Design and fabrication of pneumatic loaded simply supported beam apparatus

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY
KAKINADA
Design and fabrication of pneumatic loaded simply supported beam apparatus
A project report submitted to
Jawaharlal Nehru Technological University Kakinada
in partial fulfillment for the award of the degree of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
By
P. OJES SAI
(Regd. No. 13H71A0323)
Under the Esteemed Guidance of
Mrs. K.SHAMNUKHI
Assistant Professor
DEPARTMENT OF MECHANICAL ENGINEERING
Devineni Venkata Ramana & Dr. Hima Sekhar
MIC College of Technology
Approved by AICTE, Affiliated to JNTUK,
NBA Accredited: B. Tech CSE | ECE | EEE | MECH
Kanchikacherla, Krishna District, Pin: 521180. A.P. India.
2016-17
IS0 9001:2008
Certified Institution

ACKNOWLEDGEMENT
We would like to express our profound sense of gratitude to our guide, Mrs. K.
Shanmukhi (Assistant Professor), for her encouragement, advice, mentoring and research
support throughout our project. Her technical and editorial advice was essential for the
completion of this dissertation.
We have the immense pleasure in extending our sincere thanks and deep sense of
gratitude to, Dr. Y.Sudheer Babu, Principal and Dr. M. Sreenivasa Rao, Professor and Head
of the Mechanical Engineering Department, for their advice and providing necessary facility for
our work.
We would also like to thank our project coordinator Mr. R. Ranjit Kumar, Assistant
Professor, Department of Mechanical Engineering.
Making the project reality takes many dedicated people and it is our immense pleasure to
acknowledge the contribution to the entire Mechanical Engineering Staff.
We thank one and all who either directly or indirectly co-operated in successful
completion of our project work.

Contents:
1. Abstract
2. List of Figures
3. List of tables
4. List of Graphs
Chapter 1: Introduction
1.1 Introduction of Beams
1.2 Types of Beams
1.2.1 Based on Equilibrium Conditions:
1.1.2 (a) Statically Determinate Beam
1.2.2 (b) Statically Indeterminate Beam
1.2.3 Beams Based On the Type of Support
1.2.3 (a) Simply Supported Beam
1.2.3 (b) Fixed Beam
1.2.3 (c) Cantilever Beams:
1.2.3 (d) Continuously Supported Beam
1.3 Types of Loads:
1.3.1 Concentrated or Point Load
1.3.2 Uniformly Distributed Load
1.3.3 Uniformly Varying Load
1.4 Types of Beam Materials
1.5 Deflection
1.6 Bending Stress
1.7 Shear Force
1.8 Bending Moment
1.8.1 Positive Bending Moment

1.8.2 Negative Bending Moment
1.9 Assumption in the Theory of simply bending:
1.10. Simply Supported Beam Apparatus:
1.10.1 Theoretical calculation:
1.10.2 Experimentation
1.11 Drawbacks of Conventional Apparatus
1.12 Aim and Objective
1.12.1 Aim
1.12.2 Objective
Chapter 2: Literature Survey
Chapter 3: Design & Fabrication
3.1 Design & Fabrication
3.2 Design Consideratiion for Simply Supported Beam
3.2.1Design of the Pneumatic Loaded Simply Supported Beam Structure
3.2.2 Design of Supporting Beam
3.2.3 Design of Loading Beam
3.2.3 Design of Point Load Fixture
3.2.4 Design of Knife Edge Supports
3.2.5 Design of Mountings
3.3 Design in AUTOCAD
3.4 Design in Solidworks
3.4.1 Loaind & Suppoting Beam & Side Beam
3.4.2 Knife Edge Supports
3.6 Pneumatic circuit Design
3.7 Components Used
3.7.1 Pneumatic Cylinders

3.7.2 Pressure Regulators
3.7.3 Direction Control Valve
3.7.4 Pressure Gauges:
3.7.5 Flow Control Valves
3.7.6 Air Filter
3.7.6 Pneumatic lubricator
3.7.7 Pneumatic Silencer
3.7.8 T-Connectors
3.7.9 Hose Pipes
3.7.10 Dial Indicator
3.7.11 Air Compressor
3.7.12 Pressure Transducer
3.8 Fabrication
3.8.1 Fabrication of Apparatus Structure
3.8.2 Fabrication of Supporting and loading beam
3.8.3 Fabrication of Point Load Fixture
3.8.4 Fabrication of Knife Edge Supports
3.8.4 Fabrication of Mounting Plates
Chapter 4: Working & Experimentation
4.1 Working of Beam Apparatus:
4.2Experimentation Procedure
4.3 Experimentation on Conventional Simply Supported Beam Apparatus:
4.3 Pressure to Force calculation:
Chapter 5: Results and Discussion

Abstract
A beam is a structural member which is subjected to loads applied transverse
to long dimensions, causing the member to bend.
The main motive of project is to replace traditionally used beam with the
present need, by using components like pneumatic cylinders for applying loads and
dial gauges for deflection measurement.
Conventionally used apparatus are made of wood, have low rigidity and
load bearing capacity. In order to overcome these drawbacks a simply supported
beam is designed using solid works and fabricated, which is suitable for different
material types. Loading capacity of the fabricated apparatus is increased drastically
and load can be applied simultaneously at any two points. The deflection analysis
of beams will be observed by applying different loads at different points.
This experimental setup also subjugated the drawback of manual loading
and parallax errors.
Keywords: Beam, loading, pneumatic cylinders, deflection, dial gauges, pressure
gauges

