Yo Bc.docx

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Table Of Content INDEX Page

Sr.No. Topics

No. 1.

ABSTRACT

i

2.

INTRODUCTION

ii

3.

LITERATURE REVIEW

1

4.

PROBLEM DEFINITION

4

5.

OBJECTIVES

5

6.

METHODOLOGY

6

7.

WORKING PRINCIPLE

7

8.

COMPONENTS

8

9.

ADVANTAGES, DISADVANTAGES &

9

APPLICATIONS 10.

FUTURE SCOPE

10

11.

REFERENCES

11

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CHAPTER 1 Abstract Nowadays the world is focusing into automation. Each and every work of human is reduced by a machine, but few areas like construction they use human effort to make the stirrups which used to withstand load in beam and columns of buildings they need skilled labour to make it. So the aim of this project is to reduce the human effort by making pneumatic rod bending machine which is very useful on construction site. To make pneumatic rod bending machine it required component like pneumatic compressor, pneumatic cylinder, hoses, directional control valve, holding attachments on steel frame etc. In this project it is aimed to do bending operation for stirrups using pneumatic and named as pneumatic rod bending machine. The main objective of our project is to implement the pneumatic rod bending machine in the construction sites with less cost compared to the existing bending machines, and increasing the productivity of the stirrups. Pneumatic rod bending machine consist of Pneumatic cylinder, Compressor, Hoses, Pulley, Cutting blades, Fixture. The rod is bent by the Pneumatic cylinder piston with holding the rod in the fixture. The main advantage of our project is the square shape of the Stirrups is bent contain.

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Chapter 2 Introduction Since long time ago labour work was ver essential in constructions including mixing coarse aggregate-sand-water- cement, ramming sand, land levelling, and digging the foundation for base of structure, cutting rod in required length, rod bending and pouring the mixture of concrete in columns and beams. Now days, due to development in technology it is required to reduce the labour work and time since there are lot of available resources. As population increasing very rapidly, demand of the construction to build the buildings for industries, overhead bridges, human livings and population is continuously increases. Several problems come in to the picture when we consider human work with respect to automation. By using conventional method it is not possible to reduce construction time and building it as early as possible.This project is to bend the rod at the specified dimensions which is used in the building construction which called as Stirrups. Stirrup is an important reinforced element which acts as a shear reinforcement. Presently, stirrups are made manually, which suffers from many drawbacks like lack of accuracy, low productivity and resulting into severe fatigue in the operator. In manual stirrup making process, operators not only subjecting their hands to hours of repetitive motion, but also sometimes suffers internal injury to his body organ.The system that we propose is that bending of square and rectangular stirrups. The rod is bent with the help of pneumatic force because pneumatic system has less costly compared to hydraulic system.

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Chapter 3 Literature Review Have developed dedicated electro pneumatic positioned for a class of process valves. The position uses solid-state electronics to combine the functions of both the electric to pneumatic converter and valve positioner. Such are the savings in size and weight that have been achieved by the use of electronics that the resulting unit is housed in an enclosure small enough to be mounted directly on the actuator, which it is to operate. (Virvalo et al., 1988). Showed that electro pneumatic servo systems are viable alternatives to hydraulic systems for control of such machines as robots, but most of the research has been carried out on them using comparatively small cylinders.

Bar-bending machine is a semi-automatic type of machine which utilizes less man-power. This reduction in manual work results increased output. The Principle advantages are less time consuming, production of identical stirrups, higher production rate than old traditional method. Our goal is to develop & design a machine to achieve high production rate with less man power & of desired accuracy.

The bend has been made with the help of punch which exerts large force on the work clamped on the die. The bending machine is designed in such a way that, it works automatically. The automation strategy, when implemented is believed to result in reduced cycle time, costs and improved product quality. Other possible advantages are repeatability, increased productivity, reduced labor and integration of business systems. Automation is achieved with the help of Electro pneumatic system. Bending can be done with required dimensions and accuracy is maintained during the entire operation. By changing the dimensions of the die required bents are made on the rods. Along with the ease of operation use of hydraulics also makes it more precise, economical and compact. The entire machine is easily portable and having nice aesthetics as well. Keywords: hydraulic system, indexing mechanism, bending operation.

