fabrication of geneva wheel based edting
TRANSCRIPT
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FABRICATION OF GENEVA WHEEL BASED
AUTO ROLL PUNCHING MACHINE
ABSTRACT
In this auto roll punching machine consists of two sections. One sections is automatic
metal sheet feeding mechanism and the second section is conversion of rotary motion into linear
reciprocating motion of punching tool . The first section consists of geneva wheel disc keyed
with a shaft at one end and the other end is connected with chain sprocket wheel. This geneva
wheel shaft is supported on two plummer block bearings. This sprocket wheel transmit the
rotary motion from the geneva wheel to the metal sheet feeding rollers through a chain drive.
Hence when the geneva wheel is rotated , the metal sheet also moved for punching operation.
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CONTENTS
CHAT!" TOIC A#! $O
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6 )$CHI$# ACHI$! 68
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0 %ATT!"1 67
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CHAPTER 1
1,1 INTRODUCTION:
The present invention relates to an automatic punching machine
using Geneva mechanism, particularly one suitable for performing punching
of a metal sheet in a programmed and programmable manner according to a
predetermined number of dierent punching shapes.
The punching machine of this invention is of the type
comprising a punching head provided with a plurality of punch/die pairs for
eecting the desired punching of a metal sheet, and a numerically controlled
programmable manipulator, equipped with gripping means for the said metal
sheet, for displacing it over a horizontal plane passing between the said
punches and their associated dies. In nown punching machines of the said
type there e!ists a single, well determined and unchangeable operative
position, into which each punch/die pair is carried by appropriate automatic
means and retained for the time necessary for the e!ecution of all the
punching of the same predetermined shape envisaged in a metal sheet.
In operation of such a nown punching machine using Geneva
mechanism, whilst a "rst punch/die pair is maintained in the said operative
position the manipulator causes the displacement of the metal sheet in such
a way that the said pair performs the predetermined number of identical
punching in a corresponding number of predetermined and dierentpositions in the said metal sheet. #nce this "rst series of punching has been
completed the punch/die pair "rst considered is replaced with another pair of
dierent shape to eect a second series of punching on the same metal
sheet. This mode of operation, which is tied to the structural and functional
characteristics of the nown punching machine and, above all, to the
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fundamental characteristic consisting in a single and unchangeable operative
position, involves dead times which until now were inevitable, for the
substitution of the punch/die pair in the operative position, as well as a not
inconsiderable consumption of time tied to the movements which the
manipulator must perform in order to displace a metal sheet during the
operation of successive punch/die pairs.
1.1.1 Definition of Po!"e#:
In conventional punching machine, the
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CHAPTER $
METHODOLOG):
This pro$ect is designed with using Geneva mechanism, moving
arrangement and punching mechanism. %unching machine is designed with
mechanical arrangement in which movements are controlled by using
Geneva mechanism. &oving mechanism is attached with punching spindle.
'o we can move the punching spindle anywhere within the area of machine.
&oving mechanism also controlled using Geneva mechanism.
In this punching machine using Geneva mechanism consists of two
sections. #ne is automatic punching mechanism and the second section is
conversion of rotary motion into linear reciprocation motion of punching tool.
The "rst sections consist of Geneva wheel disc eyed with a shaft of one end
and the other end is connected to chain sprocet wheel. This Geneva wheelshaft is supported on two %lummer bloc bearings. This sprocet wheel
transmit the rotary motion from the Geneva wheel.
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figure .* Auto roll punching by using geneva mechanism
$.1.1 Wo*in+ &in%i&"e:
2hen the switch is on the motor rotates the crank wheel. Hence the punching slide with
punching tool moved up and down and make a punch on the metal sheet. The crank wheel face
have a pin which touches the slot in the geneva wheel and also rotates the geneva wheel .+ue to
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the rotation or inde=ing of geneva wheel , the metal sheet feeding rollers are rotated through the
chain drive mechanism and hence the metal sheet is feeded automatically.
