Beam Engine Powered Punching Machine

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International Journal of Mechanical Engineering and Technology (IJMET) Volume 9, Issue 6, June 2018, pp. 248–253, Article ID: IJMET_09_06_029 Available online at http://iaeme.com/Home/issue/IJMET?Volume=9&Issue=6 ISSN Print: 0976-6340 and ISSN Online: 0976-6359

BEAM ENGINE POWERED PUNCHING MACHINE

R.E. Ravalika, V. Dharani and N. Lavanya Assistant Professor, Department of Mechanical Engineering, G Pulla Reddy College of Engineering (Autonomous), Kurnool, Andhra Pradesh, India ABSTRACT

Beam engines came into existence in 1745. Beam Engine mechanism is popularly used crank and lever mechanism. The purpose of this mechanism is to convert rotary motion into reciprocating motion. This mechanism is used for sawing. The crank is rotated initially by using handle or motor. Here, levers are used to transmit motion. One end of these levers is connected to required tool and the other is to crank. The rotary motion of crank is transmitted to the tool using levers. Beam engine mechanism can be used for other purposes like forging, extrusion of rods and a part of black smithy. There is a small table attachment for supporting the work piece. The work piece is placed on the table and pushed towards the reciprocating tool, which results in the required action. Beam engine mechanism can be used for punching of sheet metals. The punch tool is used for punching, which is connected to other end of lever. Beam engine used for punching operation has no particular instances available in the commercial market. The aim of this project is to show that this type of machine is an option for small scale industry. Further improvements include using gears for varying the speed of punch. By having an adjustable bed, large size of work pieces can be punched by varying the length of the table and the size of the punch. Key words: Beam engine mechanism, Machine set up, Applications. Cite this Article: R.E. Ravalika, V. Dharani and N. Lavanya, Beam Engine Powered Punching Machine, International Journal of Mechanical Engineering and Technology 9(6), 2018, pp. 248–253. http://iaeme.com/Home/issue/IJMET?Volume=9&Issue=6

1. INTRODUCTION A beam engine is a type of steam engine where a pivoted overhead beam is used to apply the force from a vertical piston to a vertical connecting rod. This configuration, with the engine directly driving a pump, was first used by Thomas around 1705 to remove water from mines in Cornwall. The efficiency of the engines was improved by engineers including James Watt who added a separate condenser, Jonathan-Horn-blower and Arthur Woolf who compounded the cylinders, and William-Mc-Naught (Glasgow) who devised a method of compounding an existing engine. Beam engines were first used to pump water out of mines or into canals, but could be used to pump water to supplement the flow for a waterwheel powering a mill.

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Thomas New-comen (February 1664 to 5 August 1729) was an English inventor who created the first practical steam engine in 1712, the New-comen atmospheric engine. He was an iron-monger by trade and a Baptist lay preacher by calling. He was born in Dartmouth, Devon, England, to a merchant family and baptized at St. Saviour’s Church on 24 February 1664. In those days flooding in coal and tin mines was a major problem, and New-comen was soon engaged in trying to improve ways to pump out the water from such mines. His ironmonger's business specialized in designing, manufacturing and selling tools for the mining industry. James Watt was born in (19 January 1736-25august 1819) in United Kingdom. He was a sootiest inventor, mechanical engineer, and chemist steam engine with his watt steam engine in 1781.Watt introduced a design enhancement, the separate condenser, which avoided this waste of energy and radically improved the power, efficiency and cost-effectiveness of steam engines. He invented the compound steam engine in 1781 and patented it on 16 July in the same year. This type of engine has two cylinders instead of old single-cylinder engine, it contains a high-pressure and a low-pressure steam cylinder. The principle is that the steam first expands in the high-pressure cylinder and afterwards expands again in the low-pressure cylinder. Even though this was a revolutionary new steam technology, he was unfortunately prevented from pursuing his invention by litigation with James Watt over intellectual property his compound engine principle was not revived until 1804.

