pneumatic hammer

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1. PROJECT PLANING

Before starting every project its planning is to be done. Planning is

very important task and should be taken with great care, as the efficiency of

the whole project largely depends upon its planning while planning a project

each and every details should be worked out in anticipation and should

carefully is considered with all the relating provisions in advance. Project

planning consists of the following steps.

PROJECT CAPACITY

The capacity of the project must be decided considering the amount of

money which can be invested and availability of material and machines.

DRAWINGS

Drawing been decided for the project to be manufacture. Its detailed

drawing specification for raw material and finished products should be

decided carefully along with the specification of the machines required for

their manufacture.

MATERIAL EQUIPMENT

The list of materials required for manufacture is prepared from the

drawings. The list of is known as BILL OF MATERIALS. This passes to

the store keeper and the required materials taken from the store under

permission of store keeper operation, the necessity of operation, the person


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to do the job, machine to be used to do the job are considered while planning

the operation. After considering tea above questions a best method is

developed and the best method is applied to the operation.

MACHINE LOADING

While planning proper care should be taken to find the machining

time for each operation as correct as possible. So that the arrangement for

full utilization of machine can be made machine loading programmed is also

known.

PURCHASE CONSIDERATION

It is different to manufacture all the component needed for the

equipment in the workshop it self. The decision about a particular item

whether to purchase or to manufacture is taken by planning after making

through study of relative merits demerits.

EQUIPMENT CONSIDERATION

Result obtained from PROCESS PLANNING and MACHINE

LODING helps in calculating the equipment requirement specification of

the equipment should be laid down by considering the drawing. Drawing

will also help in deciding and necessary requirement of tools, accessories.

COST CALCULATION

The cost of the project can be calculated by adding following.


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Material Cost

Machining Cost

Overhead Expenses.

COMPARISION

The various items in the finished project are compared to the

standards for the further correction.

REPORT

At the end of the project work report is prepared for future references.

The report consists of all the items done the project work.


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1. PNEUMATIC JACK HAMMER

Ajackhammer is apneumatic tool that combines a hammerdirectly with a

chisel that was invented by Charles Brady King.[1] Hand-held jackhammers

are typically powered by compressed air, but some use electric motors.

Larger jackhammers, such as rig mounted hammers used on construction

machinery, are usually hydraulically powered. They are usually used to

break up rock, pavement, and concrete. In modern terminology, a

"jackhammer" does not have the capacity to drill rock.

A jackhammer operates by driving an internal hammer up and down. Thehammer is first driven down to strike the back of the bit and then back up to

return the hammer to the original position to repeat the cycle. The bit usually

recovers from the stroke by means of a spring. The effectiveness of the

jackhammer is dependent on how much force is applied to the tool.

HistoryPneumatic drills were developed in response to the needs of mining,

quarrying, excavating, and tunneling. The first "percussion drill" was made

in 1848 and patented in 1849 by Jonathan J. Couch of Philadelphia,

Pennsylvania. [2] In this drill, the drill bit passed through the piston of a

steam engine. The piston snagged the drill bit and hurled it against the rock

face. It was an experimental model. In 1849, Couch's assistant, Joseph W.

Fowle, filed a caveat for a percussion drill of his own design. In Fowles

drill, the drill bit was connected directly to the piston in the steam cylinder;

specifically, the drill bit was connected to the pistons crosshead. The drill
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also had a mechanism for turning the drill bit around its axis between strokes

and for advancing the drill as the hole deepened.[3] By 1850 or 1851, Fowle

was using compressed air to drive his drill, making it the first true pneumatic

drill.[4]

The demand for pneumatic drills was driven especially by miners and

tunnelers because steam engines required fires in order to operate and the

ventilation in mines and tunnels was inadequate to vent the fires' fumes;

there was also no way to convey steam over long distances (e.g., from the

surface to the bottom of a mine); furthermore, mines and tunnels

occasionally contained flammable explosive gases such as methane. By

contrast, compressed air could be conveyed over long distances without loss

of its energy, and after the compressed air had been used to power

equipment, it could still serve to ventilate a mine or tunnel.