CHAT!" 4
.1 DESIGN AND FABRICATION OF GENEVA CONVE)OR:
The #eneva drive or altese cross is a gear mechanism that translates a continuous
rotation into an intermittent rotary motion. The rotating drive wheel has a pin that reaches into
a slot of the driven wheel advancing it by one step. The drive wheel also has a raised circular
blocking disc that locks the driven wheel in position between steps.
The geneva mechanism is a timing device.
According to 5ector echanics for !ngineers for (erdinand . %eer and !. "ussell
/ohnston /r.says >Is used in many counting instruments and in other applications where an
intermittent rotary motion is re?uired.@ !ssentially the #eneva mechanism consists of a
rotating disk with a pin and another rotating disk with slots into which the pin slides.
According to %rittanica.com, the #eneva mechanism was originally invented by a watch
maker. The watch maker only put a limited number of slots in one of the rotating disks so that
the system could only go through so many rotations. This prevented the spring on the watch
from being wound too tight, thus giving the mechanism its other name, the #eneva &top. The
#eneva &top was incorporated into many of the first film pro
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the use of the #eneva mechanism to provide an intermittent motion the conveyor belt of a film
recording marching. He also discusses several weak points in the #eneva mechanism. (or
instance, for each rotation of the #eneva Bslotted gear the drive shaft must make one complete
rotation. Thus for very high speeds, the drive shaft may start to vibrate. Another problem is wear,
which is centraliDed at the drive pin. (inally, the designer has no control over the acceleration the
#eneva mechanism will produce. Also, the #eneva mechanism will always go through a small
backlash, which stops the slotted gear. This backlash prevents controlled e=act motion. %elow
are models of the #eneva mechanism made with 2orking odel d v-.;. The second model
shows velocity vectors for the slotted gear and the drive shaft. 5elocity is the black arrow and
acceleration is the green arrow. ove the mouse them running. over the mechanisms to start.
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(I#)"! 4.* !=ternal geneva mechanism in starting position
3.2 SYNOPSIS:
This is the new innovative concept mainly used for industries. It is simple in construction
and the working process is easy. In industries, it is very necessary to move the components from
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one area to the other in a regular basis. It is necessary to minimiDe the workers involved in it. 2e
have designed a conveyor with #eneva drive which is useful in industries. &o, here we have
made a conveyor model which is used for material transformation from one place to another.
ain components used in this pro
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Fi+-e .$ Gene/ #e%'/ni0#
. USES AND APPLICATIONS OF GENEVA CONVE)OR:
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One application of the #eneva drive is in movie pro
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Inten/" Gene/ ie:
(igureE4.4 Internal #eneva conveyor.
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(igureE4.- Animation showing an internal #eneva drive in operation.
An internal #eneva drive is a variant on the design. The a=is of the drive wheel of the
internal drive can have a bearing only on one side. The angle by which the drive wheel has to
rotate to effect one step rotation of the driven wheel is always smaller than *8;J in an e=ternal
#eneva drive and always greater than *8;J in an internal one, where the switch time is therefore
greater than the time the driven wheel stands still. The e=ternal form is the more common, as it
can be built smaller and can withstand higher mechanical stresses.
http://en.wikipedia.org/wiki/Stress_(mechanics)http://en.wikipedia.org/wiki/Stress_(mechanics)
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CHAT!" -
2.1 DESIGN OF GENEVA DRIVE GEOMENTR) OF GENEVA DRIVE:
Fi+-e 2.1 DESIGN PARAMETERS OF GENEVA DRIVE
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aKdrive crank radius,
nKdriven slot ?uantity,
pKdrive pin diameter,
tKallowed clearance
cKcentre distanceKaFsin B*8;Fn,
bK#eneva wheel radiusKcGa,
sKslot centre lengthK BaLbGc,
wKslot widthKpLt,
yK stop arc radiusKaGBpMB*.9,
DKstop disc radiusKyGt,
vKclearance arcK %NFa,
2.$ DIMENSIONS OF GENEVA DRIVE
aKdrive crank radiusK9; mm,
nKdriven slot ?uantityK-,
pKdrive pin diameterK- mm,
tKallowed clearanceK mm,
cKcentre distanceKaFsin B*8;Fn K6; mm,
bK#eneva wheel radiusKcGaK9; mm,
sKslot centre lengthK BaLbGcK4; mm,
wKslot widthKpLtK7 mm,
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yK stop arc radiusKaGBpMB*.9K-- mm,
DKstop disc radiusKyGtK-- mm,
vKclearance arcK %NFa, K-9 mm
2. APPLICATIONS GENEVA DRIVE:
One application of the #eneva drive is in movie pro
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2.3 DISADVANTAGES OF GENEVA MECHANISM:
i. The #eneva is not a versatile mechanism.
