this project is design engineering 4th sem project for mechanical student

1. GUJARAT TECHNOLOGICAL UNVIERSITY
Chandkheda, Ahmedabad
Affiliated
SMT. SHANTABEN HARIBHAI GAJERA ENGINEERING
COLLEGE
A project report on
(Pneumatic cutting and punching combined machine)
Under subject of
DESIGN ENGINEERING – Ib
BE – II, SEM – IV
(MECHANICAL BRANCH)
Submitted by:
Group:
Sr. Name Enrollment no.
1. CHHATBAR GAURAVKUMAR .P 161303119005
2. BARAIYA VIPULKUMAR .A 161303119002
3. RAMANI MAYUR 161303119015
4. JANI NIKUNJ 161303119006
5. VANI BRIJESH 151300102005
Prof.Vijay Gajera
(Faculty Guide&
Head of department)
Academic year
(2016-17)

2. Certificate
SMT. SHANTABEN HARIBHAI GAJERA ENGINEERING
COLLEGE
(APPROVED BY AICTE)
(Affiliated to Gujarat Technological University)
DEPARTMENT OF MECHANICAL ENGINEERING
CERTIFICATE
This is to certify that Mr./Ms._______________________________________
Enrollment No. ___________________ of semester _____________________has satis-
factorily completed the laboratory work in the course DESIGN ENGINEERIN-1b within
the four walls of the Institute.
Date of submission: ____________________
Faculty In-Charge Internal Examiner External Examiner

3. ACKNOWLEDGEMENT
We are acknowledging my indebtedness and convey my sincere to our project
guide prof.vijay gajera faculty of mechanical, “Smt. SHANTABEN HARIBHAI GAJE-
RA ENGINEERING COLLEGE.” Who sincerely helped us to given inspiration, new
ideas and Infrastructure throughout the semester I would also like to thanks Mechanical
department of S.H.G.E.C. at last I again convey my Special thanks to project guide.
Date:
Place:
Group name:
CHHATBAR GAURAVKUMAR P.
BARAIYA VIPULKUMAR A.
RAMANI MAYUR K.
JANI NIKUNJ J.
VANI BRIJESHKUMAR N.

4. ABSTRACT
We are using scissors for simple sheet metal cutting .it is manual method so that sheet
metals are to be wasted some time because of mistakes happened such as wrong dimen-
sions etc., and also even simple cutting may take long time. Hydraulic machines are also
available for sheet metal cutting. But this method is used for simple metal cutting and its
cost is very high. We are using ta pneumatic system in an easy way. It is operated by a
pneumatic hand lever of four way control valve. Control valve is operated by a compres-
sor.
The press is punching machine tool designed by applying mechanical force or pressure
with the help of compressor .the metal is punched to the desired requirement. The presses
are exclusively intended for mass production and the represent the fastest and more effi-
cient way to a metal into a finished punched product. Press tools are used to form cut thin
metals. Press tools operation can be simplified to a few simple operations involving
punch a die.

5. CONTAIN
CHAPTER 1 INTRODUCTION
1.1 Design Thinking
1.2 Pneumatic cutting and punching combined
machine
CHAPTER 2 AEIOU SUMMARY
2.1. Activities
2.2. Environment
2.3. Interactions
2.4. Object
2.5. Users
CHAPTER 3 EMPATHY MAPPING
3.1. User
3.2. Stakeholders
3.3. Activities
3.4. Story Boarding
(a) Happy story
(b) sad story
(c) happy story
(d) Sad story
CHAPTER 4 IDEATION CANVAS
4.1. People
4.2. Activities
4.3. Situation/Context/Location
4.4. Props/Possible Solutions
CHAPTER 5 PRODUCT DEVELOPMENT CANVAS
5.1. Purpose
5.2. People
5.3. Product Experience
5.4. Product Function

6. 5.5. Product Features
5.6. Components
5.7. Customer Revalidation
5.8. Reject/Redesign/Retain
CHAPTER 6 LEARNING NEED MATRIX
6.1. Purpose/Product concept
6.2. Tools/Methods/Theories/Application process
6.3. Application standards and Design specifica-
tion /Principle & Experiments
6.4. Software / Simulation / Skill /Mathematical
Requirement
6.5. Component materials criteria (Exploration -
varieties / Testing Requirements)
CHAPTER 7 REFERENCE