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Three Stirrups are prepared at a time, which makes the machine more productive. The use of Scotch yoke Mechanism is used to convert the reciprocating motion of pneumatic cylinder into rotary motion. Main purpose of use of pneumatic System is to save cost of overall machine. Main purpose of automation is fast and continuous production without much attention on machine. Need of automation was felt and so the machine is made automatic

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Chapter 4 Problem Definition Presently, stirrups are made manually, which suffers from many drawbacks like lack of accuracy, low productivity and resulting into severe fatigue in the operator. In manual stirrup making process, operators not only subjecting their hands to hours of repetitive motion, but also sometimes suffers internal injury to his body organ.The system that we propose is that bending of square and rectangular stirrups. The rod is bent with the help of pneumatic force because pneumatic system has less costly compared to hydraulic system.

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Chapter 5 Objective Rod and pipe bending is widely used for various industrial purposes. Most of the rod bending machines are hydraulic or screw based that require a lot of time and energy for bending rods. So here we propose a compact and pneumatic based rod and pipe bending machine that bends pipes and rods as per angle set by user. Our system uses pneumatic piston, pipes, valves, hinges, supporting frame and electronics mechanism to achieve accurate bending. We use pneumatic piston attached to a movable bed that is attached to the supporting frame using hinges for vertical movement. This bed is used to support the materials to be bent. We then use the supporting frame to mount the rod support and holders. We now use electronic sensors to get reading of the bending angle. User is allowed to select the angle at which bending is needed. As per users settings made the system operates the pneumatic system once user starts bending process. The system now operates the pneumatic cylinder automatically until desired bending has been achieved. This machine demonstrates the concept of fully automatic pneumatic bending system.

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Chapter 6 Methodology Pneumatic cylinder is used to provide the force required for bending rod to make stirrups. As we are bending three rods at a time we required more force. Assuming TATA TISCON 500D material rod which is generally used at construction side. This are available in diameter of 6, 8, 10, 16, 20 and 25 mm generally to make stirrups 8 or 10mm rod are taken. Mechanical properties of TATA TISCON 500D Yield stress = 500 N/mm2 Ultimate stress = 545 N/mm2 Assuming Factor of safety (FOS) = 1.5 Therefore, allowable bending stress = Yield stress / F.O.S σb = 500 / 1.5 σb = 340 N/mm2 Force required to bend one rod of 8mm by flexural formula M / I = σb / Y Bending moment (M) = Force * Perpendicular distance M = F * L (N-mm) Moment of inertia (I) = π / 64 * d4 = π / 64 * 84 = 201.06 mm4 Y = d / 2 = 8 / 2 = 4 mm M / I = σb / Y M / 201.06 = 340 / 4 4

M = 17136 N-mm Assuming eccentricity 25 mm M=F*L 17136 = F * 25 Force required to bend one rod of 8 mm F = 690 N Force required to bend 3 rods of 8 mm

F = 3 * 690 F = 2070 N Pneumatic cylinder design We know pressure given by P=F/A Assuming pressure in cylinder 5 bar = 5 * 105 N/mm2 5 * 105 = 2070 / π/4 (d)2 d = 0.0726 m d = 72.6 mm Cylinder diameter = 72.6 mm Selecting Diameter = 80 mm.

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Chapter 7 Working We will be using compressor of pressure of 10 bar as per availaible We will be regulating this pressure using pressure regulator and reducing the pressure up to approximate 5 bar. Therefore, this pressurized air will pass through pressure regulator. Then 2/2 direction control valve is used to control the direction of the air. Then it will pass through the flow control valve to control the flow of air. Then it is sent to spring control double acting cylinder to create the force to bend the rod. Then it is passed to further mechanism to carry the process.

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Chapter 8 Components 1.PNEUMATICS ACTUATORS Pneumatic actuators are the devices used for converting pressure energy of compressed air into the mechanical energy to perform useful work. In other words, Actuators are used to perform the task of exerting the required force at the end of the stroke or used to create displacement by the movement of the piston. The pressurised air from the compressor is supplied to reservoir. The pressurised air from storage is supplied to pneumatic actuator to do work. The air cylinder is a simple and efficient device for providing linear thrust or straightline motions with a rapid speed of response. There are three types of pneumatic actuator: they are Linear Actuator or Pneumatic cylinders ii) Rotary Actuator or Air motors iii) Limited angle Actuators

A compressed air system transfers power in the form of air pressure. A device somewhere else in a workshop can use the energy the compressor creates. The basics of compressed air pipework are simple. You just need to attach a compressor to an end-use device via a pipe. 4

Corrosion in a piping system can break off and accumulate into obstructions. Plastic pipes over many benefits over metal. They do not corrode, so you don’t have to worry about rust dropping into your air flow. This, in turn, reduces the risk of obstructions. The interior surface is smooth and never deteriorates, which encourages laminar flow. The pipes are lightweight and easy to transport and fit. Cutting through plastic pipes is quick and simple and requires basic tools. Plastic pipes can be glued together, which is less costly and quicker than welding metal.