ii. The ratio of dwell period to motion is also established Once the no of dwells per
revolution has been selected.iii. All #eneva acceleration curves start and end 2ith finite acceleration deceleration.
iv. This means they produce
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Fi+-e 2. Gene/ ie
2.4 USES GENEVA DRIVE:
&T!!"
!CHA$ICA' 2ATCH!&
'OTT!"&
C$C ACHI$!
I"O$ "I$# C'OC3
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&odern "lm pro$ectors may also use an electronically controlled
inde!ing mechanism or stepper motor, which allows for fastforwarding
the "lm. Geneva wheels having the form of the driven wheel were also used in
mechanical watches, but not in a drive, rather to limit the tension of
the spring, such that it would operate only in the range where its
elastic force is nearly linear. Geneva drive include the pen change mechanism in plotters,
automated sampling devices Inde!ing tables in assembly lines, tool changers for 010 machines, and
so on. The Iron 2ing 0loc uses a Geneva mechanism to provide intermittent
motion to one of its rings.
2.4.1 MERITS:
The se?uence of slides can be altered to meet specific needs.
o ay be adopted to group or to individual user
o !asily handled, stored and rearranged for various uses.
o The room need not be e=tremely dark for pro
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CHAT!" 9
3.1 DC MOTOR
3.1.1PRINCIPLES OF OPERATION:
In any electric motor, operation is based on simple electromagnetism. A currentGcarryingconductor generates a magnetic fieldP when this is then placed in an e=ternal magnetic field, it
will e=perience a force proportional to the current in the conductor, and to the strength of the
e=ternal magnetic field. As you are well aware of from playing with magnets as a kid, opposite
B$orth and &outh polarities attract, while like polarities B$orth and $orth, &outh and &outh
repel. The internal configuration of a +C motor is designed to harness the magnetic interaction
between a .currentGcarrying conductor and an e=ternal magnetic field to generate rotational
motion.
'ets start by looking at a simple Gpole +C electric motor Bhere red represents a magnet
or winding with a $orth polariDation, while green represents a magnet or winding with
a &outh polariDation.
http://encyclobeamia.solarbotics.net/articles/current.htmlhttp://encyclobeamia.solarbotics.net/articles/current.htmlhttp://encyclobeamia.solarbotics.net/articles/dc.htmlhttp://encyclobeamia.solarbotics.net/articles/current.htmlhttp://encyclobeamia.solarbotics.net/articles/dc.htmlhttp://encyclobeamia.solarbotics.net/articles/current.htmlhttp://encyclobeamia.solarbotics.net/articles/current.htmlhttp://encyclobeamia.solarbotics.net/articles/dc.htmlhttp://encyclobeamia.solarbotics.net/articles/current.htmlhttp://encyclobeamia.solarbotics.net/articles/dc.html
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(igure 9.* +C otor
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!very +C motor has si= basic parts GG a=le, rotor, stator, commutator, field magnet,
and brushes. In most common +C motors, the e=ternal magnetic field is produced by
highGstrength permanent magnets.The stator is the stationary part of the motor this
includes the motor casing, as well as two or more permanent magnet pole pieces. The
rotor rotate with respect to the stator. The rotor consists of windings Bgenerally on a
core, the windings being electrically connected to the commutator. The above diagram
shows a common motor layout GG with the rotor inside the stator Bfield magnets.
http://encyclobeamia.solarbotics.net/articles/dc.htmlhttp://encyclobeamia.solarbotics.net/articles/dc.html
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(igure 9. Two poles in dc motor
The geometry of the brushes, commutator contacts, and rotor windings are such that
when power is applied, the polarities of the energiDed winding and the stator magnetBs are
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misaligned, and the rotor will rotate until it is almost aligned with the stators field magnets. As
the rotor reaches alignment, the brushes move to the ne=t commutator contacts, and energiDe the
ne=t winding. #iven our e=ample twoGpole motor, the rotation reverses the direction of current
through the rotor winding, leading to a flip of the rotors magnetic field, driving it to continue
rotating.