7. CHAPTER 1
INTRODUCTION
1.1Design Thinking
1.2Pneumatic cutting and punching combined machine
1.1Design Thinking
Design thinking has come to be defined as combining empathy for the context of a prob-
lem, creativity in the generation of insights and solutions, and rationality in analysing
and fitting various solutions to the problem context. According to our team the goal of
Design Thinking is "matching people’s needs with what is technologically feasible and
viable as a business strategy". The premise of teaching Design Thinking is that by know-
ing about how to successfully approach and solve difficult, multidimensional problems
more specifically, effective methods to ideate select and execute solutions individuals
and businesses will be able to improve their own problem solving processes and skills.
There is also significant academic interest in understanding how designers think and de-
sign cognition.
Design thinking is a formal method for practical, creative resolution of problems and cre-
ation of solutions, with the Intent of an improved future result. In this regard it is a form
of solution based or solution focused thinking; starting with a goal (a better future situa-
tion) instead of solving a specific problem. By considering both present and future condi-
tions and parameters of the problem, alternative solutions may be explored simultaneous-
ly. Cross asserted that this type of thinking most often happens in the built, or artificial,
environment (as in artefacts).
Focus on people / customers and their needs and not on a specific technology or oth-
er conditions.
 Methods therefore used are observations, interviews, brainstorming, prototyping…
 Innovating at the intersection of business, technology and people leads to radical,
new experience innovation.
 The user is the one to decide if a product or a service should exist or be established

8.  In short Design Thinking is a process through which we can make or modify new
technology for betterment of common people.

9. 1.2. Pneumatic cutting and punching combined machine
As mentioned above, several cutting processes exist that utilize shearing force to cut
sheet metal. However, the term “shearing” by itself refers to specific cutting process that
produces straight line cuts to separate a piece of sheet metal. Most commonly, shearing is
used to cut a sheet parallel to an existing edge which is held square, but angled cuts can
be made as well. For this reason, shearing is primarily used to cut sheet stock in to a
smaller size in preparation for other processes. Shearing has the following capabilities.
Sheet thickness: 1-3 mm
the pneumatic machine includes a table with supports arm to hold the sheet ,stops or
guides to secure the sheet , upper and lower straight-edge blades a gauging device to pre-
ciously position the sheet. The table also includes the two way directional valve is con-
nect to the compressor .the compressor has a piston for a movable member. The piston is
connected to a crank shaft, which turn connected to a prime mover.at inlet and outlet
parts, valves allow air to enter and exit the chamber. When the compressor switches on,
the compressed air is flow to inlet of the pneumatic cylinder.
The sheet is placed between upper and lower blade. The lower blade remains stationary
while upper blade is forced down word. The upper blade is slightly offset from the lower
blade, approximately 5-10% of the sheet thickness .also the upper blade is usually angled
so that the cut progresses from one end to other, thus reducing the required force.
When the pneumatic hand operated lever is moved forward, the piston starts moving in
the forward direction. The upper blade which are the forced again the sheet, cutting the
material. When the pneumatic hand operated lever is moved backward, the upper blade
will come to the original position.
 After the material; is cut, adjust the pneumatic hand lever to the mid position and
then the compressor is switched off.
 Punching is a metal forming process that punch press to a force a tool, called a
paunch through work piece to create a hole is sheet metal is deposited into the die
in the process.
 The punch is located on the opposite side of the work piece and supports the mate-
rial around the perimeter of the hole to localize the sharing forces for a cleaner
edge.
 There is small amount of clearance between the punch and the die to the prevent
the punch from sticking in the die and so less force is needed to make the hole.

10. When the air compressor, it will be Decision to move the tool down also it will up and
down movement when the obstacle crossing time the will also press sheet with help of
the pneumatic cylinder, and it will be given to the solenoid valve and then it will move up
and down depends upon air speed, the tool movement up and down can be done with the
help of pneumatic cylinder

11. CHAPTER 2
AEIOU SUMMARY
2.1. Activities
2.2. Environment
2.3. Interactions
2.4. Object
2.5. Users
2.1. Activities
 Machine setup
 Sheet load on machine
 Cutting operation
 Punching operation
 Production of desired components
 inspection
2.2. Environment
 Sunny day
 Green area
 Clean the research area
 Regular Garbage disposal
 Controlled use water
2.3. Interactions
 Task about problem
 Area pro habitation for worker, staff, outdoors
 Interaction with worker
 Internal conversation between supervisor and workers

12. 2.4 Object
 Cutting tool
 Punching tool
 Sheet metal
 Double acting cylinder
 Pressure gauge
 Pressure control valve
 Air tube
2.5. Users
 Workers
 Supervisor
 Inspection engineer
 Manager

13. AEIOU Summary canvas

14. CHAPTER 3
EMPATHY MAPPING
3.1. User
3.2. Stakeholders
3.3. Activities
3.4. Story Boarding
(a) Happy story
(b) Sad story
(c) Happy story
(d) Sad story
3. Empathy Mapping
 We are regularly seen this problem which is very important. So we decided to
work on this problem and want to find valuable solution. We put ourselves in this
kind of condition and though what kind of problem we have to face and what can
we do for it.
3.1. User
 Workers
 Supervisor
 Inspection engineer
 Manager
3.2. Stakeholders
 Automobile industries
 Sheet cutting industries
 Punching industries
 Boiler industries

