International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056

Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072

DESIGN OF GENEVA WHEEL BASED AUTO-ROLL PUNCHING MACHINE

R. Syam Sudhakar Rao1, A. Hari Tej2, C. Siva Sai3, A. Rupesh Kumar4, A. Narayana Reddy5,
B. Sai Krishna6
[1]Professor, Dept. of Mechanical Engineering, S.V.C.E.T Chittoor, Andhra Pradesh, India.
[2][3][4][5][6]Students,
Dept. of Mechanical Engineering, S.V.C.E.T Chittoor, Andhra Pradesh, India

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Abstract - On the conventional punching machine the time
for job setting, marking, punching operation is more. Labor 1.1 Methodology [2]
cost is also more. With Geneva based punching machine the
time for job setting, marking, punching, labor cost decreases This project is designed with using Geneva mechanism
and also less maintenance cost. In this project we are moving arrangement and punching mechanism. Punching
designing and fabricating the prototype of Auto roll punching machine is designed with mechanical arrangement in which
machine using Geneva mechanism. This project is specially movements are controlled by using Geneva mechanism.
designed for automatic punching in metal sheet. This project is
to introduce automation in industries. The major components Auto roll punching machine consists of two sections. One
involved in this project are dc motor, cam arrangement, chain section is automatic feeding mechanism and the second
drive, Geneva mechanism and punching tool. In this project we section is conversion of rotary motion into linear
are using two rollers for moving the sheet during operation. A reciprocating motion of punching tool. The first section
dc motor is connected with cam. The cam has a pin which consists of Geneva wheel disc keyed to shaft at one end and
rotates the Geneva wheel. The Geneva wheel is attached to the the other end is connected with chain sprocket wheel. This
chain drive. The other end of the chain drive is connected to Geneva wheel shaft is supported on nylon bushes. This
the rollers which roll the metal sheet and the punching sprocket wheel transmit the rotary motion from the Geneva
operation is done by the punch tool. It is suitable for making wheel to the feeding rollers through a chain drive. Hence
mass production of the sheet metal punching. when the Geneva wheel is rotated, the paper also moved for
punching operation.
Key Words: Geneva wheel, Cam drive, Dc motor, Punch
tool, Auto-roll punching.

1. INTRODUCTION [1]

The Geneva drive or Maltese 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 name derives from the device's earliest application in Fig -1: Geneva wheel based auto roll punching machine
mechanical watches; Geneva in Switzerland being an
important center of watchmaking. The Geneva drive is also The second section consists of electrically operated DC
commonly called a Maltese cross mechanism due to the motor, nylon bush, crank wheel with a pin, connecting rod
visual resemblance when the driven wheel has four spokes. and punching tool. The second section is used to convert the
Since they can be made small and are able to withstand rotary motion of the crank wheel into reciprocating motion
substantial mechanical stress, these mechanisms are of punching tool. The rotating shaft is keyed to the crank
frequently used in watches. wheel at one end and the other end is connected to DC
motor. This shaft is supported on nylon bush. The punch tool
In the most common arrangement, the driven wheel has
slide is reciprocated by the connecting the crank wheel
four slots and thus advances by one step of 90 degrees for
through the connecting rod .The paper is fed automatically
each rotation of the drive wheel. If the driven wheel has n
by the rotation of Geneva wheel.
slots, it advances by 360°/n per full rotation of the drive
wheel.

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072

1.2 Working [2]  Dwell time or processing time

(Td) = (180 - θ)/360 x N = (180 - 90)/360 x 51
When the motor is powered the cam drive disc is rotated.
The linear rod which is attached to the cam drive disc with = 4.901 x 10-3 min
eccentricity from the center is reciprocated on the punching
machine. The punching machine consists of a punch head,
when the linear rod is moved down it presses the punch 2.2 Design of roller chain drive [4]
head. The punch head consists of punch tools which punches  Pitch of chain (p) = 3.17 mm
the paper in required manner.  No. of teeth on smaller sprocket Z1 = 18 teeth
The cam drive disc has a pin attached to it, which enters  No. of teeth on larger sprocket Z2 = 28 teeth
into the slot of the Geneva wheel and turns the Geneva
 Diameter of smaller sprocket d1 = 70 mm
wheel. For every one rotation of cam drive disc, the Geneva
 Diameter of larger sprocket d2 = 130 mm
wheel rotates 1/4th of the rotation. The shaft of the Geneva
 No. of links in roller chains = 49 links
wheel is attached to the sprocket wheel. When the Geneva
wheel rotates, the sprocket wheel also rotates which in turn  Center distance between two sprocket wheels = 410
rotates the rollers attached to the other sprocket wheel. The mm
two sprocket wheels are connected by a roller chain. With
the help of rollers the paper moves forward and the 2.3 Motor calculations [5]
punching operation is done on it.
 Current (I) = 1.5 Amps
2. DESIGN  Voltage (V) = 12 V
 The consumed electric power of the motor (Pin) = I x
2.1 Design of Geneva mechanism [3] V = 1.5 x 12 = 18 W

 Geneva wheel radius (b) = 75 mm  The output mechanical power of the motor (Pout) =
T x ωout Watts
 No. of slots in Geneva wheel (n) = 4
 Drive pin diameter (p) = 8 mm  The speed of the motor (N) = 51 x 20 = 1020 rpm
 Allowed clearance (t) = 2 mm
 The actual Torque of the motor
(Tin) = Eb x Ia x 60 / 2 x π x N
 Centre distance (c) = = = 106 = 9.55 x 1.5 x 60 / 2 x 3.14 x 1020
mm = 0.1341 N-m

