Fabrication of sheet cutting machine

8/18/2019 Fabrication of sheet cutting machine

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CHAPTER: 1

INTRODUCTION

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1.1 INTRODUCTION

The sheet metal cutting process is a main part of the all industries. Cutting processes

are those in which a piece of sheet metal is separated by applying a great enough force to

cause the material to fail .Normally the sheet metal cutting machine is manually hand

operated one for medium and small scale industries. The most common cutting processes are

performed by applying a shear force, and are therefore sometimes referred to as shearing

processes. Our project is about the implementation of hydraulic pressure in the process of

cutting a metal sheet .Hence we introduce our project namely as “HYDRAULIC SHEET

CUTTING MACHINE”.

Automation in the modern world is ineitable. Any automatic machine aimed at

the economical use of man either a machine or a material is worth the most. The sheet metal

cutting machine wor!s with the help of hydraulic cylinder. The piston is connected to the

moing cutting tool. "t is used to cut small si#ed pieces of the sheet metal. The machine is

portable in si#e, so easily transportable. The hydraulic sheet cutting machine has a hydraulic

cylinder piston attached to a sheet cutter which has $mm thic! blades, used to cut the

re%uired metal sheet into pieces .&hen the hydraulic jac! is sealed and the leer arm is

moed up and down, the pressure deeloped in the cylinder reseroir leads to the lifting of

the piston rod which cause for the cutting tool to cut down the metal sheet.

The shearing is performed on a shear machine, often called s%uaring shear or

power shear, that can be operated manually or by hydraulic, pneumatic, or electric power. A

typical shear machine includes a table with support arms to hold the sheet, stops or guides to

secure the sheet, upper and lower straight ' edge blades, a gauging deice to precisely

position the sheet.

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(ig) *.* Hydraulic sheet cutting machine

The application of hydraulic to mechanical wor! helps for the reduction of human

wor! force and helps in the increase in productiity by reducing time re%uired. &hen the

hydraulic jac! is tightly air sealed, the fluid present in the hydraulic cylinder gets

compressed. &hen the leer arm is continuously moed, the pressure is applied in the

cylinder reseroir which leads to increase in internal pressure. +ue to this, the piston rod

moes upward which in turn moes the leer of the cutting machine. This leer moes in

upward direction which causes the blade to cut it down.

1.2 TYPES OF SHEET CUTTING MACHINE

There are arious types of sheet cutting machine with respect to the type of operation

applied on it. heet cutting machines are classified according to the following)'

*- Hydraulically operated

- /neumatically operated

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0- 1ac! and pinion operated

2- pring operated

3rief descriptions of all the types are as follows)

*- Hydraulically operated)'

Here the lowering and raising of the header is carried oer using the hydraulic piston and

cylinder arrangement. To actuate the piston and cylinder, the oil is enters the cylinder from

front or the bac! side of the piston. This hydraulic pressure causes for the cutting of een

heay weight objects with ease. The hydraulic operated has the most adantages than the

other mentioned below.

- /neumatically operated)'

Here the adancement of the header is carried out in the upward and the downward

direction using the pneumatic double acting piston and cylinder unit arrangement along with

the foot operated direction control ale. "n this type of machine high pressure air is used as

the wor!ing fluid for the transfer of power and the motion

0- 1ac! and pinion operated)'

Here the lowering and the raising of the header are carried out manually using the rac!

and pinion arrangement. "n this case the re%uired pressure is applied manually using direct

hand pressure on the rac! using pinion and leer arrangement. ince the machine is robust

and re%uires large pressure, hence it is not suitable.

2- pring operated)'

The wor!ing of spring operated machine is similar to the rac! and pinion operated

machine but differs from it in construction. Here the lowering and the raising of the heating

handle are carried out manually and it re%uires too much pressure for its operation and also

there is possibility of haing damage to the wor! piece if not handled carefully.

Hence from the aboe described arious types of sheet cutting machines , we can state

that the hydraulic operated sheet cutting machine is more adantageous as it is light ,

portable, easy to handle and also has a ery high cutting power than compared to all the other

gien arious types of sheet cutting machines.

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1.3 PURPOSE

heet cutting machine of hydraulic type is used to cut the sheets into two pieces by

hydraulic power, there is no need of human effect for this machine This machine has bottom

blade and top blade, where bottom blade is fi4ed one and top blade is moed by a hydraulic

cylinder, remaining structures are made of forged steel and cutting blades are made of high

carbon steel.

The sheet metal cutting machine wor!s with the help of hydraulic cylinder. The piston

is connected to the moing cutting tool. "t is used to cut small si#ed pieces of the sheet metal.