In real life, though, +C motors will always have more than two poles Bthree is a very
common number. In particular, this avoids dead spots in the commutator. 1ou can imagine
how with our e=ample twoGpole motor, if the rotor is e=actly at the middle of its rotation
Bperfectly aligned with the field magnets, it will get stuck there. eanwhile, with a twoGpole
motor, there is a moment where the commutator shorts out the power supply Bi.e., both brushes
touch both commutator contacts simultaneously. This would be bad for the power supply,waste energy, and damage motor components as well. 1et another disadvantage of such a
simple motor is that it would e=hibit a high amount of tor?ue ripple Bthe amount of tor?ue it
could produce is cyclic with the position of the rotor.
&o since most small +C motors are of a threeGpole design, lets tinker with the workings
of one via an interactive animation E
http://encyclobeamia.solarbotics.net/articles/current.htmlhttp://encyclobeamia.solarbotics.net/articles/dc.htmlhttp://encyclobeamia.solarbotics.net/articles/torque.htmlhttp://encyclobeamia.solarbotics.net/articles/torque.htmlhttp://encyclobeamia.solarbotics.net/articles/dc.htmlhttp://encyclobeamia.solarbotics.net/articles/current.htmlhttp://encyclobeamia.solarbotics.net/articles/dc.htmlhttp://encyclobeamia.solarbotics.net/articles/torque.htmlhttp://encyclobeamia.solarbotics.net/articles/torque.htmlhttp://encyclobeamia.solarbotics.net/articles/dc.html
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(igure 9.4 Three poles in dc motor
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1oull notice a few things from this GG namely, one pole is fully energiDed at a time
Bbut two others are partially energiDed. As each brush transitions from one commutator
contact to the ne=t, one coils field will rapidly collapse, as the ne=t coils field will
rapidly charge up Bthis occurs within a few microsecond. 2ell see more about the
effects of this later, but in the meantime you can see that this is a direct result of the coil
windings series wiringE
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(igure 9.- abuchi motor
The use of an iron core armature Bas in the abuchi, above is ?uite common, and
has a number of advantages. (irst off, the iron core provides a strong, rigid support for
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the windings. a particularly important consideration for highGtor?ue motors. The core also
conducts heat away from the rotor windings, allowing the motor to be driven harder than
might otherwise be the case. Iron core construction is also relatively ine=pensive
compared with other construction types.
%ut iron core construction also has several disadvantages. The iron armature has a
relatively high inertia which limits motor acceleration. This construction also results in
high winding inductances which limit brush and commutator life.
In small motors, an alternative design is often used which features a coreless
armature winding. This design depends upon the coil wire itself for structural integrity.
As a result, the armature is hollow, and the permanent magnet can be mounted inside the
rotor coil. Coreless +C motors have much lower armature inductance than ironGcore
motors of comparable siDe, e=tending brush and commutator life.
(igure 9.9 courtesy of icro motors
The coreless design also allows manufacturers to build smaller motorsP meanwhile,
due to the lack of iron in their rotors, coreless motors are somewhat prone to overheating.
As a result, this design is generally used
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+igital systems and microcontroller pins lack sufficient current to drive the
circuits like relays, buDDer circuits, motors etc. 2hile these circuits re?uire around
*;milli amps to be operated, the microcontrollerQs pin can provide a ma=imum of *G
milli amps current. (or this reason, a driver such as a power transistor is placed in
between the microcontroller and the motor.
