How to Calculate Pneumatic Cylinder Force (With Force Chart)

What Is Pneumatic Cylinder Force?

Pneumatic cylinder force is the pushing or pulling force generated when compressed air acts on the piston inside the cylinder.

This is one of the most important parameters because it determines:

1. Whether the cylinder can move the load
2. System performance
3. Operating stability

👉 Choosing the wrong force can result in:

1. Weak cylinder performance
2. Insufficient pushing power

Pneumatic Cylinder Force Formula

Cylinder force is calculated using the following formula:

F=P×AF = P \times AF=P×A

Where:

1. F = force (N)
2. P = air pressure
3. A = piston area

👉 Larger bore size → larger piston area → greater force.

How to Calculate Piston Area

Piston area is calculated using:

Where:

1. D = cylinder bore diameter

Example:

1. Bore = 63mm
2. Piston area ≈ 3117 mm²

👉 Then:

1. Piston area × air pressure
2. → gives the theoretical cylinder force.

Example: Calculating SC63 Cylinder Force

Example:

1. Bore = 63mm
2. Pressure = 5 bar (0.5 MPa)

According to the AirTAC SC thrust chart:

1. Output force is approximately 150–160kgf

👉 However:

1. This is a theoretical value
2. In real-world applications, a 20–30% safety margin is recommended

👉 These values represent theoretical pushing force during extension.

Why Is Actual Force Lower Than Theoretical Force?

Many people correctly calculate force but still experience:

👉 The cylinder cannot move the load properly.

Common reasons include:

1. Mechanical friction
2. Air leakage
3. Unstable pressure
4. Off-center loading
5. Incorrect mounting

👉 In practice:

1. Only about 60–80% of the theoretical force should be used.

How to Choose Bore Size Based on Force

Light Loads

1. Bore 32–40

Medium Loads

1. Bore 50–63

Heavy Loads

1. Bore 80–100

👉 Avoid selecting a cylinder with force exactly equal to the load.

Recommended:

1. Add 20–30% safety margin

What’s the Difference Between Push Force and Pull Force?

Many people overlook the difference between:

1. Extension force
2. Retraction force

👉 They are NOT the same.

Because:

1. During retraction, the piston rod occupies part of the piston area
2. Effective area becomes smaller

→ Retraction force is always lower than extension force.

Common Mistakes When Calculating Cylinder Force

Looking Only at Bore Size

1. Large bore with low pressure → still weak force

Ignoring Friction

1. Results in insufficient force calculation

Choosing an Oversized Cylinder

1. Higher air consumption
2. Increased cost
3. Bulky system design

👉 These are very common pneumatic system design mistakes.

When Should You Increase Bore Size?

You should increase bore size when:

1. The load becomes heavier
2. Air pressure is low
3. Stroke length is long
4. Higher stability is needed

👉 However:

1. Larger bore cylinders consume more air

Conclusion

Correct pneumatic cylinder force calculation helps:

1. Select the proper bore size
2. Ensure sufficient force
3. Reduce system failures
4. Optimize operating costs

👉 When calculating cylinder force, always consider:

1. Bore size
2. Air pressure
3. Friction
4. Actual load
5. Installation conditions

👉 If you are unsure which cylinder is suitable, you can explore various AirTAC pneumatic cylinders with detailed thrust charts and technical specifications.