In Europe since the late 1840s, the king of Sardinia, Carlo Alberto, had been

contemplating the excavation of a 12-kilometer (7.5 mi) tunnel through

Mount Frjus in order to create a rail link between Italy and France, which

would cross his realm.[5][6] The need for a mechanical rock drill was obvious

and this sparked research on pneumatic rock drills in Europe. A Frenchman,

Cav, designed, and in 1851 patented, a rock drill that used compressed air;

however, the air had to be admitted manually to the cylinder during each

stroke, so it was not successful. [7] In 1854, in England, Thomas Bartlett made

and then patented (1855) a rock drill in which the drill bit was connected

directly to the piston of a steam engine. In 1855 Bartlett demonstrated his

drill, powered by compressed air, to officials of the Mt. Frjus tunnel

project.[8] (In 1855, a German, Schumann, invented a similar pneumatic rock

drill in Freiburg, Germany.[9]) Bartletts drill was refined by the Savoy-born
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engineerGermain Sommeiller(1815-1871) and his colleagues, Grandis and

Grattoni, by 1861.[10] Thereafter, many inventors refined the pneumatic drill.

[11]

TerminologyThe word "jackhammer" is used in North American English and Australia,

while "pneumatic drill" is used colloquially elsewhere in the English

speaking world, although strictly speaking a "pneumatic drill" refers to a

pneumatically driven jackhammer.[12] In Britain, the term "jackhammer"

usually refers to electromechanical version of the tool.[citation needed]

UseA full-sized portable jackhammer is impractical for use against walls and

steep slopes, except for a very strong man, as the user would have to both

support the weight of the tool, and push the tool back against the work after

each blow. A technique developed by experienced workmen is a two-man

team to overcome this obstacle of gravity: one man operates the hammer and

the second assists by holding the hammer either on his shoulders or cradled

in his arms. Both use their combined weight to push the bit into the

workface. This method is commonly referred to as horizontal

jackhammering.

Another method is overhead jackhammering, requiring strength conditioning

and endurance to hold a smaller jackhammer, called a rivet buster, over one's

head. To make overhead work even safer a platform can be used. One such

platform is a P.A.M. PositionerActuatorManipulator. This unit take all the

weight and vibration from the user.
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TypesPneumatic

A compressor for running a pneumatic jackhammer

A pneumatic jackhammer, also known as a pneumatic drill or pneumatic

hammer,[13] is a jackhammer that uses compressed air as the power source.

The air supply usually comes from a portable air compressor driven by a

diesel engine. Reciprocating compressors were formerly used. The unit

comprised a reciprocating compressor driven, through a centrifugal clutch,

by a diesel engine. The engine's governorprovided only two speeds:

idling, when the clutch was disengaged

maximum, when the clutch was engaged and the compressor was

running
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Modern versions use rotary compressors and have more sophisticated

variable governors. The unit is usually mounted on a trailerand sometimes

includes an electrical generatorto supply lights or electric power tools.

Additionally, some users of pneumatic jackhammers may use a pneumatic

lubricator which is placed in series with the air hose powering the air

hammer. This increases the life and performance of the jackhammer.

Specific lubricant in filled in the pneumatic lubricator. Furthermore, air

compressors typically incorporate moisture into the compressed air leading

to freeze-ups of the jackhammer or air hammer in cold weather.

Electromechanical

A single phase demolition breaker.

This section requires expansion.

This tool is useful where the work is light and access to a compressor is

limited or impractical. It requires a heavy duty extension cord to power the

motor instead.

Hydraulic
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An excavator-mounted hydraulic jackhammer being used to break up

concrete.

A hydraulic jackhammer, much larger than portable ones, may be fitted to

mechanical excavators or backhoes and is widely used for roadwork,

quarrying and general demolition or construction groundwork. These larger

machine mounted breakers are known as Rig Mounted, or Machine Mounted

Breakers. Such tools can also be used against vertical walls (or ceilings for

that matter), since the vehicles involved are massive enough and powerful

enough to exert the forces involved without needing the help of gravity in

operating the tool. Pneumatic or hydraulic tools are particularly likely to be

used in mines where there is an explosion risk (such as underground coal

mines), since they lack any high-power electrical circuitry that might cause a

triggering spark.