Design & Fabrication of Pneumatic Loaded Simply Supported Beam Apparatus
DVR & Dr HS MIC COLLEGE OF TECHNOLOGY Page 1
1. INTRODUCTION
1.1 Introduction of Beams:
A beam is a structural element that capable of withstanding load primarily by
resisting against the bending.
In general, whenever a horizontal beam is loaded with vertical loads, sometimes, it
bend i.e. deflects due to the action of the loads. The amount with which beam bends is
depends upon the type of loads, length of beam, elasticity of beam and type of beam.
The beam theory is one of the basic knowledge to be acquired for all industrial
engineers. The beam deflection is capable of measuring support reaction, shearing force,
bending moment, deflection, deflection angle, young modulus of various materials. In the
same way, the apparatus allow deeper understanding of the significance of the beam
theory through comparative examination between obtained experimental values and the
theoretical values.
1.2 Types of Beams:
Beams can be classified into many types based on three main criteria. They are as follows:
1.2.1 Based on Geometry:
1. Straight beam – Beam with straight profile
2. Curved beam – Beam with curved profile
3. Tapered beam – Beam with tapered cross section
4. Based on the shape of cross section:
i. I-beam – Beam with ‘I’ cross section
ii. T-beam – Beam with ‘T’ cross section
iii. C-beam – Beam with ‘C’ cross section
1.2.2 Based on Equilibrium Conditions:
1.2.2 (a) Statically Determinate Beam:
For a statically determinate beam, equilibrium conditions alone can be used to solve
reactions.
Ex: Cantilever Beam, Simply Supported beam, Over hanging beam

1.2.2 (b) Statically Indeterminate Beam:
For a statically indeterminate beam, equilibrium conditions are not enough to solve
reactions. Additional deflections are needed to solve reactions.
Ex: Fixed (or) built in beam, Continuous Beam
1.2.3 Based on the Type of Support:
1.2.3 (a) Simply Supported Beam:
If the ends of a beam are made to rest freely on supports beam, it is called a simply
(freely) supported beam.
Fig: 1.1 Simply Supported Beam
1.2.3 (b) Fixed Beam:
If a beam is fixed at both ends it is free called fixed beam. It’s another name is
built-in beam or encastre beam.
Fig: 1.2 Fixed Beam
1.2.3 (c) Cantilever Beam:
If a beam is fixed at one end while the other end is free, it is called cantilever
beam.
Fig: 1.3 Cantilever Beam:

1.2.3 (d) Continuously Supported Beam:
If more than two supports are provided to beam, it is called continuously
Supported beam.
Fig: 1.4 Continuously Supported Beam
1.3 Types of Loads:
A beam may be subjected to either or in combination of the following loads:
1.3.1 Concentrated or Point Load
A point load is a load applied to a single, specific point on a structural member.
FIG: 1.5 Concentrated or Point Load
1.3.2 Uniformly Distributed Load:
A uniformly distributed load has a constant value, for example, 1kN/m; hence the
"uniform" distribution of the load. Each uniformly distributed load can be changed to a
simple point force that can be used to determine the stresses in an object.

Fig: 1.6 Uniformly Distributed Loads
1.3.3 Uniformly Varying Load:
Uniformly Distributed Load (UDL) is that whose magnitude remains
uniform throughout the length.
Fig: 1.7 Uniformly Varying Load:
1.4 Types of Beam Materials:
In general, beam materials are
 Wood
 Steels
 Concrete
 Composites
1.5 Terms Used in Beam Analysis
1.5.1 Deflection:
It is the degree to which a structural element is displaced under a load. It refers to
an angle or a distance.

1.5.2 Bending Stress:
The resistance offered by the internal stresses to the bending is called bending
stress.
1.5.3 Shear Force:
The algebraic sum of the vertical forces at any section of a beam to right or left of
the section is known as Shear force.
1.5.4 Bending Moment:
The algebraic sum of the moments of all the forces acting to right or left of the
section is knows as Bending.
1.5.4 (a) Positive Bending Moment:
We take the bending moment at a section as positive, if it tends to bend the bean at
that point to a curvature having concavity at top; it is called as Sagging moment.
1.5.4 (b) Negative Bending Moment:
We take the bending moment at a section negative, it tends the bean at point to a
curvature having convexity at top, it is also called as Hogging moment.
Fig 1.8 Positive & Negative Bending Moment
1.6 Assumption in the theory of simple bending:
The following assumption is made in the theory of simple bending:
 The material of beam is perfectly homogenous and isotropic.
 The beam material is stressed within its elastic limit and thus, obeys Hooke’s law.
 The transverse section, which was plane before bending, remains plane after
bending also.

 Each layer of the beam is free to expand or contract, independently, of the layer
above or below it.
 The valve of Young’s modulus of elasticity is same in tension and compression.
 The beam is in equilibrium i.e., there is no resultant pull or push in the beam
section.
1.7 Conventional Simply Supported Beam Apparatus:
Simply supported beam is supported at both ends. It allows rotation at either end
(support) but doesn't allow for vertical movement. As a result of this vertical reactions are
produced at the supports as movement or displacement is not allowed in the vertical
direction. But the supports are free from rotational moments (reactions).
Deflection of beams can be calculated theoretically and can experimentally
calculate.
1.7.1 Theoretical calculation:
For a Simply supported beam
Deflection mm
Where W= Load in Newton’s N
E=Young’s modulus of beam material in
L= Length of beam in mm
I= moment of inertia about material axis =
b=breadth of beam in mm
1.7.2 Experimentation:
It consists of on fixed and movable wood supports on which beam is placed. The
span, breadth and depth are too measured with ruler and venires callipers. Loads are
applies on beam by means of dead weights and handing pane, beam deflections are
obtained by outside callipers with respect to other member , and reading are tabulates and
compared. And graph is plotted between load and deflection.

Fig 1.9 Conventional Simply Supported Beam Apparatus
1.7.3 Drawbacks of Conventional Apparatus:
1. Loading capacity is limited to 2.5 kg.
2. Whole setup is made of wood, which doesn’t with stand heavy load.
3. Deflections are taken from outside calliper, which is not accurate because for every
reading calliper distance to be measured.
4. Amount of deflection is taken with respect to other member (ruler).
5. Only wood beam can be experimented in this apparatus.
6. This apparatus are not rigid.
1.8 Proposed Work
To design a simply supported beam apparatus using solid works and fabricate the
apparatus to achieve following
1. To increase the loading capacity of simply supported beam apparatus up to 25 kg
by avoiding manual loading.
2. To achieve higher accuracy level.
3. To facilitate different beam materials for experimentation.
4. To build rigid apparatus.

