suitable, particularly in industries where the
factory units are plumbed for compressed air.
Moreover, to avoid corrosive actions, oil or
lubricants are added so that friction effects can
be reduced.
Compressed air is used in most of the
machines and in some cases compressed
carbon dioxide, whereas cutting process is
become easy.
Fast cutting action is carried out.
Cutting without bending is achieved.
 Sheet more than 1 mm thickness cannot cut
easily.
 Compressed air is must.
 Foundation is required also safety measurer
must be taken.
5/19/2016 22

23. Conclusion
Now we know that Pneumatic Shearing machine is very cheap as compared to
hydraulic shearing machine.
The range of the cutting thickness can be increased by arranging a high
pressure compressor and installing more hardened blades. This machine is
advantageous to small sheet metal cutting industries as they cannot afford the
expensive hydraulic shearing machine.
Thus we can say that our Product was up to the mark and it hold a good
running condition for a sheet of 1 mm thickness.
The Team performed in all activities in the project and gave their optimum
values in dedication. We learnt the basics and established a well capable
model that can fulfill our customer demand and satisfy their needs.
5/19/2016 23

24. References
Ajit Kumar Singh, Harpreet Singh and Dharmendra Sharma, “Design and Fabrication of
Pneumatic Auto Sheet Metal Cutting Machine Using Solar Energy”, International Journal
of Engineering Research & Technology (IJERT): ISSN: 2278-0181: Vol. 4 Issue 03, March-
2015
A.S. Aditya Polapragada & K. Sri Varsha , “Pneumatic Auto Feed Punching, cutting and
Riveting Machine “, International Journal of Engineering Research & Technology (IJERT)
Vol. 1 Issue 7, September - 2012 ISSN: 2278-0181.
P.M.Pradhan, “Experimental Investigation and Fabrication of Pneumatic Cutting tool”,
International Journal of Innovative Research in Science, Engineering and Technology, Vol. 2,
Issue 6, June 2013.
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