The machine is portable in si#e, so easily transportable. The hydraulic sheet cutting machine

has a hydraulic cylinder piston attached to a sheet cutter which has $mm thic! blades, used to

cut the re%uired metal sheet into pieces .&hen the hydraulic jac! is sealed and the leer arm

is moed up and down, the pressure deeloped in the cylinder reseroir leads to the lifting of


1.4 PROBLEMS

The hydraulic sheet cutting machine has a hydraulic cylinder piston attached to a

sheet cutter which has $mm thic! blades, used to cut the re%uired metal sheet into pieces

&hen the hydraulic jac! is sealed and the leer arm is moed up and down, the pressure

deeloped in the cylinder reseroir leads to the lifting of the piston rod which cause for the

cutting tool to cut down the metal sheet.

There are major problems present in the hydraulic sheet cutting machine which hae

to be dealt to reduce loss of output and for safe wor!ing of machine. The first problem is the

friction between the moing parts such as handle grooes and the upper !nife grooes which

causes the loss of motion in the sheet material. The second major problem is lea!age of oil

from hydraulic jac! which causes for the jac! to be replaced.

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CHAPTER: 2

PROBLEMS AND LITERATURE VIEW

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2.1 INTRODUCTION TO PROBLEMS AND LITERATURE VIEW

Cutting processes are those in which a piece of sheet metal is separated by applying a

great enough force to cause the material to fail. 5ost of the sheet metal cutting processes

discussed can be performed on both sheet and plate metal, although for many sheet metal

operations difficulties will arise with increasing plate thic!ness. 6sually 7sheet7 and 7sheet

metal7 is also referencing plate. The angle that the punch may be inclined aries from 2 to *8

degrees, howeer the higher the angle, the greater the magnitude of the hori#ontal force

component acting to displace the wor!. (or that reason angles are usually less than 9 degrees .

Cutoffs and partings are important basic sheet metal cutting processes performed inmanufacturing industry. Cutoffs need not be straight: rather they may be oer seeral lines

and;or cures. /artings are similar, in that a discrete part is cut from a sheet or strip of metal

along a desired geometric path. The difference between a cutoff and a parting is that a cutoff

can be nestled perfectly on the sheet metal, due to its geometry. &ith cutoffs, the cutting of

sheet metal can be done oer one path at a time and there is practically no waste of material.

&ith partings, the shape cannot be nestled precisely. /artings inole cutting the sheet metal

along two paths simultaneously. /artings waste a certain amount of material, which can be

significant.

2.2 RECTIFICATION


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2.3 MERITS OF HYDRALIC SHEET CUTTING MACHINE:

*- =ow cost

- =ess consumption of time

0- - ?ood surface finish

@- =ess floor space

2.4 DEMERITS OF HYDRAULIC SHEET CUTTING MACHINE:*- Oil lea!age

- 1educes employment

0- Hard to refill is any loss.

2.5 Li!"#$"! Vi!%

The formation of any business begins with someone producing the initial idea for the

project. The continued success of an established business depends upon the number and

%uality of the ideas fed intuits. &ithout a continual flow of new ideas, a business cannot

function profitably or e4pand successfully and must, therefore eentually fade into total

obscurity.

"deas for a new business project, a new product, a means of reducing manufacturing

costs, or for soling industrial labor problems, begin in the human mind. 5ost people

conceie their ideas unconsciously, and because they are unaware of the mental mechanicsthat caused the idea to be produced, they cannot repeat the ideation process to produce

further profitable ideas at will.

(ortunately, there are aailable established creatie techni%ues which, when used

correctly, do enable a person to produce a large number of first'class ideas at will. One such

creatie techni%ue, and probablyB the most widely used in American industry, is

brainstorming.

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"n shearing operation as the punch descends upon the metal, the pressure e4erted by

the punch first cause the plastic deformation of the metal. ince the clearance between the

punch and the die is ery small, the plastic deformation ta!es place in a locali#ed area and the

metal adjacent to the cutting edges of the punch and die edges becomes highly stressed,

which causes the fracture to start on both sides of the sheet as the deformation progresses and

the sheet is also sheared in the deformation process causing to cutting of the sheet.

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CHAPTER: 3

DESIGN

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3.1 E&PLANATION OF DESIGN

The word design means different things to different people a wallpaper pattern afashionable dress, the appearance of a racing car and so on. &e therefore start by defining

what we mean by design in the present conte4t i.e. what design is all about

This understanding will lead to an e4amination of

* &hy we need to design particularly in an engineering enironment, and

How we might best go about designing

&hat is design

The Concise O4ford +ictionary e4plains design as a mental plan a scheme of attac!, end

in iew, adaptation of means to ends preliminary s!etch for picture inention


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problems. &e shall focus on problems inoling engineering hardware particularly for

+esign and 3uild Competitions howeer the approach is perfectly general and applicable to

problems arising from a mar!eting sortie or a labour wrangle for e4ample. The approach is

thus ery releant to managers and the li!e not just to hardware designers.

3.2 SHEARING

As mentioned aboe, seeral cutting processes e4ist that utili#e shearing force to cut

sheet metal. Howeer, the term “shearingE by itself refers to a specific cutting process that

produces straight line cuts to separate a piece of sheet metal. 5ost commonly, shearing is

used to cut a sheet parallel to an e4isting edge which is held s%uare, but angled cuts can be

made as well. (or this reason, shearing is primarily used to cut sheet stoc! into amaller si#es

in preparation for other processes. hearing has the following capabilities

heet thic!ness) F.FF8 G F.8 inches

Tolerance) F.* inches

The shearing is performed on a shear machine, often called as%uaring shear or power

shear, that can be operated manually or by hydraulic, pneumatic, or electric power. A typical

shear machine includes a table with support arms to hold the sheet, stops or guides to secure

the sheet, upper and lower straight ' edge blades, a gauging deice to precisely position the

sheet. The sheet is placed between the upper and the lower blade, which are then forced

together against the sheet, cutting the material. "n most deices, the lower blades remain

stationary while the upper blade is forced downward. The upper blade is slightly offset from

the lower blade, appro4imately 8 G *F of the sheet thic!ness. Also the upper blade is

usually angled so that the cut progresses from one end to the other, thus reducing the re%uired

force. The !nife edge and are aailable in different materials, such as low alloy steel and high

carbon steel.

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(ig) 0.* shearing force acting on a metal sheet

3.3 SHEET METAL

heet metal is simply a metal formed into thin and flat pieces. "t is one of the

fundamental forms used in metal wor!ing and can be cut and bent into a ariety of different

shapes. Countless eeryday objects are constructed of the material. Thic!nesses can ary

significantly, although e4tremely thin thic!nesses are considered foil or leaf, and pieces

thic!er than $ mm IF.8 in- are considered plate.

heet metal is aailable in flat pieces or as a coiled strip. The coils are formed by

running a continuous sheet of metal through a roll slitter.

The thic!ness of the sheet metal is called its gauge. Commonly used steel sheet metal

ranges from 0F gauges to about @ gauge. The larger the gauge number, the thinner the metal.

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?auge is measured in ferrous Iiron based- metals while nonferrous metals such as aluminium

or copper are designated differently: i.e., Copper is measured in thic!ness by Ounce.

There are many different metals that can be made into sheet metal, such as

aluminium, brass, copper, steel, tin, nic!el and titanium. (or decoratie uses, important sheet

metals include siler, gold and platinum Iplatinum sheet metal is also utili#ed as a catalyst.-

heet metal also has applications in car bodies, airplane wings, medical tables, roofs for

buildings IArchitectural- and many other things. heet metal of iron and other materials with

high magnetic permeability, also !nown as laminated steel cores, has applications in

transformers and electric machines. Historically, an important use of sheet metal was in plate

armour worn by caalry, and sheet metal continues to hae many decoratie uses, including

in horse tac!. heet metal wor!ers are also !nown as 7Tin 3ashers7,I7Tin Dnoc!ers7- which

is deried from the hammering of panel seams when installing tin roofs.

3.4 SHEARED EDGE

A ariety of cutting processes that utili#e shearing forces e4ist to separate or remoe

material from a piece of sheet stoc! in different ways. . lotting

@. /erforating

9. Notching

*F. Nibbling

**. =ancing

*. litting

*0. /arting

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*2. Cut'off

*8. Trimming

*$. haing

*>. +in!ing

(ig) 0. +ifferent stages of metal shearing

3.5 COMPONENTS

*- B'#(!)) ' The blades area also called as !nies. They are the ery important parts of

the sheet cutting machine which helps in the process of cutting the sheet in arious

small pieces

- G!#")' The gear is a small attachment present to the handle and the upper !nife to

transmit the motion from handle to the upper !nife

0- F"#*!) ' The frame is the main part connecting the all the parts and causing the sheetcutting to ta!e place.

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H+("#$'i, -#, ) 'A hydraulic jac! is a mechanical deice used as a lifting deice to lift

heay loads or apply great forces

heet cutting machine of hydraulic type is used to cut the sheets into two pieces by

hydraulic power, there is no need of human effect for this machine This machine has bottom

blade and top blade, where bottom blade is fi4ed one and top blade is moed by a hydraulic

cylinder , remaining structures are made of forged steel and cutting blades are made of high

carbon steel.