Hydraulic breakers usually use a hydraulic motor driving a sealed pneumatic

hammer system, as a hydraulic hammer would develop a low strike speed

and transfer unacceptable shock loads to the pump system.

Health

A jackhammer with black silencer attached
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The sound of the hammer blows, combined with the explosive air exhaust,

makes pneumatic jackhammers dangerously loud, emitting 100 decibels at

two meters. Sound-blocking earmuffs must be worn by the operator to

prevent a form of hearing damage of which tinnitus is the main symptom.

Most pneumatic jackhammers now have a silencer around the barrel of the

tool.

Prolonged exposure to the pronounced vibration set up by the tool can lead

to blood-circulation failures in the fingers, a condition known as white

finger. Applying athletic tape is not effective in preventing white finger but

seems to help alleviate some of its discomfort. Pneumatic drill usage can

also lead to a predisposition for development ofcarpal tunnel syndrome.

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
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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

standing advantages in terms of safety.

2. CLASSIFICATION OF AIR COMPRESSOR


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2.1 INTRODUCTION OF THE COMPRESSOR

A gas compressor is a mechanical device that increases the pressure of a gas

by reducing its volume.

Compressors are similar to pumps, both increase the pressure on a fluid and

both can transport the fluid through a pipe. As gases are compressible, the

compressor also reduces the volume of a gas. Liquids are relatively

incompressible, so the main action of a pump is to pressurize and transport

2.2 Types of compressors

Centrifugal compressors

Diagonal or mixed-flow compressors

Axial-flow compressors

Reciprocating compressors


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Rotary screw compressors

Rotary vane compressors

Scroll compressors

The main types of gas compressors are

CENTRIFUGAL COMPRESSOR

Centrifugal compressors use a rotating disk or impeller in a shaped

housing to force the gas to the rim of the impeller, increasing the velocity of

the gas. A diffuser (divergent duct) section converts the velocity energy to

pressure energy. They are primarily used for continuous, stationary service

in industries such as oil refineries, chemical and petrochemical plants and

natural gas processing plants. Their application can be from 100 horsepower

(75 kW) to thousands of horsepower. With multiple staging, they can

achieve extremely high output pressures greater than 10,000 psi (69 MPa).

Many large snow-making operations (like ski resorts) use this type of

compressor. They are also used in internal combustion engines as

superchargers and turbochargers. Centrifugal compressors are used in small

gas turbine engines or as the final compression stage of medium sized gas

turbines.

MIXED FLOW COMPRESSOR

Diagonal or mixed-flow compressors are similar to centrifugal compressors,

but have a radial and axial velocity component at the exit from the rotor. The


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diffuser is often used to turn diagonal flow to the axial direction. The

diagonal compressor has a lower diameter diffuser than the equivalent

centrifugal compressor.

[edit]

Axial-flow compressors

Main article: Axial-flow compressor

AXIAL FLOW COMPRESSOR

Axial-flow compressors are dynamic rotating compressors that use arrays of

fan-like airfoils to progressively compress the working fluid. They are used

where there is a requirement for a high flow rate or a compact design.

The arrays of airfoils are set in rows, usually as pairs: one rotating and one

stationary. The rotating airfoils, also known as blades or rotors, accelerate

the fluid. The stationary airfoils, also known as a stators or vanes, decelerate

and redirect the flow direction of the fluid, preparing it for the rotor blades

of the next stage.[1] Axial compressors are almost always multi-staged, with

the cross-sectional area of the gas passage diminishing along the compressor

to maintain an optimum axial Mach number. Beyond about 5 stages or a 4:1

design pressure ratio, variable geometry is normally used to improve

operation.

Axial compressors can have high efficiencies; around 90% polytropic at

their design conditions. However, they are relatively expensive, requiring a

large number of components, tight tolerances and high quality materials.


