Pneumatic Calculator (Cylinder Force, Compressor & Pipe Sizing)
Free pneumatic calculators for cylinder force, compressor CFM/HP, and pipe sizing—workflows from bore selection to plant air distribution for automation teams.
Start with the actuator: size the pneumatic cylinder for your required force, then calculate total air demand to size the compressor, and finally size the distribution piping for acceptable velocity and pressure drop. This hub is the primary entry for the Pneumatics cluster—follow the workflow from cylinder → compressor → pipe.
FAQ — Pneumatic Calculators
How do you size a pneumatic cylinder?
Calculate the required bore using D = sqrt(4F / (π × P × load_factor)), where F is the required force, P is supply pressure, and load_factor is 0.5-0.85 depending on application. Select the next larger standard bore (ISO 6432: 8, 10, 12, 16, 20, 25, 32, 40, 50, 63, 80, 100 mm). Use the Pneumatic Cylinder Sizing Calculator for instant force, bore, and air consumption results.
What size air compressor do I need?
Sum the CFM requirements of all pneumatic tools, multiply by a simultaneous use factor (0.65-0.85), add 10-20% for leakage and 10-15% for growth. The result is your required FAD (Free Air Delivery). A typical screw compressor delivers 3.5-4.5 CFM per HP at 100 PSI. Use the Air Compressor Sizing Calculator for HP, kW, tank size, and annual energy cost.
How do you calculate compressed air pipe size?
Find the smallest pipe diameter that keeps air velocity below 20-30 ft/s (6-9 m/s) for main headers and pressure drop below 0.1 bar (1.5 PSI) per 100 ft. Use the Darcy-Weisbach equation: ΔP = f × (L/D) × (ρV²/2). Include equivalent length for elbows, tees, and valves. Use the Compressed Air Pipe Sizing Calculator for steel, copper, aluminum, and HDPE pipe.
What is the formula for pneumatic cylinder force?
Push force (extend): F = P × π × D² / 4. Pull force (retract): F = P × π × (D² - d²) / 4, where D = bore diameter, d = rod diameter, P = gauge supply pressure. Apply a load factor of 0.5-0.9 for real-world force due to seal friction and pressure losses. The rod reduces effective area on the retract side, so pull force is always less than push force.
How much air does a pneumatic cylinder consume?
Air consumption per cycle = (extend volume + retract volume) × absolute pressure ratio. Extend volume = π/4 × D² × S, retract volume = π/4 × (D² - d²) × S (double-acting only). Convert to FAD by multiplying by (P_gauge + P_atm) / P_atm. Multiply by cycles per minute for continuous CFM demand on the compressor.
What is the difference between pneumatic and hydraulic actuators?
Pneumatics use compressed air (typically 4–7 bar) for fast, clean motion with moderate force density. Hydraulics use oil at 100–350 bar for much higher force in compact cylinders but require fluid management. Use the pneumatic vs hydraulic actuators guide for force density, lifecycle cost, and selection criteria.