The operation of this circuit is as followsE
The input to the base of the transistor is applied from the microcontroller port pin
The transistor will be switched on when the base to emitter voltage is greater than ;.65.
Thus when the voltage applied to the pin *.; is high. the transistor will be switched on
and thus the motor will be O$.
2hen the voltage at the pin *.; is low. the transistor will be in off state and the
motor will be O((. Thus the transistor acts like a current driver to operate the motor
accordingly.
CHAT!" 74.1 C'/in
4.1.1 CHAIN DRIVE :
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(igure 6.*E &imple chain drive mechanism
.A. K 5.". K $%5 $A RRR.. B* 2here,
.A. K echanical Advantage. 5.". K 5elocity "atio.
$A, $% K $umber of rotation of sprocket wheel A and % respectively.
&o, if we able to increase 5.". we will get more .A. i.e. more efficient drive.
Chain types are identified by numberP ie. a number -; chain. The rightmost digit is ; for
chain of the standard dimensionsP * for lightweight chainP and 9 for roller less bushing chain. The
digits to the left indicate the pitch of the chain in eighths of an inch. (or e=ample, a number -;
chain would have a pitch of fourGeighths of an inch, or *F, and would be of the standard
dimensions in width, roller diameter, etc.
The roller diameter is nearest binary fraction B4nd of an inch to 9F8ths of the pitchP
pin diameter is half of roller diameter. The width of the chain, for standard chain, is the nearest
binary fraction to 9F8ths of the pitchP for narrow chains width is -*S of the pitch. &procket
thickness is appro=imately 89G0;S of the roller width.
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4.$ Ge/in+
There are several gears available on the rear sprocket assembly, attached to the rear
wheel. A few more sprockets are usually added to the front assembly as well. ultiplying the
number of sprocket gears in front by the number to the rear gives the number of gear ratios, often
called speeds.
Hub gears use epicycle gearing and are enclosed within the a=le of the rear wheel.
%ecause of the small space, they typically offer fewer different speeds, although at least one has
reached *- gear ratios and (allbrook Technologies manufactures a transmission with technically
infinite ratios. Causes for failure of bicycle gearing includeE worn teeth, damage caused by a
faulty chain, damage due to thermal e=pansion, broken teeth due to e=cessive pedaling force,
interference by foreign ob
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unching is more than
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Anyone who has ever punched holes in paper has made use of the punching principle.
The punch presses the paper from above against the plate of the hole puncher and ultimately in
a round opening. This produces a circular hole in the paper. The round pieces of paper that are
cut out are collected in the container under the puncher. And punching sheets is no different.
The sheet is positioned between a punch and a die . The punch moves down and plunges into
the die. The edges of the punch and die are displaced parallel to each other, so cutting the
sheet. (or this reason punching is categoriDed as a shear cutting process. +I$ 8988 defines
shear cutting as dividing a material with two cutting edges moving past each other.
To be precise here, the punching process takes place in four phases. 2hen the punch
touches the sheet, it first of all deforms it. This is followed by cutting. The level of tension
produced inside the material is ultimately so great that the sheet breaks along the contour of
the cut. The piece of metal punched out here U the soGcalled punching slug U is e
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that is important for people who work on punching machines 2using especially ?uiet punching.
6.2 P-n%'in+ fo%e:
The ma=imum punch siDe which can be used on a punching machine 2 depends
essentially on two factorsE the thickness and tensile strenDDof the material to be punched. The
greater the tensile strength and thickness of a material, the more force that needs to be applied by
the machine to cut the material. If you wish to determine the ma=imum punch diameter that can
be achieved by a machine, there are not only values in tables but also formulae which can be
used to calculate the relevant values.