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Axial-flow compressors can be found in medium to large gas turbine

engines, in natural gas pumping stations, and within certain chemical plants.

RECIPROCATING COMPRSSOR

A motor-driven six-cylinder reciprocating compressor that can operate with

two, four or six cylinders.

Reciprocating compressors use pistons driven by a crankshaft. They can be

either stationary or portable, can be single or multi-staged, and can be driven

by electric motors or internal combustion engines. Small reciprocating

compressors from 5 to 30 horsepower (hp) are commonly seen in automotive

applications and are typically for intermittent duty. Larger reciprocating

compressors well over 1,000 hp (750 kW) are still commonly found in large

industrial and petroleum applications. Discharge pressures can range from

low pressure to very high pressure (>6000 psi or 41.4 MPa). In certain

applications, such as air compression, multi-stage double-acting

compressors are said to be the most efficient compressors available, and are

typically larger, noisier, and more costly than comparable rotary units.[6]

Another type of reciprocating compressor is the swash plate compressor,

which uses pistons which are moved by a swash plate mounted on a shaft.

ROTARY SCREW COMPRESSOR

Rotary screw compressors use two meshed rotating positive-displacement

helical screws to force the gas into a smaller space. These are usually used


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for continuous operation in commercial and industrial applications and may

be either stationary or portable. Their application can be from 3 horsepower

(2.2 kW) to over 1,200 horsepower (890 kW) and from low pressure to very

high pressure (>1200 psi or 8.3 MPa).

ROTARY VANE COMPRESSOR

Rotary vane compressors consist of a rotor with a number of blades inserted

in radial slots in the rotor. The rotor is mounted offset in a larger housing

which can be circular or a more complex shape. As the rotor turns, blades

slide in and out of the slots keeping contact with the outer wall of the

housing.[1] Thus, a series of decreasing volumes is created by the rotating

blades. Rotary Vane compressors are, with piston compressors one of the

oldest of compressor technologies.

With suitable port connections, the devices may be either a compressor or a

vacuum pump. They can be either stationary or portable, can be single or

multi-staged, and can be driven by electric motors or internal combustion

engines. Dry vane machines are used at relatively low pressures (e.g., 2 bar)

for bulk material movement whilst oil-injected machines have the necessary

volumetric efficiency to achieve pressures up to about 13 bar in a single

stage. A rotary vane compressor is well suited to electric motor drive and is

significantly quieter in operation than the equivalent piston compressor.

SCROLL COMPRESSOR

Mechanism of a scroll pump


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A scroll compressor, also known as scroll pump and scroll vacuum pump,

uses two interleaved spiral-like vanes to pump or compress fluids such as

liquids and gases. The vane geometry may be involutes, Archimedean spiral,

or hybrid curves. They operate more smoothly, quietly, and reliably than

other types of compressors in the lower volume range

Often, one of the scrolls is fixed, while the other orbits eccentrically without

rotating, thereby trapping and pumping or compressing pockets of fluid or

gas between the scrolls.

This type of compressor was used as the supercharger on Volkswagen G60

and G40 engines in the early 1990's.


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3. INTRODUCTION OF PEUMATIC YLINDER

Pneumatic cylinders are the devices for converting the air pressure into

linear mechanical force and motion. They are basically used for single

purpose applications such as clamping, tilting, bending, turning and many

other applications.

The Pneumatic power is converted to straight line reciprocating motion by

pneumatic cylinders. The various industrial applications for which air

cylinders are used can be divided duty wise into the groups. They are light

duty, medium duty and heavy duty but according to the operating principle

air cylinders can be sub divided as 1.single-acting, 2.Double- acting

cylinders. Since our project is based on single acting cylinder we shall see

deep about it.

In a single-acting cylinder, compressed air is fed only in one side hence, this

cylinder can produce work only in one direction the return movement of the

piston is affected by a builtin spring or by application of an external force


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the spring is designed to return the piston to its initial position with a

sufficiently high speed.

4. PNEUMATIC COMPONENTS

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 operation. 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 system 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 standing advantages in terms of safety.