2. LITERATURE REVIEW
Literature survey is done on the areas of simply supported beam analysis, beam
deflection apparatus and pneumatic systems, books and research articles are referred. The
details are discussed below.
Review of Literature
Buliaminu Kareem[1]
This paper review that, continued hike in cost of laboratory equipment calls for
seeking an alternative way of manufacturing such equipment using indigenously sourced
material. The most critical laboratory equipment useful in material testing is Beam
Deflection Apparatus (BDA) which is useful in the determination of elastic modulus of
engineering materials and among others. It was designed to comprise a spring, dial gauge,
beam support and measuring scale. The spring permitted the horizontal movement, while
the deflection of beam was measured by the dial gauge with the scale measuring the length
of the expansion. The assembled apparatus comprised leaf spring, bolts, load hanger, T-leg
and spring support with one side fixed. Test experiments were carried out on the
apparatus, in the areas of young’s modulus of material determination under a given
loading system. The results from the test showed that the apparatus performance is
adequate. This has supported the efficacy of the apparatus as a replacement to the
imported ones in the institutional laboratories.
Shahin Nayyeri Amiri, Mbakisya Onyango[2]
The response of a simply-supported beam on elastic foundation to repeated moving
concentrated loads is obtained by means of the Fourier sine transformation. The cases of
the response of the beam to loads of different and equal magnitude are studied. Numerical
examples are given in order to determine the effects of various parameters on the response
of the beam.

Kyungwoo Lee [3]
Large deflection of cantilever beams made of Ludwick type material subjected to a
combined loading consisting of a uniformly distributed load and one vertical concentrated
load at the free end was investigated. Governing equation was derived by using the
shearing force formulation instead of the bending moment formulation because in the case
of large deflected member, the shearing force formulation possesses some computational
advantages over the bending moment formulation. Since the problem involves both
geometrical and material non-linearities, the governing equation is complicated non-linear
differential equation, which would in general require numerical solutions to determine the
large deflection for a given loading. Numerical solution was obtained by using Butcher's
fifth order Runge–Kutta method and are presented in a tabulated form.
A.N. Kounadis, D. Sophianopoulos. G. Michaltsos [4]
This paper deals with the linear dynamic response of a simply supported uniform
beam under a moving load of constant magnitude and velocity by including the effect of
its mass. Using a series solution for the dynamic deflection in terms of normal modes the
individual and coupling effect of the mass of the moving load, of its velocity and of other
parameters is fully assessed. A variety of numerical results allows us to draw important
conclusions for structural design purposes.
Nie Jianguo, Shen Jumin [5]
Theoretical analysis and derivation are conducted for the effect of slip on the
deformation of simply supported composite steel concrete beams. On the basis of
established differential equation of relative slip, formulae predicting the deflection due to
the effect of slip are proposed for different loading cases. Revised and simplified, a
general formula predicting the deflection of simply supported composite steel concrete
beams is suggested, with the consideration of effect of slip and incomplete shear
connection. The proposed formula is well coincided with the experimental results.

S.C Fok, E.K Ong [6]
Pneumatic cylinder systems have the potential to provide high output power to
weight and size ratios at a relatively low cost. However, they are mainly employed in
open-loop control applications where positioning repeatability is not of great importance.
In this paper the repeatability of a pneumatic rod less cylinder system under closed-loop
PD control is examined for its potential use in robotic applications. Our analysis shows
that the linearized continuous time dynamics is dependent on the trimmed and operating
conditions. This can cause positioning problems when a controller is designed based upon
the transfer function obtained at a particular trimmed point. Furthermore, there are
uncertainties associated with the dynamics which can lead to precision errors in both
transient and steady-state responses. Due to these complexities, a pragmatic gain tuning
methodology is proposed to achieve satisfactory nominal transient response characteristics
over the range of loading requirements. With this scheme, it is suggested that the
performance of the conventional controller be evaluated in terms of its repeatability. The
repeatability of the system under different start–stop positions and loading conditions is
experimentally found to be less than ±0.3 mm. This repeatability value is within typical
industrial requirements.
Yunxu SHI, Xiaoping LI and Yan TENG [7]
The air with certain pressure in a pneumatic cylinder is usually exhausted into the
atmosphere after work process. It is of significant that the air energy can be saved and re-
used. In this paper, the constitution of an exhausted-air reclaiming system for pneumatic
cylinders is studied. To find the possible influence on the cylinder work process, the effect
of the system on the cylinder velocity characteristics is also researched and different
control switch points are tested. Experimental results show that attaching a reclaiming
device would not cause bad influence on the velocity stability if the switch point could be
properly controlled. Experiments also indicate that the switch control differential pressure
varies with in the receiver and the supply pressure would affect the velocity
stability of cylinders. Therefore to reclaim more energy and make less influence on the
cylinder velocity characteristics, the suitable differential pressure and switching-
point are also tested and suggested.

G. McLatchey, J. Billingsley [8]
The supporting legs of legged robots form part of multiple closed kinematic chains in
which antagonistic forces can pose a problem. In this paper, methods of compliance and
force control are explored to resolve this. A ‘nested loop’ topology of non-linear control
for pneumatic cylinders is outlined and its performance in actual implementation is
reported.