 Drive crank radius (a) = =  Angular speed (ωout) = 2 x π x rpm / 60 = 2 x 3.14 x

= 75 mm 1020 / 60 = 106.8 rad/sec
 Slot center length (s) = (a + b) - c = (75 + 75) – 106 =  Pout = 0.3141 x 106.8 = 14.3 W
44 mm
 Efficiency of motor = Pout / Pin = 14.3 / 18
 Width of slot (w) = p + t = 8 + 2 = 10 mm
 Angle between two slots (θ) = 2 x 180/n = 2 x 180/4 = 0.794 x 100 = 79.4%
= 90º
 Input angular speed (ωin) = 2 x π x rpm / 60
 Angle at the entrance of the pin into the slot (Ø) =
45º = 2 x 3.14 x 51 / 60 = 5.34 rad/sec
 Stop arc radius (y) = a – (p x 1.5) = 75 – (8 x 1.5) = 63  Fundamental equation for Gear pair = Tout / Tin
mm
 Thickness of Geneva wheel (h) = 6 mm = ωout / ωin = Tout / 0.1341 = 106.8 / 5.34
 Stop disc radius (z) = y – t = 63 – 2 = 61 mm  Tout = 6.282 N-m
 Thickness of crank drive (i) = 9mm
 Height of pin = h + t = 6 + 2 = 8mm
 Distance of drive pin from the center of the disc (a) = 2.4 Puncher specifications [6]
75 mm
 Punching diameter = 5.5 mm
 Number of revolutions per minute (N) = 51 rpm
 Total cycle time (Tc) = 1/N = 1/51 = 0.0196 min  Punching distance = 80 mm
 Available service time per cycle (Ts) = (180 + θ)/360  Punching Capacity = 22 sheets
x N = (180 + 90)/360 x 51
= 0.014 min

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072

 Ultimate shear stress of a carbonless paper

(𝜏)= 500 KPa
 Area under shear stress A = π x d x t mm2
2.5 Roller specification = π x 5.5 x 0.5
 Diameter of Rollers = 45 mm = 8.63 mm2
 Force required to punch F = A x τ Newton
 Length of the rollers = 430 mm = 8.63 x 0.5
 Center distance between two rollers = 45 mm = 4.315 N

2.6 Design in solid works 3.3 Punching on G. I. Sheet

 Hole diameter = 5.5 mm

 Thickness of sheet = 0.5 mm
 Ultimate shear strength of galvanized iron sheet
(τ) = 800 KPa
 Area under shear stress A = π x d x t mm2
= π x 5.5 x 0.5
= 8.63 mm2
 Force required to punch F=Axτ N
= 8.63 x 0.8
= 6.904 N
4. CONCLUSION
Fig -2: Design in solid works
The project carried out by us is used to make punching on
paper and G. I. Sheet with more prescribed than a
conventional punching machine. As conventional punching
machine takes more time for Job setting, Marking, Punching
operation. Labor cost is also more. With this Geneva wheel
based auto roll punching machine the time taken for all this
process can be reduced and production time also reduced
and production rate will be high. No extra skill is required
for operating this system. Operation is very smooth and in
this system we can get more output by applying less effort.
It is very much useful for making series of holes of same
diameter and constant pitch. Thus it can be useful for
punching application.
Fig -3: Auto roll punching machine
ACKNOWLEDGEMENT

3. RESULTS The authors want to thank Dr. C. VIJAYA BHASKAR REDDY,

Professor and Head of the Department of Mechanical
3.1 Power required to punch Engineering, SVCET, Chittoor, who has extended his support
for the success of this project.
 Power required to punch (p) = 2πNT/60 W
 Torque input to the cam drive (Tin) = 6.22 N-m REFERENCES
 The output torque of cam drive (T) = Tin (√2 cosθ –
1)= 6.22 (√2 cos0 – 1) = 2.57 N-m [1] https://en.wikipedia.org/wiki/Geneva_drive
(At maximum acceleration θ = 0) [2] A. Hari Tej, “Design of geneva wheel based autoroll
 Power required to punch = 2 x π x N x T / 60 punching machine,” unpublished
= 2 x 3.14 x 51 x 2.57 / 60 [3] https://newgottland.com/2012/01/08/make-geneva-
= 13.72 W wheels-of-any-size/
[4] R.S. Khurmi, J.K. Gupta, “THEORY OF MACHINES”,
3.2 Punching done on papers Eurasia Publishing House, 2005.
[5] www.mqitechnology.com/downloads/motor.../MotorDe
 Hole diameter (d) = 5.5 mm sign-06-WiperMotor.pdf
 Thickness of the paper (t) = 0.5 mm [6] Kangaroo DP-500 puncher details

© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 3
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 03 | Mar -2017 www.irjet.net p-ISSN: 2395-0072

[7] Kundan Kumar, “DESIGN AND FABRICATION OF AUTO

ROLL PUNCHING MACHINE”, International Journal of
Innovative Research in Science, Engineering and
Technology, Vol. 5, Special Issue 8, May 2016, 96-104.

BIOGRAPHIES (Optional not mandatory )

Mr. R. Syam Sudhakar Rao M.Tch.,

Assistant professor,
S.V.C.E.T Chittoor.

1’st
Author A. Hari Tej
Photo S.V.C.E.T Chittoor

C. Siva Sai
S.V.C.E.T Chitoor

A. Rupesh Kumar
S.V.C.E.T Chittor

A. Narayana Reddy
S.V.C.E.T Chittoor

B. Sai Krishna
S.V.C.E.T Chittoor

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