1.2. Beam Engine Principle A beam engine is a type of steam engine where a pivoted overhead beam is used to apply the force from a vertical piston to a vertical connecting rod. Beam engine works on crank and lever mechanism.

Figure 1 Beam Engine Mechanism 1.2.1. Parts of Beam Engine Crank Machines of several types of arms or levers for imparting rotary or oscillatory motion to a rotating shaft. One end of the crank being fixed to the shaft and the other end is receiving reciprocating motion from the hand, connecting rod, etc. Connecting rod A connecting rod is a shaft which connects a lever to a crank or crankshaft in a beam engine. Together with the crank, it forms a simple mechanism that converts rotary motion into

http://iaeme.com/Home/journal/IJMET 249 [email protected] R.E. Ravalika, V. Dharani and N. Lavanya reciprocating motion. A connecting rod may also convert reciprocating motion into rotating motion. Lever A lever is a machine member which is used to transmit the motion from the connecting rod to a punching tool. Base support It is fixed on the floor and it supports the lever while transmitting the motion during punching of the metal sheets. Punch tool It is used to make holes on thin metal sheets.one end is connected to the lever from which the motion is transmitted and other end is used to make punch on metal sheets. Work table It is fixed on the floor and it has a conveyer to give automatic feed to the punching tool to make holes on metal sheets.it is also used to hold the work piece. 1.2.2. Working of Beam Engine A crank is an arm attached at a right angle to a rotating shaft by which reciprocating motion is imparted to or received from the shaft. It is used to convert circular motion into reciprocating motion, or vice versa. The arm may be a bent portion of the shaft, or a separate arm or disk attached to it. Attached to the end of the crank by a pivot is a rod, usually called a connecting rod. . The end of the rod attached to the crank moves in a circular motion, while the other end is usually constrained to move in a linear sliding motion. The term often refers to a human- powered crank which is used to manually turn an axle, as in a bicycle crank-set or a brace and billet drill. 1.2.3. Applications 1. This set up is most commonly used in control valve actuators in high pressure oil and gas pipe lines. 2. It is used in making double hacksaw.it is used in reciprocating pumps to convert rotational motion into reciprocating motion required for piston movement. 3. It is used in beam engine pumps to convert rotational motion into reciprocating motion. 4. It is used in making toys which have to and fro motion.

2. PUNCHING MACHINE SET UP

Figure 2 Punching Machine Setup

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2.1. Components of Punching Machine Base or frame Base or frame is a structural member which is fixed on the floor. it holds the entire set up of the punching machine on it. Material used for the base or frame is low carbon steel or mild steel. Pulley A pulley is a wheel on an axle or shaft that is designed to support movement and change of direction of a taut cable or belt, or transfer of power between the shaft and cable or belt. In the case of a pulley supported by a frame or shell that does not transfer power to a shaft, but is used to guide the cable or exert a force, the supporting shell is called a block, and the pulley may be called a sheave. A pulley may have a groove or grooves between flanges around its circumference to locate the cable or belt. The drive element of a pulley system can be a rope, cable, belt, or chain. Crank and crank pin Machines of several types of arms or levers for imparting rotary or oscillatory motion to a rotating shaft. One end of the crank being fixed to the shaft and the other end is receiving reciprocating motion from the hand, connecting rod, etc. Connecting rod A connecting rod is a shaft which connects a lever to a crank or crankshaft in a beam engine. Together with the crank, it forms a simple mechanism that converts rotary motion into reciprocating motion. A connecting rod may also convert reciprocating motion into rotating motion. Lever or ram A lever is a machine member which is used to transmit the motion from the connecting rod to a punching tool. Supporting beam It is fixed on the floor and it supports the lever while transmitting the motion during punching of the metal sheets Tool bit It is used to make holes on thin metal sheets.one end is connected to the lever from which the motion is transmitted and other end is used to make punch on metal sheets. Supporting die It is fixed on the floor and it has a conveyer to give automatic feed to the punching tool to make holes on metal sheets.it is also used to hold the work piece. Bearings and bearing pedestals A ball bearing is a type of rolling element bearing that uses balls to maintain the separation between the bearing races. The purpose of a ball bearing is to reduce rotational friction and support radial and axial loads. It achieves this by using at least three races to contain the balls and transmit the loads through the balls. In most applications, one race is stationary and the other is attached to the rotating assembly (e.g., a hub or shaft). As one of the bearing races rotates it causes the balls to rotate as well. Because the balls are rolling they have a much lower coefficient of friction than if two flat surfaces were sliding against each other. Ball bearings tend to have lower load capacity for their size than other kinds of rolling-element bearings due to the smaller contact area between the balls and races. However, they can tolerate some misalignment of the inner and outer races.