The single acting pneumatic cylinder consists of the following

components to the requirements of complete operation of the machine.

1. piston


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2. cylinder

3. Ram

4. End plate

5. Return spring

6. Nipple

4.1 COMPONENT DESCRIPTION

Cylinder

An air cylinder is an operating device in which the state input

energy of compressed air i.e., pneumatic power is converted into mechanical

output power by reducing the pressure of air to that of atmosphere

Ram

It is an output device when the pressure inside the cylinder

exceeds the limit the ram actuates. This actuation is used for the operation.

End plate

End plates are connected to both the ends of the cylinder. Pressure

acts mainly on both the end plates. It is made up of ms plate.

Nipple

Air from the compressor is passed through the nipple in to the

cylinder it is made up of mild steel


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Stud and nut

It is used to connect two plates or some members of the setup.

Here stud and nut are used to connect the plates

Spring

Open coil spring is used in this system.

Piston

It is the main component which is placed inside the cylinder. It is

used to force the ram in and out by the action of compressed air.

CYLINDER:

The cylinder is a single acting cylinder one, which means that the air

pressure operates alternatively (forward and backward). The air from the

compressor is passed through the regulator which control the pressure to

required amount by adjusting its knob. A pressure gauge is attached to the

regulator for showing the line pressure.

Then the compressed air is passed though the directional control valve

for supplying the air alternatively to either sides of the cylinder. Two hoses

take the output of the directional control valve and they are attached to twoends of the cylinder by means of connectors. One of the output from the

directional control valve is taken to the flow control valve from taken to the

cylinder.


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Pneumatic cylinder

An air cylinder is an operative device in which the state input energy

of compressed air i.e. pneumatic power is converted in to mechanical output

power, by reducing the pressure of the air to that of the atmosphere.

SOLENOID VALVE WITH CONTROL UNIT:

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 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 is which the plunger is pulled when the solenoid is energized.


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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.

Parts of a Solenoid Valve

1. Coil

The solenoid coil is made of copper wire. The layers of wire are separated

by insulating layer. The entire solenoid coil is covered with an varnish that is not

affected by solvents, moisture, cutting oil or often fluids. Coils are rated in

various voltages such as 115 volts AC, 230 volts AC, 460 volts AC, 575 Volts

AC, 6 Volts DC, 12 Volts DC, 24 Volts DC, 115 Volts DC & 230 Volts DC.

They are designed for such frequencies as 50 Hz to 60 Hz.

2. Frame

The solenoid frame serves several purposes. Since it is made of laminated

sheets, it is magnetized when the current passes through the coil. The magnetized

coil attracts the metal plunger to move. The frame has provisions for attaching the

mounting. They are usually bolted or welded to the frame. The frame has


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provisions for receivers, the plunger. The wear strips are mounted to the solenoid

frame, and are made of materials such as metal or impregnated less fiber cloth.

3. Solenoid Plunger

The Solenoid plunger is the mover mechanism of the solenoid. The

plunger is made of steel laminations which are riveted together under high

pressure, so that there will be no movement of the lamination with respect to one

another. At the top of the plunger a pin hole is placed for making a connection to

some device. The solenoid plunger is moved by a magnetic force in one direction

and is usually returned by spring action. Solenoid operated valves are usually

provided with cover over either the solenoid or the entire valve. This protects the

solenoid from dirt and other foreign matter, and protects the actuator. In many

applications it is necessary to use explosion proof solenoids.

WORKING OF 3/2 SINGLE ACTING SOLENOID (OR) CUT OFF

VALVE:


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The control valve is used to control the flow direction is called cut off

valve or solenoid valve. This solenoid cut off valve is controlled by the emergency

push button. The 3/2 Single acting solenoid valve is having one inlet port, one

outlet port and one exhaust port. The solenoid valve consists of electromagnetic

coil, stem and spring. The air enters to the pneumatic single acting solenoid valve

when the push button is in ON position.

4.2 TYPES OF CYLINDERS


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1. SINGLE ACTING

Air pushes the piston in one direction and the piston is returned by

means of an external means.