2. Pressure regulator It 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, and can be an integral device with an output pressure setting, a restrictor and a sensor all in the one body, or consist of a separate pressure sensor, controller and flow valve. In pneumatic systems, during high velocity compressed air flow, there is flow-dependent pressure drop between the receiver and load (application). Therefore the pressure in the receiver is always kept higher than the system pressure. At the application site, the pressure is regulated to keep it constant.

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3. FLOW-CONTROL VALVES Flow-control valves, as the name suggests, control the rate of flow of a fluid through a hydraulic circuit. Flow-control valves accurately limit the fluid volume rate from fixed displacement pump to or from branch circuits. Their function is to provide velocity control of linear actuators, or speed control of rotary actuators. Velocity of piston (Vp) (m/s) = Flow rate in the actuator / Piston area

Pressure-compensated flow-control valve A pressure-compensating spool built into a flow control valve maintains a constant pressure drop across the metering orifice independent of changes in supply and load pressure.

Two-port pressure-compensated flow-control valve (with symbols), see text for explanation. It shows diagrammatically a two-port pressure-compensated flow-control valve together with its symbols. Flow rate is set by an adjustable metering orifice (1) which also be viscositycompensated. In the unoperated condition, the compensating spool (2) is biassed fully open by the compensator spring (3). As soon as flows occurs, there will be a pressure drop across the valve and pressure upstream of the metering orifice tends to close the valve, but this is opposed by the spring assisted by pressure from downstream of the metering orifice. The compensator spool adopts a balanced position with a consequen-tial pressure drop over the compensating orifice (4) formed by the partially closed spool. A rise in supply pressure tends to close the spool and the. increased pressure drop across the compensating orifice balances the increase in supply pressure. If the load pressure rises, the compensating orifice opens, again maintaining the pressure drop over the metering orifice at a set value. This pressure drop is usually 3-6 bar, dependent upon the size of the metering orifice 4

Chapter 9 Advantages & Applications 9.1 Advantageso

High durability and reliability

o

Simple design

o

Pneumatic systems are safer than electromotive systems

o

Environmental friendly

o

Economical low cost

9.2 Applications

Angle bending



Metal bending



In construction fields



In production

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Chapter 10 Future Scope Operation for making stirrup is tedious and required continuous manual work to perform the bending operation. This will minimize human efforts for less physical exertion of the operator. Adverse effect of repetitive work on human health is minimising. Reduce the wastage of stirrup and this will reduce the cost of stirrup making activity. There is a scope to design the stirrup with safety standards and with ergonomic considerations which will help to avoid the incidents during manually stirrup making. There is a scope to improve the stirrup making efficiency and production capacity of stirrup by using human powered flywheel motor of stirrup making. The currently available machines are motor power (electrical supply) operation machines and hydraulic type machine which cannot work where non-availability of electricity. This research presents a new urge as method to bend the given rod of 6,8 mm diameter with the help of human power as a energy source for performing the job. This area is having a large scope because of construction in MIHAN & CARGO project, at the same time fast development in rural area.

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Chapter 11 References 

www.sciencedirect.com

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Dr.R.K.Bansal (2010) “Fluid Mechanics and Hydraulic Machines” Laxmi Publications, ISBN 978-81-318-0815-3

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International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME)

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Vol. 2, Issue 1, pp: (9-18), Month: April 2015 – September 2015. (Singh et al., 1985). [1]

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International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 04 | Apr-2018[2]

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International Journal of Recent Research in Civil and Mechanical Engineering (IJRRCME) Vol. 2, Issue 1, pp: (9-18), Month: April 2015 – September 2015, Available at: www.paperpublications.org [3]

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ISSN (PRINT): 2393-8374, (ONLINE): 2394-0697, VOLUME-5, ISSUE-1, 2018 DESIGN AND FABRICATION OF MULTIROD BENDING[4]

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International Journal of Advance Engineering and Research Development Volume 4, Issue 3, March -2017[5]

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