6.2.1 M/8i#-# i/#ete fo o-n &-n%'e0
dma=
K pF4,*-.s.;,0." m.=
wherema=imum tool diameter Bround VmmW
punching force V$W
material thickness VmmW
tensile strength V$FmmXW
* shear factor B= K* for punches without shear, =Y* for beveled punches
a=imum edge length for s?uare punchesE
ama=K pF-.s.;,0."m.=
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2herea
ma= ma=imum edge length Bs?uare VmmW
punching force V$W
& material thickness VmmW
" m tensile strength V$FmmXW= shear factor B= K* for punches without shear, =Y* for beveled punches
6.2.$ M/8i#-# %-ttin+ %i%-#feen%e fo /n9 fo#e o
%"-0te &-n%' it'o-t 0'e/
p
'ma=
K
s Z ;,0 Z " m
'ma= ma=imum cutting circumference VmmW p punching force
V$W
s material thickness VmmW " m tensile strength
V$FmmXW
CHAPTER ;
;.1 CONSTRUCTION OF AUTO ROLL PUNCHING MACHINE:
In this auto roll punching machine consists of two sections.One sections is automatic
metal sheet feeding mechanism and the second section is conversion of rotary motion into linear
reciprocating motion of punching tool . The first section consists of geneva wheel disc keyed
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with a shaft at one end and the other end is connected with chain sprocket wheel. This geneva
wheel shaft is supported on two plummer block bearings. This sprocket wheel transmit the
rotary motion from the geneva wheel to the metal sheet feeding rollers through a chain drive.
Hence when the geneva wheel is rotated , the metal sheet also moved for punching operation.
The second section consists of electrically operated +C motor,plummer block bearings,
crank wheel with a pin ,connecting rod and punching tool. The second section is used to convert
the rotary motion of the crank wheel into reciprocating motion of punching tool. The rotating
shaft is keyed to the crank wheel at one end and the other end is connected to +C motor. This
shaft is supported on two plummer block bearings. The punch tool slide is reciprocated by the
connecting the crank wheel through the connecting rod .The metal sheet is feeded automatically
by the rotation of geneva wheel.
;.1.1 ADVANTAGES:
Compared to hydraulic and ,pneumatic system, it is economical.
$o e=tra skill is re?uired for operating this system.
Operation is very smooth and in this system we can get more output by applying less
effort.
;.$ APPLICATIONS:
• It is very much useful for making series of holes of same diameter and constant
pitch
• Thus it can be useful for punching application
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CHAPTER <
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source of electrons that when connected to an external circuit will flow and deliver energy to an
external device. hen a battery is connected to an external circuit, electrolytes are able to
move as ions within, allowing the chemical reactions to be completed at the separate terminals
and so deliver energy to the external circuit. !t is the movement of those ions within the battery
which allows current to flow out of the battery to perform work.["]
#istorically the term $battery$specifically referred to a device composed of multiple cells, however the usage has evolved to
additionally include devices composed of a single cell.
%igure &.1 battery
https://en.wikipedia.org/wiki/Electrolytehttps://en.wikipedia.org/wiki/Battery_(electricity)#cite_note-2https://en.wikipedia.org/wiki/Battery_(electricity)#cite_note-2https://en.wikipedia.org/wiki/Electrolytehttps://en.wikipedia.org/wiki/Battery_(electricity)#cite_note-2
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COMPONENTS USED FOR AUTO ROLL PUNCHING MACHINE
&.$O COO$!$T& )&!+ AT!"IA' &IN! [)A$TIT1
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* .&.(A%"ICAT!+
&TA$+B&?uare tube
9
ild steel 9;;:69;:4;;
mm B2:H:+
*
- 5+C OTO" Aluminium *; 3g Tor?ue *
4 C"A$3 +I&C 'AT!
8 THIC3$!&&
ild steel *9;mm dia *
- #!$!5A 2H!!' +I&C
8 THIC3$!&&
ild steel *9;mm dia *
9
')!" %'OC3
%!A"I$#
Casting body
Bcover
;mm dia airs
7 AI$T !namel 9;; ml *
6. CO$$!CTI$# "O+ ild steel 9mm : 7mm
: *;;
*
8
CHAI$ 2ITH &"OC3!T
Carbon steel *7;;mm :
;mm
* &et
0 /O% (!!+ "O''!"& ild steel 9mm dia :9;mm
*;
)$CH TOO'
Hardened mild
steel
7mm dia *
** !TA' "I!" aint \ litre *
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CO$C')&IO$: