It is not full upto fabrication, upto functional decomposition only. i will upload next parts soon...

1. Mechanical engineering
Section A, Group no. A9
26th February, 2016
Guided By: Prof. D.N Thatoi
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Ansita Mohanty
Jyoti Panda
Basundhara Pradhan
Shubhendu Verma
Rohit Ranjan
Smurtipiyush Sahoo

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.
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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.
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Schematic
representation

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. 3/5/2016 5
Pneumatically
Operated
Sheet cutter
Hand Operated
Sheet Metal
cutter
Pictures

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CUSTOMER SURVEY FORM

7. Customer Name: Rabindra Pradhan
Address: Ashirvad Furniture, Laxmi Sagar
Interviewer: Smruti
Date: 15/02/2016
Questions Customer Statement Interpreted Need Importance
Typical Uses
Cutting of aluminum
plates
Both Industrial and
general purpose should
be there
Very important
Cutting of mild steel
Cutting of thick paper in
industry
LIKES
Handy in operation No laborious worker
needed, also no use of
manual work which
ensures safety
Very important
No skilled user needed
Easy to use
Power consumption is
less
Use of pneumatic
control reduces Human
effort
Ease of Operation Important
Reduced cost compared
to Hydraulics
Suitable for small
Industries
Genuine factor for small
industries
Easy maintenance
compared to spring
operated and rack &
pinion operated
Effectiveness
throughout the year
Depends on the use
DISLIKES
Lesser Sheet Thickness Limitation of Sheet type
i;e sheet metal is very
thin
Much needed
Less width of sheet
Not suitable for large
scale production or
Batch production
Comparably less use for
mass production
industries
Not needed
Suggested
Improvement
Safety should be
ensured, Operation
should be easy and it
should cut the sheet
effortlessly
Try to make the
thickness more, obtain
the cutting operation
comfortably.
Important
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8. 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
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Customer Need Statements and Importance Ranking

9. SELECTED NEEDS FOR REDESIGN
The following functions were selected for redesign:
 Improvisation in Cutting
 Operational Suitability
 Portability
 Occupying Less space
PROBLEM DEFINITION (Our Objective)
A Pneumatic sheet cutter has to be designed and developed. In order
to reduce human effort in manual operated machine our machine
should ensure automatic operation, finer cutting. In addition to that
the product should be small in size so that it is easier to carry the
product from one place to another.
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10. FUNCTIONAL DECOMPOSITION
The approaches for developing functions that were followed are
 Fast method
Objective: To relate one sub-function to another and so to
increase the product value.
 Subtract Operate Procedure Method
Objective: To disassemble each component from the product
and analyze the effect in a logical way.
 Activity diagram and Function structure method
Objective: To describe the overall process description of
customer from buying the product to operating it. Also to describe the
flow paths from start of machine to end of the action.
 Functional hierarchical decomposition
Objective: To trace the flow of energy, material and signals from
the bottom to the top level.
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11. SMOOTH
OPERATION
TRANSMIT
MECHANICAL
ENERGY
PRODUCE
CUTTING FORCE
PISTON CYLINDER
COMPRESS IT
PNEUMATICALLY
LUBRICATION
DAMP
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
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PORTABILITY
LINEAR SMOOTH
OPERATION
FAST Method

12. AIR COMPRESSOR FRL CONTROL UNIT PNEUMATIC
CYLINDER
CUTTER BLADE
ASSEMBLY
 Compressed Air
can’t be
Generated
 Compressed air
flow can’t be
regulated
 Pressurized air
can’t be
expanded
 No up-down
motion of blade
for cutting
 Main source of
energy i;e
Compressed air
Pressure can’t be
given to Cylinder
 The FRL
(Filtration-
Regulation-
Lubrication)
process can’t be
performed
 As expansion
wont take place,
piston
movement can’t
occur
 Moving blade
can’t be pushed
down
 Energy can’t be
stored in the
Cylinder to
perform
mechanical work
 Connecting rod
can’t Reciprocate
 Shearing
operation can’t
take place
 The Rod can’t
push the Upper
blade
 Also no support
arms to hold and
secure the sheet
SUBTRACT AND OPERATE APPLIED TO THE PNEUMATIC
SHEET CUTTER

13. Cut The Metal Sheet
Input Metal
Sheet
Input Air
Pressure
Hold
Reciprocate
Connecting
Rod
Permit Finer
Cut
Fix the
Metal
Under
Cutter
Provide
Indication
for Cutting
Accept it
through FRL
Control Unit
Transmit
Pressure to
Connecting
Rod
Support the
Pneumatic
Cylinder
Convert
Compressed
Air Pressure to
Mechanical
work
Reciprocation
of Cylinder
Rod
Movement of
the Blade
Fix The
Pneumatic
Cylinder On
the
Machine
SOP Diagram

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Purchase
Transport in
Package
Unpackaged
Main Frame
for Support
Store
Prepare to
Cut the
Sheet
Flow of
compressed
air to the
Cylinder
Motion of
connecting
rod
Cutting of
Sheet metal
Throw away
Debris
Process
descriptions
as Activity
Diagrams for
Sheet cutter
product

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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
Compress
ed air
pressure
Air
Uncut
Sheet
Sheared
metal
K.E of
blade
Cutting of
metal as
required
Desired
cut

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Cut the metal
sheet
Supply
power
Use
electricity
Supply
electricity
Generate
compressed
air
Automatic
work
Use
different
sheets
Accept
sheets
Hold sheets
Movement
of upper
blade
Feel easier
operation
Use
regulating
switch
Convert elet.
To
compressed
air
Apply K.E to
blade
Reciprocate
connecting
rod
Convert air
Pr. to K.E
Expansion of
compressed
air in cylinder
Regulate air
flow
Withstand
air flow
Motion of
connecting
rod
Use FRL
control unit
Use tubes
to allow air
flow
Provide
compressed
air
Hierarchical
Decomposition

17. Conclusion
 Thus our concept is complying to the demands of the
customer whose use the products as well as those who
are new.
 The latent needs of customers, which they were not
able to reciprocate properly is estimated successfully.
 The individual functions were studied thoroughly and
were evaluated by each group member.
 Further study will involve more analysis about the
product and comparison of similar products available in
the market.
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18. 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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