2. DOUBLE ACTING CYLINDER

The force exerted by the compression spring moves the piston in both the

direction.

3. CUSHION END CYLINDER Cushion is used in the end position to prevent sudden damaging impacts.

4. TANDEM CYLINDER

Here two cylinders are arranged in series so that the force obtained from

the cylinder is almost double.

5. DUAL LINER CYLINDER (3-POSITION)

Similar to the tandem cylinder, but the piston and the rod assemblies of a

dual actuator are not fastened together like tandem cylinder.

6. DOUBLE -ROD CYLINDER (THROUGH ROD CYLINDRE)

It has piston rod extending from both the ends of the cylinders. It

produces equal force and speed on both sides of the cylinder.


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7. TELESCOPIC CYLINDER

It is a two stage double acting telescopic cylinder.

8. TURN CYLINDER (ROTARY CYLINDER)

It has a piston rod having rack and pinion arrangement in such a manner

that liner movement of the piston rod ,the worm wheel rotates at

45,90,180.

5. CONSTRUCTION AND WORKING OF PNEUMATIC


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CYLINDER

CONSTRUCTION

Generally a single acting cylinder mainly consists

of following parts such as end plate, piston, cylinder, return spring, ram and

nipple. The spring is placed inside the cylinder and it covers the ram. The piston

is placed upon the spring. The end plates are fitted on both sides of the cylinder

by four cover screws or tie rods. Ram is fixed to the piston and it moves along the

piston. The nipple is found outside the cylinder.

Working

In pneumatic cylinder air is being compressed by the compressor and it is fed

into the cylinder through the nipple using dc valve. This compressed air moves

the piston in one direction against the spring force. The maximum pressure

applied inside the cylinder is 10-12bar.The piston is connected by a ram, the ram

moves along with the piston when the compressed air moves the piston. This

makes a linear movement of the ram. In single acting cylinder the stroke is

limited to the compressed length of the spring. When the compressed air entering

the cylinder is less the piston comes to its original position by the action of spring

force. The moving ram performs many operations such as slotting, punching etc.

6. BORING OPERATION OF PNEUMATIC CYLINDER

FORMING


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Boring is the operation of enlarging a hole. The single point cutting

tool is used for a boring operation. Generally a single point tool bit is

mounted in the boring bar of suitable diameter commensurate with the

diameter to be bored. The over hang of the tool is to be made as small as

possible to reduce the chatter which is very common in boring. The work

piece were a hole is already existing is mounted on the table of a horizontal

boring machine. The table of a horizontal boring machine has accurate guide

ways to move the table into perpendicular direction.

HONING

Honing is a low abrading process whish uses bonded abrasive Sticks

for removing stock from metallic surfaces. However, it can also be Used for

external cylindrical surfaces as well as flat surfaces. It is most Commonly

used for internal surface. Those is an operation performed as The final

operation to correct the errors that have occurred from the previousMachining operation. The advantages of honing are.

(a) Correction of geometrical accuracy

(1)Out of roundness

(2)Taper

(3)Axial distortion

(b)Dimensional accuracy


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7. INTRODUCTION OF THE STRUCTURE

Structural steel is steel construction material, a profile, formed with a

specific shape or cross section and certain standards of chemical

composition and strength. Structural steel shape, size, composition, strength,

storage, etc, is regulated in most industrialized countries.

Structural steel members, such as I-beams, have high second moments of

area, which allow them to be very stiff in respect to their cross-sectional

area.

A steel I-beam, in this case used to support wood beams in a house.

Structural steel in construction: A primed steel beam is holding up the floor

above, which consists of a metal deck (Q-Deck), upon which a concrete slab

has been poured.

Steel beam through-penetration with incomplete fireproofing.


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Metal deck and OWSJ (Open Web Steel Joist), receiving first coat of spray

fireproofing plaster, made of polystyrene leavened gypsum. Contents

1 Common structural shapes

2 Standards

2.1 Standard structural steels

2.2 Standard structural steels

2.2.1 Carbon steels

2.2.2 High strength low alloy steels

2.2.3 Corrosion resistant high strength low alloy steels

2.2.4 Quenched and tempered alloy steels

3 Steel vs. concrete

4 Thermal properties

5 Fireproofing of structural steel

COMMON STRUCTURAL SHAPES

In most developed countries, the shapes available are set out in

published standards, although a number of specialist and proprietary cross

sections are also available.