3. Design & Fabrication
3.1 Design & Fabrication
The main aim of the project is to design and fabricate simply supported beam
apparatus that will accommodate all types of beam materials which can be loaded by
concentrated loads.
3.2 Design Consideration for Simply Supported Beam Apparatus:
This is concerned with the detailed design of the beam deflection apparatus. This
includes design specification and choice of material used in the constructing of the
apparatus. In the production of apparatus, cost, maintenance, portability, efficiency and
other characteristics were considered. The beam deflection apparatus is laboratory
equipment widely used in construction industry and tertiary institutions. Some of the
design consideration includes:
Reliability:
This is the acceptability of the apparatus over a period of time. It is the possibility
of the apparatus to perform without failure under a given condition for a specific period.
Thus, from the design stage, the possibility of operating the apparatus for a long period of
time without excessive failure of component parts or breakdown of operation was
considered.
Ergonomics:
This can be defined as the study of working condition. It is important in the design
of equipment to enable people work more efficiently. It is the study of objects, systems
and the environment for their safe and efficient use by people concerned and those within
the operational environment. It deals with human comfort obtained in the use of a given
product. The apparatus was designed in such a way that the operator can operate it safely,
easily and effectively by putting the following factors into consideration; personnel
protection, and stability. Personnel protection entails designing for consideration for safety
of the personnel such as minimizing excessive noise, guarding moving parts that can
course injury and ensuring the comfort of the operator. Stability involves designing to
ensure rigidity and stability of the apparatus. The height of the beam deflection apparatus
was carefully chosen and considered during the design and construction of the apparatus.
This allows the operator to operate the apparatus at a convenient working height. The size

of the individual components, sub-system and the entire apparatus were designed to ensure
portability, easy accessibility for maintenance and operation.
3.2.1Design of the Apparatus Structure:
The structure consists of three different support frames namely loading beam,
supporting beam, side Channels.
Mild steel C-channels 75×35 mm are selected for fabrication of these frames. This
material was found to be easily machinable by cutting and wieldable during fabrication.
3.2.2 Design of Supporting Beam:
Supporting beam are made from the C channel a 14mm slot is made on it to
provide way to the knife edge supported.
3.2.3 Design of Loading Beam:
It also contain 14 mm slot to hold the pneumatic cylinders ,supporting beam
material is made of mild steel.
3.2.3 Design of Point Load Fixture:
Point load fixtures were made for easy application of point loads. This is done by
hanging at Specific position on the beams; these are fixed to pneumatic cylinders,
The fixtures were designed to consist of mild steel 20 mm round rod welded to 20
mm angle cut square rod.
3.2.4 Design of Knife Edge Supports:
The knife edge supports are designed from mild steel rectangular solid block and
square rods. These are placed on supporting beam and can be fixed by studs. Beam is
placed on these knife edge supports.
3.2.5 Design of Mountings:
Mounting for pneumatic cylinder are made for MS flats 40×100 mm, 8 mm holes
are made on to hold the cylinders rigidly.

3.3 Design in AUTOCAD
Fig: 3.1 Simple Supported Beam Design in AutoCAD
3.3.1 Commands Used:
 Line (l)
 Dimensions
 Circle(c)
 Dimension styles
 Offset(0)
 trim (tr)
 Copy(co)
 By layer
 Mirror(Mi)
 Plot
 Move (m)
 text
 Construction line (xl)
 Rectangle (Rec)

3.4 Design in Solidworks:
Fig:3.2 Isomertic View Of beam Apparatus

3.4.1 Loaing & Suppoting Beam & Side Beam
Fig: 3.3 Loading beam Fig: 3.4 Supporting beam

3.4.2 Knife Edge Supports
Fig :3.5 Knife Edge supports
Commands Used :
Extrude
Extrude Cut
Mate
Hole
Line
Hole Wizard
Slot
Circle
Smart Dimensions
2D Drawing View

3.6 Pneumatic circuit Design :
Fig: 3.6 Pneumatic Circuit
The pneumatic circuit is necessary for working of pneumatic cylinders. It has
compressor which draws air atmosphere and increases its pressure.
Pressurized air enters the air filter in which dirt particles and moister contents are
removed.
Purified air now mixes with lubricating oil in lubricator, to reduce friction for
moving parts such as cylinders direction control valve.
Then air goes to Direction control valve which helps the cylinder to move TDC to
BDC and vies versa.
Pressure Regulators in line maintain the constant pressure in the system.
The regulated pressure can be seen in pressure gauges.
For rated pressure the pneumatic cylinder open and applies load according to the
pressure applied on it.
T connectors connect the hose pipes in the circuit.

3.6.1 Pressure Measurement:
Pressure gauges are regularly used for pressure measurement, as we need accurate
and minute change in pressure we go with pressure sensor which requires Arduino board
in which progress is dumped.
Arduino board is signal process unit which receive signals from the sensor, here
the signals are manipulated according to code dumped in it and show the output in bar.
Fig 3.7 Arduino Board
3.6.2Code for Pressure Sensor:
Void setup()
{
Serial.begin(9600);
}
void loop(){
int sensorVal=analogRead(A1);
//Serial.print("Sensor Value: ");
//Serial.print(sensorVal);
float voltage = (sensorVal*5.0)/1024.0;
//Serial.print("Volts: ");
//Serial.print(voltage);
float pressure_pascal = (3.0*((float)voltage-0.47))*1000000.0;
float pressure_bar = pressure_pascal/10e5;
float load_value = pressure_bar*8.1936799;
Serial.print("Pressure = ");
Serial.print(pressure_bar);
Serial.print(" bars");