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V-belt Trade journal coverage of V-belts in automobiles from 1916 mentioned leather as the belt material, and mentioned that the V angle was not yet well standardized. The endless rubber V- belt was developed in 1917 by John Gates of the Gates Rubber company. Multiple-V-belt drive was first arranged a few years later by Walter Geist of the Allis-Chalmers Corporation, who was inspired to replace the single rope of multi-groove-sheave rope drives with multiple V-belts running parallel. Geist filed for a patent in 1925, and Allis-Chalmers began marketing the drive under the trope brand, the patent was granted in 1928. The texrope brand still exists, although it has changed ownership and no longer refers to multiple-V-belt drive alone. A belt is a loop of flexible material used to link two or more rotating shafts mechanically, most often parallel. Belts may be used as a source of motion, to transmit power efficiently or to track relative movement. Belts are looped over pulley and may have a twist between the pulleys, and the shafts need not be parallel. In a two pulley system, the belt can either drive the pulleys normally in one direction (the same if on parallel shafts), or the belt may be crossed, so that the direction of the driven shaft is reversed (the opposite direction to the driver if on parallel shafts). As a source of motion, a conveyor belt is one application where the belt is adapted to carry a load continuously between two points.

2.2. Punching Machine Working Procedure Crank driven by a motor with the help of v-belt and crank connected to the lever with the eccentric position on rotor, so that the rotary of the rotor converts reciprocating motion by crank and lever mechanism. When the lever oscillating in vertical direction then the punching tool will move uniformly in vertical direction to perform the punching operation on sheet metals.

2.3. Specifications of Punching Machine Length of the frame = 80 cm Width of the frame = 13 cm Length of lever or ram = 50 cm Width of the lever = 4 cm V-type supporting beam length = 26 cm Width of beam (upper) = 20 cm Width of beam (lower) = 13 cm Pulley or rotor diameter = 12 inch or 30.48 cm Diameter of motor pulley = 50 mm Length of connecting rod = 6 cm Diameter of crank pin and connecting pin = 25 mm Eccentric distance = 2.2 cm Speed of motor = 1440 rpm Diameter of tool bit = 8 mm Die hole diameter = 8.3 mm Distance between tool bit to center pin = 30 cm Distance between connecting pin to center pin = 15 cm Diameter of the main spindle pin = 25 mm Height of die supporting stand = 23 cm

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2.4. Punching Force Calculation Punching force (F) = Perimeter * Thickness * Shear Strength Perimeter = π * diameter of tool bit (for circular tool bit) = π * 8 mm Thickness of sheet metal (t) = 0.6 mm Shear strength of the sheet metal (low carbon steel) = 0.3447 kn/mm2 Punching force (F) = π * diameter of tool bit * thickness of sheet metal * shear strength of the sheet metal. Punching force (F) = 4.8 KN

2.5. Applications 1. This operation is used in pressing operation in all industries. 2. Paper punching industries 3. Bending of sheet metals 4. Punching of sheet metals

3. CONCLUSIONS We here by conclude that the beam engine mechanism is generally used to convert reciprocating motion into rotary motion, but here we are using this mechanism to convert rotary motion into reciprocating motion. We are attaching punching tool to this mechanism, which performs punching operation. By giving automatic feed to punching tool through table, punching operation is continued.

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