I-beam (I-shaped cross-section - in Britain these include Universal Beams

(UB) and Universal Columns (UC); in Europe it includes the IPE, HE, HL,

HD and other sections; in the US it includes Wide Flange (WF) and H

sections)


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Z-Shape (half a flange in opposite directions)

HSS-Shape (Hollow structural section also known as SHS (structural hollow

section) and including square, rectangular, circular (pipe) and elliptical cross

sections)

Angle (L-shaped cross-section)

Channel ( [-shaped cross-section)

Tee (T-shaped cross-section)

Rail profile (asymmetrical I-beam)

Railway rail

Vignoles rail

Flanged T rail

Grooved rail

Bar a piece of metal, rectangular cross sectioned (flat) and long, but not so

wide so as to be called a sheet.

Rod, a round or square and long piece of metal or wood, see also rebar and

dowel.

Plate, sheet metal thicker than 6 mm or 1/4 in.

Open web steel joist

While many sections are made by hot or cold rolling, others are made by

welding together flat or bent plates (for example, the largest circular hollow

sections are made from flat plate bent into a circle and seam-welded).

Standard structural steels


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Most steels used throughout Europe are specified to comply with the

European standard EN 10025. However, many national standards also

remain in force.

Typical grades are described as 'S275J2' or 'S355K2W'. In these examples,

'S' denotes structural rather than engineering steel; 275 or 355 denotes the

yield strength in newtons per square millimetre or the equivalent

megapascals; J2 or K2 denotes the materials toughness by reference to

Charpy impact test values; and the 'W' denotes weathering steel. Further

letters can be used to designate normalized steel ('N' or 'NL'); quenched and

tempered steel ('Q' or 'QL'); and thermo mechanically rolled steel ('M' or

'ML').

The normal yield strength grades available are 195, 235, 275, 355, 420, and

460, although some grades are more commonly used than others e.g. in the

UK, almost all structural steel is grades S275 and S355. Higher grades are

available in quenched and tempered material (500, 550, 620, 690, 890 and

960 - although grades above 690 receive little if any use in construction at

present).

]

Thermal properties

The properties of steel vary widely, depending on its alloying elements.

The austenizing temperature, the temperature where a steel transforms to an

austenite crystal structure, for steel starts at 900C for pure iron, then, as

more carbon is added, the temperature falls to a minimum 724C for eutectic


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steel (steel with only .83% by weight of carbon in it). As 2.1% carbon (by

mass) is approached, the austenizing temperature climbs back up, to 1130C.

Similarly, the melting point of steel changes based on the alloy.

The lowest temperature at which a plain carbon steel can begin to melt, its

solidus, is 1130 C. Steel never turns into a liquid below this temperature.

Pure Iron ('Steel' with 0% Carbon) starts to melt at 1492 C (2720 F), and is

completely liquid upon reaching 1539 C (2802 F). Steel with 2.1% Carbon

by weight begins melting at 1130 C (2066 F), and is completely molten

upon reaching 1315 C (2400 F). 'Steel' with more than 2.1% Carbon is no

longer Steel, but is known as Cast iron. http://www.msm.cam.ac.uk/phase-

trans/images/FeC.gif

]

Fireproofing of structural steel

In order for a fireproofing product to qualify for a certification listing of

structural steel, through a fire test, the critical temperature is set by the

national standard, which governs the test. In Japan, this is below 400C. In

China, Europe and North America, it is set at ca. 540C. The time it takes

for the steel element that is being tested to reach the temperature set by the

national standard determines the duration of the fire-resistance rating.

Care must be taken to ensure that thermal expansion of structural elements

does not damage fire-resistance rated wall and floor assemblies. Penetrants

in a firewalls and ferrous cable trays in organic firestops should be installed

in accordance with an appropriate certification listing that complies with the

local building code.