Serial.print(" Load_value = ");
Serial.print(load_value);
Serial.println("Kg");
delay(2000);
}
3.7 Components Used:
Table 3.1 List of Components
S.no Item Name QTY Specifications
1. Pneumatic Cylinders 2 Double acting,0-10 bar
2. Pressure Regulators 2 0-10 bar, Single stage regulator
3. Direction Control valve 1 5/2 Level operated, 0-10 bar
4. Pressure Gauges 2 0-10 bar
5. Flow control valve 3 ¼ inch 8mm OD
6. Lubricator 1 ¼ inch,0-10 bar
7. Air Filter 1 ¼ inch , 0-10 bar
8. Ball valve brass 1 ¼ inch
9. Steel rule 2 SS,1m length
10. Silencer 2 ¼ inch
11. T- Connectors 4 8mm
12. Nipples 12 ¼ inch
13. C- Channel 1 14ft,75×35×4mm,
14. MS flat 1 2ft,50×5mm
15. Bolt & Nuts 4 M12
16. Hose Pipe 1 6mt,8mm,PVC
17. Dial Gauge 1 50mm range
18. Lubricating oil 1 32 grade,1lt
19. Pressure Transducers 2 0-12 bar
20. LED display, panel 1 16×2
21. Arduino board 1 UNO. 12v

3.7.1 Pneumatic Cylinders:
Pneumatic cylinders are also known as air cylinders, there are mechanical devices
which use the power of compressed gas to produce a force in a reciprocating linear
motion.
Double-acting cylinders (DAC) use the force of air to move in both extends and
retract strokes. They have two ports to allow air in, one for outstroke and one for in stroke.
This are used to apply loads on the beams.
Fig 3.8 Pneumatic Cylinders
3.7.2 Pressure Regulators:
A pressure regulator is a control valve that reduces the input pressure of a fluid to a
desired value at its output. Regulators are used for gases and liquids. Its primary function
is to match the flow of gas through the regulator to the demand for gas placed upon it,
whilst maintaining a constant output pressure.
High pressure gas from the supply enters into the regulator through the inlet valve.
The gas then enters the body of the regulator, which is controlled by the needle valve. The
pressure rises, which pushes the diaphragm, closing the inlet valve to which it is attached,
and preventing any more gas from entering the regulator.
Fig 3.9 Pressure Regulators

3.7.3 Direction Control Valve:
Directional control valves are one of the most fundamental parts in hydraulic
machinery as well as pneumatic machinery. They allow fluid flow into different paths
from one or more sources. They usually consist of a spool inside a cylinder which is
mechanically or electrically controlled. The movement of the spool restricts or permits the
flow, thus it controls the fluid flow.
A 5/2 way directional valve from the name itself has 5 ports equally spaced and 2
flow positions. It can be used to isolate and simultaneously bypass a passage way for the
fluid which for example should retract or extend a double-acting cylinder.
Fig 3.10 Direction Control Valve
3.7.4 Pressure Gauges:
Pressure gauges are the most frequently used pressure measuring instruments.
Their pressure element is often referred to as a Bourdon tube. The principle is based on an
elastic spring, a c-shaped, bent tube with an oval cross-section.
When the internal space of the Bourdon tube is pressurised, the cross-section is thus
altered towards a circular shape. The hoop stresses that are created in this process increase
the radius of the c-shaped tube. As a result, end of the tube moves by around two or three
millimetres. This deflection is measure of pressure. It is transferred to a movement, which
turns the linear deflection into rotary movement and, via a pointer makes this visible on a
scale.
Fig 3.11 Pressure Gauges

3.7.5 Flow Control Valves:
Flow Control Valves are used to reduce the rate of flow in a section of a pneumatic
circuit, resulting in a slower actuator speed. Unlike a Needle Valve, a Flow Control Valve
regulates air flow in only one direction, allowing free one flow in the opposite direction.
Fig 3.12 Flow Control Valves
3.7.6 Air Filter:
A pneumatic filter is a device which removes contaminants from a compressed
air stream. This can be done using a number of different techniques, from using a "media"
type that traps particulates, but allows air to pass through to a venture, to a membrane that
only allows air to pass through.
Typical commercial pneumatic filters will remove particles as small as 5
micrometres from the air. The filters protect pneumatic devices from damage that would
be caused by these contaminants. These contaminants include lubricant particles ejected
by the compressor, dirt particles, small water droplets or aerosols.
Fig 3.13 Air Filter

3.7.6 Pneumatic lubricator:
A pneumatic lubricator injects an aerosolized stream of oil into an air line to
provide lubrication to the internal working parts of pneumatic tools, and to other devices
such as actuating cylinders, valves and motors.
Compressed air enters the inlet port and passes over a needle valve orifice attached
to a pick-up tube. This tube - often equipped with a sintered bronze filter - is submerged
into a reservoir bowl filled with light machine oil. Oil is pulled up by the venture effect,
and emitted as an aerosol at the outlet port. The needle valve is typically situated within a
clear polycarbonate or nylon housing to aid in oil flow rate adjustment. Some Compressor
oils and external chemicals can cause polycarbonate and/or nylon sight glass to be
degraded and create a safety hazard.
Fig 3.14 Pneumatic lubricator
3.7.7 Pneumatic Silencer:
Pneumatic Silencers can effectively reduce pneumatic equipment noise. The
mufflers are engineered to provide an optimal balance between noise reduction and
acceptable backpressure in the pneumatic system. Silencers are installed in pneumatic
devices wherever compressed air is set free to atmosphere. Silencer can reduce noise up to
20 dB.
Fig 3.15 Pneumatic Silencer

3.7.8 T-Connectors:
A Tee connector is that connects three hose pipes together. It is usually in the
shape of a capital and the three connector points can be either female or male gender, and
could be different or the same.
Fig 3.16 T-Connectors
3.7.9 Hose Pipes:
A hose is a flexible hollow tube designed to carry fluids from one location to
another. Hoses are flexible vessels that are constructed of multiple layers of different
materials. Fittings for hoses are often not permanent, since the hose itself is often replaced
in time due to wear.
Fig 3.17 Hose Pipes
3.7.10 Dial Indicator:
Probe indicators typically consist of a graduated dial and needle driven by
clockwork (thus the clock terminology) to record the minor increments, with a smaller
embedded clock face and needle to record the number of needle rotations on the main dial.
The dial has fine gradations for precise measurement. The spring-loaded probe (or
plunger) moves perpendicularly to the object being tested by either retracting or extending
from the indicator's body.