15. 3.3. Activities
 Machine setup
 Sheet load on machine
 Cutting operation
 Production of desired components
 inspection
3.4. Story Boarding
(a) Happy story: After visit we research about this problem we find the solution. The
pneumatic cylinder arrange in the cutting machine and consist tube, punch tool, four way
control valve etc. And make the design. These solutions say to workers. Hence workers
are happy.
(b) Sad story: We arrange the industrial visit for our domain, we go to the GIDC area
in sheet cutting industries there we meet their workers and discuss about the operation
and working etc. and their one worker kishorbhai take sheet and go for punching other
section and kishorbhai say this problem and he was sad.
(c) Happy story: We meet again industries manager to give this solution. He was sur-
prised. He gives good compliments of our solution. We are so happy for manager com-
pliments of our solution.
(b) Sad story: We meet the industries manager and discuss about the production line.
He said sometime I can’t achieve my production target because of material handling for
different operations.

16. Empathy Mapping Canvas

17. CHAPTER 4
IDEATION CANVAS
4.1. People
4.2. Activities
4.3. Situation/Context/Location
4.4. Props/Possible Solutions
4.1. People
 Students
 Workers
 Supervisor
 Inspection engineer
 Manager
4.2. Activities
 Machine setup
 Sheet load on machine
 Cutting operation
 Punching operation
 Production of desired components
 inspection
4.3. Situation/Context/Location
 Automobile industries
 Sheet cutting industries
 Punching industries
 Boiler industries
 Tools industries
4.4. Props/Possible Solutions
 Cutting and punching combined operation
 Production of desired components

18. Ideation Canvas

19. CHAPTER 5
PRODUCT DEVELOPMENT CANVAS
5.1. Purpose
5.2. People
5.3. Product Experience
5.4. Product Function
5.5. Product Features
5.6. Components
5.7. Customer Revalidation
5.8. Reject/Redesign/Retain
5.1. Purpose
 Combined operation
 Less time
 High accuracy
 Low cost
5.2. People
 Students
 Workers
 Supervisor
 Inspection engineer
 Manager
5.3. Product Experience
 Time less operation
 Two operation at one time
 Accurate

20. 5.4. Product Function
 Cutting operation
 Punching operation
 Cutting and punching combined operation
5.5. Product Features
 Renewable
 Sustainable
 Low costly
 Less time
 Two operation
5.6. Components
 Cutting Tool
 Punching Tool
 Sheet Metal
 Double Acting Cylinder
 Pressure Gauge
 Pressure Control Valve
 Air Tube
5.7. Customer Revalidation
 they can get optional operation
5.8. Reject/Redesign/Retain

21. Product Development Canvas

22. CHAPTER 6
LEARNING NEED MATRIX
6.1. Purpose/Product concept
6.2. Tools/Methods/Theories/Application process
6.3. Application standards and Design specification /Principle &
Experiments
6.4. Software / Simulation / Skill /Mathematical Requirement
6.5. Component materials criteria (Exploration - varieties / Testing
Requirements)
6.1. Purpose/Product concept
 Combined operation
 Less time
 Flexibility
 High accuracy
6.2. Tools/Methods/Theories/Application process
Stage-1
 research about combined operation
 check the design cutting machine
Stage-2
 tools arrangements
 flexibility arrangements
 computer graphics
Stage-3
 developed punching machine in the cutting machine
 cutting and punching combined process
 two operation can be performed

23. 6.3. Application standards and Design Specification /Principle
&Experiments
Stage-1
 flexible manufacturing principle fixing principle
Stage-2
 design specification as a design checked
 tools standard
 ASME standard
Stage-3
 For validation part need to understand as per Industrial Staff Requirement

6.4. Software / Simulation / Skill /Mathematical Requirement
Stage-1
 2D Modelling(Auto cad)
 Image possessing
Stage-2
 3D Modelling(Auto cad)
 Image possessing
Stage-3
 Drafting detail list
 Assumable design

24. 6.5. Component materials criteria (Exploration - varieties / Testing Re-
quirements)
Stage-1
 List of material
 Availability of material in market
Stage-2
 Material testing as per application
 Cost comparison
Stage-3
 cutting tool
 punching tool
 sheet metal
 double acting cylinder
 pressure gauge
 pressure control valve
 air tube

25. Learning Need Matrix

26. CHAPTER 7
REFERENCE
 en.wikipedia.org
 A Text book of machine design by r s khurmi and j k gupta
 www.scrib.com
 www.google.com