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8.PROCESS CHART

PART NAME MACHINING OPERATION

Cylinder bore Boring, hack sawing, Reaming.

Pneumatic Cylinder Turning, Grooving, Drilling,

Tapping.

Ram Turning, Facing, Thread forming.

End plate / Gas cutting Grinding, Shaping, grooving,

Drilling.


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Stud Turning, Threading.

Guide ` Facing, chamfering, welding.

9. DESIGN ASPECTS

PROPERTIES OF MILD STEEL:

Physical property

density-7860kg/m

melting point-1427C

thermal conductivity-63w/mk

CARBON CONTENT

Low corrosion or mild steel-0.15% to 0.45% of carbon

MECHANICAL PROPERTY


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elasticity

ductility

toughness

weld ability

In our design screwed spindles have a main part hence the calculations are

concentrated on it.

10. MATERIALS USED

NAME OF THE COMPONENTS MATERIALS

Cylinder M.S rod

Piston M.S with chromium

Ram M.S rod

Spring M.S

Nipple M.S rod

End plate M.S plate


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11. COST ESTIMATION

S.NO COMPONENT QUANTITY MATERIAL

USED

COST(RS)

1 Pneumatic

cylinder

1 M.S 2800

2 3/2 Direction

control valve

1 - 750

3 Pneumatic

accessories

1 - 450

4 Structure work

Machining cost

1 M.S 1450


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TOTAL 5450

Total material cost =5450

Assembly cost =150

Total cost of the project=5600

12. ADVANTAGE

1. It does not require current carrying cables.

2. No extra skill is required for operating this system.

3. Easier maintenance

4. Operation is very smooth and in this system we can get more output

by applying less effort.

5. Simple construction of pneumatic elements and easy handling.

6. Comparatively cheaper in cost then the other systems.


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7. Compared to hydraulic and mechanical Punching machine pneumatic

Punching machine is economical

8. Efficient Hammer action.

LIMITATION

1. Stroke length is fixed

2. Even a bit of leakage may result in power loss

3. The max pressure is used in the cylinder is (6-12bar)

13. APPLICATIONS

A hammer drill is well suited for drilling hole in msonary or stone. It is also

used to drill holes in concrete footings to pin concrete wall farms to drill

holes in concrete floors to pin wall framing.


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14. WORKING PRINCIPLES OF THE PNEUMATIC

HAMMER

A Pneumatic hammer machine is used for blow and drilling for any

hard surface.. The pneumatic hammer machine is ideal for job fixers and

general engineering applications. They are smooth operating systems for

both vertical and horizontal operations. The fixing capacity of Pneumatic

ram fixers varies as per the strength, power and performance. They are

suited for various types of fixing and forming applications. Before operating


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the hammering machine, first insert the required fixing job in the bed to the

release valve turn the operating handle clock wise until release valve.

After the job is fixed on the base the pneumatic source is executed. At once

the system will function aswellas hammering action will performed.

15. LINE DIAGRAM OF THE PNEUMATIC HAMMER

PUNCHING MACHINE


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CONCLUSION:

This report deals with the design and fabrication of pneumatic

hammer machine and it is attached with the line diagram with design . The


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pneumatic system can be found in almost all industries /fields. However

some of the industrial application is punching, clamping, materials handling,

hammering throughout the project period we gained knowledge on all type

of machining Process and pneumatic system is controlled. We have done to

our ability and skill making maximum use of available facilities.

BIBLOGRAPHY

GUPTA J.K and KHURUMI R.S (1981) Text book of Machine

Design, S.Chand & comp and.

Parr. ANDREW (2003) Hydraulic & Pneumatics Butterworth

Heimann Ltd


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Dr.D.K.AGGARVAL & Dr.P.C SHARMA(2004) machine design,

S.K.Kataria and sons

MAJUMDAR.S.R Pneumatic systems, Tata mcgraw-hills company

ltd.

SRINIVASAN.R(2004) Hydraulic & pneumatic controls, vijay

Nicole imprints private ltd.

pneumatic hammer

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