Fig 3.18 Dial Indicator
3.7.11 Air Compressor:
An air compressor is a device that converts power (using an electric motor, diesel
or gasoline engine, etc.) into potential energy stored in pressurized air (i.e., compressed
air). By one of several methods, an air compressor forces more and more air into a storage
tank, increasing the pressure. When tank pressure reaches its upper limit the air
compressor shuts off. The compressed air, then, is held in the tank until called into use.
The energy contained in the compressed air can be used for a variety of applications,
utilizing the kinetic energy of the air as it is released and the tank depressurizes. When
tank pressure reaches its lower limit, the air compressor turns on again and re-pressurizes
the tank
Fig 3.19 Air Compressor
3.7.12 Pressure Transducer:
A pressure transducer, often called a pressure transmitter, is a transducer that
converts pressure into an analog electrical signal. Although there are various types of
pressure transducers, one of the most common is the strain-gage base transducer. The
conversion of pressure into an electrical signal is achieved by the physical deformation of
strain gages which are bonded into the diaphragm of the pressure transducer and wired
into a Wheatstone bridge configuration.

Pressure applied to the pressure transducer produces a deflection of the diaphragm
which introduces strain to the gages. The strain will produce an electrical resistance
change proportional to the pressure
Fig 3.20 Pressure Transducer
3.8 FABRICATION
The fabrication process consists of a number of fabrication processes for different
parts of the apparatus. These parts were made from different mild steel bars of different
cross-section. The complete parts were later assembled to make the beam apparatus
The following methods of fabrication were used
i. Cutting
ii. Slotting on Universal Milling Machine
iii. Chamfering the slot by flat , round files
iv. Angle cutting for knife supports
v. Drilling on Radial drilling machine
vi. Welding
vii. Grinding
viii. Facing, Turning on lathe
ix. Tapping

3.8.1 Fabrication of Apparatus Structure:
The structure consisted of three support frames each which of was made from
75×35×4 mm mild steel C- channel. The channels were marked to the required dimensions
and cut using power saws.
Then the channels joined together by welding to form rectangular frame. Care was
taken to ensure corners at right angle. This was done by using try square during welding.
The frames were first spot welded while angle was tested. The frames were then
permanently welded.
3.8.2 Fabrication of Supporting and loading beam:
The two C channel is cut in required dimension for supporting, loading beam and
slot of 14 mm was made on Universal milling machine as per the design.
3.8.3 Fabrication of Point Load Fixture:
Two point load Fixture are made from 20 mm round rod, 20 mm square rod.
Turning and facing operations are done on the round rod and 8.5 mm hole is drilled for
tapping operation to have 10mm internal threading of 1.25mm pitch. And at top a 20×40
mm angle cut square rod is welded to facilitate point contact with beam.
3.8.4 Fabrication of Knife Edge Supports:
Knife edge supporter are prepare from 40×16 mm solid square rod, 20×40 square
rod. A hole is dilled at center for internal threading for both jobs and welded together and
at top a 20×40 mm angle cut square rod is welded.
3.8.4 Fabrication of Mounting Plates:
For mounting pneumatic cylinders MS flat of 40×5×80 mm is marked with
dimension of the cylinder and 6mm holes are drilled on radial drilling machine

4. WORKING & EXPERIMENTATION
4.1 Working of Conventional Simply Supported Beam Apparatus:
Simply supported beam is supported at both ends. It allows rotation at either end
(support) but doesn't allow for vertical movement. As a result of this vertical reactions are
produced at the supports as movement or displacement is not allowed in the vertical
direction. But the supports are free from rotational moments (reactions).
Deflection of beams can be calculated theoretically and can experimentally
calculate.
4.1.1 Experimentation Procedure:
It consists of on fixed and movable wood supports on which beam is placed. The
span, breadth and depth are too measured with ruler and venires callipers. Loads are
applies on beam by means of dead weights and handing pane, beam deflections are
obtained by outside callipers with respect to other member , and reading are tabulates and
compared. And graph is plotted between load and deflection.
4.2 Experimentation on Conventional Simply Supported Beam
Apparatus:
Observation:
Material of beam =wood
Length of beam=1000mm
Breadth of beam=20mm
Depth of beam=12mm
Deflection mm
Young’s modulus E=

Moment of inertia
= =2880
Table 4.1 Results of Young’s modulus for wood beam
S.NO Load
(N)
Deflection in divisions (mm) Young’s Modulus
Initial Final
1 0.5 9.81 33 35 2 17.7408
2 1 9.81 33 38 5 14.192
3 1.5 9.81 33 40 7 15.206
4 2 9.81 33 43 10 14.192
5 2.5 9.81 33 46 13 13.646
Average: 14.995
Table 4.2 Results of Deflection for wood beam
S.NO Load
N
Load
acting
from A
‘a’ (mm)
Load
acting
from B
‘b’
(mm)
Deflection in divisions
(mm)
Theoretical
deflection
initial final (mm)
1 0.5 9.81 600 400 30 32 2 2.180
2 1 9.81 600 400 30 34 4 4.361
3 1.5 9.81 600 400 30 36 6 6.524
4 2 9.81 600 400 30 39 9 8.722
5 2.5 9.81 600 400 30 41 11 10.903

Graph 4.1 Load Vs Deflection for wood beam
Moment of inertia
= =8000
Table 4.3 Results of Young’s modulus for wood beam
S.NO Load
(N)
Deflection in divisions (mm) Young’s Modulus
Initial final
1 0.5 9.81 25 26 1 12.773
2 1 9.81 25 28 3 8.5156
3 1.5 9.81 25 29 4 9.580
4 2 9.81 25 30 5 10.218
5 2.5 9.81 25 32 7 9.12
Average: 10.045
0
2
4
6
8
10
12
0 5 10 15 20 25 30
DEFLECTIONmm
LOAD N
Load Vs Deflection
Y-deflection mm

Table 4.4 Results of Deflection for wood beam
S.NO Load
N
Load
acting
from A
‘a’
Load
acting
from B
‘b’
Deflection in divisions
(mm)
Theoretical
deflection
initial final (mm)
1 0.5 9.81 600 400 23 24 1 1.172
2 1 9.81 600 400 23 25 2 2.34
3 1.5 9.81 600 400 23 26 3 3.514
4 2 9.81 600 400 23 27 4 4.68
5 2.5 9.81 600 400 23 28 5 5.86
Graph 4.2 Load Vs Deflection for wood beam
0
1
2
3
4
5
6
7
0 5 10 15 20 25 30
DEFLECTIONmm
LOAD N
Load Vs Deflection
Y- deflection mm

4.3 Working of Fabrication Apparatus:
The apparatus works on the pneumatic power; it takes pressurized air from
compressor. The working range of the pneumatic set is 0-10 bar range. We can apply up
to ten bar pressure i.e. nearly 80kg of load. For working of apparatus the pressure of
compressor must more than the pressure we apply on the beam.
For applying load first we have switch the compressor to rated pressure, then gate
valve is opened to allow the pressure air to enter the filter in which moisture, dirt from
compressor is removed and stored in it ,which can be drain through drain valve. Now air
enter lubricator in lubricating oil mixes with pressurized air splash over the moving parts
and enters the direction control valve (DCV).
DCV control the flow direction of the air which is a lever operated, its main
function is to active the cylinder by means of connectors and joints. At rated pressure the
cylinder plunger move downward and apply the load on beam.
Load can be varied by adjusting the pressure regulator and applied load is obtained
from display unit. For removing load the pressure regulators should be off position and
the DVC is operated.
4.3.1Experimentation Procedure:
Beam to test is placed on the knife edge supports. Rated pressure is maintained in
the compressor. Span and loading position are adjusted by moving the knife edge supports
and pneumatic cylinders respectively .load is applied on the beam with the help of the
DCV. Load applied can vary by varying the pressure regulator. The deflection is take from
dial gauge and applied load from the display. The values are tabulated and graph is draw
between load and deflection.

Fig 4.1 Pneumatic loaded Apparatus
Fig 4.2 Applying Pneumatic Load on Beam

4.3.2 Pressure to Force calculation:
In general, Pressure is the amount of force acting per unit area. And it is denoted
by P.
Mathematically:
P=
F=PA
Where
F= force N
A= area of cylinder
r=radius of piston=0.016m
A= =0.0008038
Sample Calculation:
For 0.5 bar
Load =
= 4.096 Kg

Table 4.5 Pressure to Load Conversion
Load (kg) Force (N) Pressure (bar)
1 9.81 0.122
1.5 14.715 0.183
2 19.62 0.244
2.5 24.525 0.305
3 29.43 0.366
3.5 34.335 0.427
4 39.24 0.488
4.5 44.145 0.549
5 49.05 0.610
5.5 53.955 0.671
6 58.86 0.732
6.5 63.765 0.793
7 68.67 0.854
7.5 73.575 0.915
8 78.48 0.976
8.5 83.358 1.037
9 88.29 1.09
9.5 93.195 1.159
10 98.1 1.220
10.5 103.005 1.281
11 107.91 1.342
11.5 112.815 1.403
12 117.72 1.464
12.5 122.625 1.525
13 127.53 1.586
13.5 132.435 1.647
14 137.34 1.708
14.5 142.245 1.769
15 147.15 1.830
15.5 152.055 1.891
16.5 161.865 2.013
17 166.77 2.074
17.5 171.675 2.135
18 176.58 2.196
18.5 181.485 2.257
19 186.39 2.318
19.5 191.295 2.379
20 196.2 2.440
21 206.01 2.562
22 215.82 2.684
24 235.44 2.929
25 245.25 3.051

4.4 Experimentation on Pneumatic loaded Simply Supported Beam
Apparatus:
Observation:
Material of beam = Stainless steel
Length of beam=1000mm
Breadth of beam=18 mm
Depth of beam=5 mm
Deflection mm
Young’s modulus E=
Moment of inertia
= =187.5

Table 4.6 for young’s modulus for single pneumatic loaded beam (central load)
Average =510936
Graph 4.3 Load Vs Deflection on Fabricated Apparatus Central loading
0
5
10
15
20
25
0 20 40 60 80 100 120
Deflectionmm
load N
S.NO
Load N
Deflection mm Young’s modulus
Initial final
1. 0.21×9.81 40 39+0.01×5 0.95 240947
2. 0.57×9.81 40 39+0.01×5 0.95 653998
3. 1.05×9.81 40 37+0.01×33 2.67 428650
4. 2.01×9.81 40 35+0.01×81 4.19 522886
5. 3.09×9.81 40 33+0.01×4 6.96 483921
6. 4.05×9.81 40 31+0.01×66 8.34 529315
7. 5.09×9.81 40 29+0.01×70 10.29 539172
8. 6.09×9.81 40 27+0.01×56 12.44 533608
9. 7.05×9.81 40 26+0.01×22 13.78 557655
10. 8.1×9.81 40 24+0.01×4 15.96 553194
11. 9.09×9.81 40 20+0.01×99 19.01 521203
12. 10.05×9.81 40 19+0.01×34 20.66 530226

Table 4.7 Deflection for single pneumatic loaded beam (Eccentric Loading)
Graph 4.4 Load Vs Deflection on Fabricated Apparatus eccentric loading
0
2
4
6
8
10
12
14
16
18
20
0 20 40 60 80 100 120
S.no Load N Actual Deflection mm Theoretical
deflection (mm)
Initial final
1. 1.05×9.81 40 37+0.01×34 2.66 2.06
2. 2.01×9.81 40 35+0.01×93 4.07 3.95
3. 3.09×9.81 40 34+0.01×15 5.85 6.07
4. 4.05×9.81 40 32 8.00 7.96
5. 5.09×9.81 40 27+0.01×5140- 9.49 9.84
6. 6.09×9.81 40 26+0.01×79 11.21 11.67
7. 7.05×9.81 40 24+0.01×31 13.69 13.86
8. 8.1×9.81 40 22+0.01×85 15.15 15.76
9. 9.09×9.81 40 20+0.01×63 17.37 17.87
10. 10.05×9.81 40 17+0.01×54 18.46 19.75

5. RESULTS AND DISCUSSION
From the table 4.4 table, a graph is drawn between load, deflection for both actual
and theoretical deflection. On working with conventional apparatus it is observed that
there is difference between partial and theoretical valve i.e. ±2.
Graph 5.1 Load Vs Deflection for Conventional Apparatus actual & theoretical
For the fabricated apparatus, from the table 4.7 graph is drawn same as that of
conventional apparatus that showed a deflection less than ±1. It can further be decreased
by arrange the dial gauge appropriately.
0
2
4
6
8
10
12
0 5 10 15 20 25 30
Deflectionmm
Load N
Acutaul
Thero

Graph 5.2 Load Vs Deflection for Fabricated Apparatus actual & theoretical
0
5
10
15
20
25
0 20 40 60 80 100 120
deflectionmm
load N
Actual
Thero

6. CONCLUSION AND FUTURE SCOPE
Conclusion:
Simply supported beam apparatus is designed using AutoCAD & solid works and
fabricated using different machining and joining processes .by doing so we have achieves
the aim of the work i.e. to fabricate the beam apparatus to meet the present needs. That is
the loading capacity of simply supported beam apparatus up to 25 kg, achieve higher
accuracy level, different beam materials can be facilitated for experimentation, rigid
apparatus is build.
Future Scope:
1. Experimentation can be done by using simultaneous weights and by using
different material types.
2. Different beam can be experimented using this process
3. By Adding additional fixtures setup it can be used as cantilever bean and over
hanging beam

7. References
[1] “DEVELOPMENT OF A BEAM DEFLECTION APPARATUS FROM
LOCALLY SOURCED MATERIAL”. Buliaminu Kareem. International Journal of
Engineering and Innovative Technology (IJEIT) Volume 2, Issue 6, December 2012
[2]“SIMPLY SUPPORTED BEAM RESPONSE ON ELASTICFOUNDATION
CARRYING REPEATED ROLLINGCONCENTRATED LOADS”. SHAHIN
NAYYERI AMIRI*, MBAKISYA ONYANGO Journal of Engineering Science and
Technology Vol. 5, No. 1 (2010) 52 – 66.
[3]“LARGE DEFLECTIONS OF CANTILEVER BEAMS OF NON-LINEAR
ELASTIC MATERIAL UNDER A COMBINED LOADING”. Kyungwoo Lee
Mechanics Volume, April 2002, Pages 439–443.
[4]“THE EFFECT OF A MOVING MASS AND OTHER PARAMETERS ON THE
DYNAMIC RESPONSE OF A SIMPLY SUPPORTED BEAMA”. N. Kounadis, G.
Michaltsos .
[5]“A GENERAL FORMULA FOR PREDICTING THE DEFLECTION OF
SIMPLY SUPPORTED COMPOSITE STEEL-CONCRETE BEAMS WITH THE
CONSIDERATION OF SLIP EFFECT”. Nie Jianguo, Shen Jumin .
[6]POSITION CONTROL AND REPEATABILITY OF A PNEUMATIC RODLESS
CYLINDER SYSTEM FOR CONTINUOUS POSITIONING”. S.C Fok,
, E.K Ong.
[7]“RESEARCH ON PNEUMATIC CYLINDER’S EXHAUSTED-AIR
RECLAIMING CONTROL DEVICES”. Yunxu SHI, Xiaoning LI and Yan TENG.
Proceedings of the 6th JFPS International Symposium on Fluid Power, TSUKUBA 2005.
[8]“FORCE AND POSITION CONTROL USING PNEUMATIC CYLINDERS”. G.
Mc Latchey, J. Billingsley .
TEXT BOOK
 Strength of Materials by S S Bhavikatti.
 Strength of Materials by R S Khurmi.
 Design of Machine Elements by Khurmi.

 Pneumatic Actuating Systems For Automatic Equipment By Igor L. Krivts,
German V. Krejnin.
 Pneumatic Conveying Design Guide by David Mills.
URL
http://web.mit.edu/4.441/1_lectures/1_lecture13/1_lecture13.html
http://www.sketchup3dconstruction.com/const/types-of-beams-in-construction.html
http://www.aboutcivil.org/types-of-supports.html
http://www.mechanical-engineering-assignment.com/2-3-types-of-supports-and-their-
reactions
https://www.quora.com/What-are-the-types-of-beams
http://me-mechanicalengineering.com/different-types-of-beams
http://mechteacher.com/beam/
https://skyciv.com/education/types-of-supports-in-structural-analysis/
http://www.freestudy.co.uk/engineering%20science%20h1/outcome%201%20t1.pdf
http://paws.wcu.edu/radams/intro_to_beam_theory.pdf
http://www.assakkaf.com/courses/ence355/lectures/part2/chapter8a.pdf
https://www.google.co.in/webhp?sourceid=chrome-instant&ion=1&espv=2&ie=UTF-
8#q=introduction+to+beams
http://www.engr.uvic.ca/~mech466/Mechanics-Shear-and-Bending-Moment-in-Beams.pdf
http://www.ijeit.com/vol%202/Issue%206/IJEIT1412201212_61.pdf
http://www.idc-
online.com/technical_references/pdfs/mechanical_engineering/Speed_Control_of_Cylinders.
pdf
https://www.frightprops.com/faq/content/2/66/en/controlling-the-speed-of-a-cylinder.html

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