The sheet metal cutting machine wor!s with the help of hydraulic cylinder. The piston

is connected to the moing cutting tool. "t is used to cut small si#ed pieces of the sheet metal.

The machine is portable in si#e, so easily transportable. The hydraulic sheet cutting machine

has a hydraulic cylinder piston attached to a sheet cutter which has $mm thic! blades, used to

cut the re%uired metal sheet into pieces .&hen the hydraulic jac! is sealed and the leer arm

is moed up and down, the pressure deeloped in the cylinder reseroir leads to the lifting of


3./ COST ESTIMATION

3./.1 INTRODUCTION

Cost estimation may be defined as the process of forecasting the e4penses that must

be incurred to manufacture a product. These e4penses ta!e into a consideration all

e4penditure inoled in a design and manufacturing with all related serices facilities such as

pattern ma!ing, tool, ma!ing as well as a portion of the general administratie and selling

costs.

3./.2 PURPOSE OF COST ESTIMATING

*. To determine the selling price of a product for a %uotation or contract so as to

ensure a reasonable profit to the company.

. Chec! the %uotation supplied by endors.

0. +etermine the most economical process or material to manufacture the product.

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2. To determine standards of production performance that may be used to control

the cost

3.0 TYPES OF COST ESTIMATION

*. 5aterial cost

. 5achining cost

0. =abour cost

3.0.1 MATERIAL COST ESTIMATION

5aterial cost estimation gies the total amount re%uired to collect the raw material

which has to be processed or fabricated to desired si#e and functioning of the components.

These materials are diided into two categories)'

*. 5aterial for fabrication)

"n this the material in obtained in raw condition and is manufactured or processed to

finished si#e for proper functioning of the component.

. tandard purchased parts)

This includes the parts which was readily aailable in the mar!et li!e Allen screws

etc. A list in for chard by the estimation stating the %uality, si#e and standard parts, the weight

of raw material and cost per !g for the fabricated parts.

3.0.2 CALCULATION OF MATERIAL COST

The general procedure for calculation of material cost estimation is

*. After designing a project a bill of material is prepared which is diided into two categories.

a. (abricated components

b. tandard purchased components

. The rates of all standard items are ta!en and added up.

0. Cost of raw material purchased ta!en and added up.

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3.0.3 MACHINING COST ESTIMATION

This cost estimation is an attempt to forecast the total e4penses that may include

manufacturing apart from material cost. Cost estimation of manufactured parts can be

considered as judgment on and after careful consideration which includes lab our, material

and factory serices re%uired to produce the re%uired

Table) 0.* 5achining cost

3.0.4 LABOUR COST

"t is the cost of remuneration Iwages, salaries, commission, bonus etc.- of the employees

of a concern or enterprise. This cost can be reduced by 8, if this machine is manufactured

on mass %uantity

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=abor cost is classifies as)

*. +irect labor cost

. "ndirect labor cost

+irect labor cost)

The direct labor cost is the cost of labor that can be indentified directly with the

manufacture of the product and allocated to cost centers or cost units. The direct labor is one,

who counters the direct material into saleable product, the wages etc. of such employees

constitute direct labor cost. +irect labor cost may be apportioned to the unit cost of job or

either on the basis of time spend by a wor!er on the job or as a price for some physical

measurement of product.

"ndirect labor cost)

"t is that labor cost which cannot be allocated but which can be apportioned to or

absorbed by cost centers or cost units. This is the cost of labor that doesnt alters the

construction, confirmation, composition or condition of direct material but is necessary for

the progressie moement and handling of product to the point of dispatch e.g. maintenance,

men, helpers, machine setters, superisors and foremen etc.

The total labor cost is calculated on the basis of wages paid to the labor for @hours per day.

Total Cost estimation is done as under

Cost of project J IA- material cost K I3- 5achining cost K IC- labor cost

IA- 5aterial cost is calculated as under)'

i- 1aw material cost

ii- (inished product cost

i- 1aw material cost)'

"t includes the material in the form of the 5aterial supplied by the teel authority of "ndia

limited as the round bars Channels, angles, s%uare rods, plates along with the strip material

form. &e hae to search for the suitable aailable material as per the re%uirement of designed

safe alues.

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1ateJ 2F;' per !g.

Hence the cost of the raw material is as follows)'

Total of aboe J 1s *88;'

ii- (inished product cost)'

(ollowing the components which we hae directly purchased from the 5ar!et, being

easily aailable and cheaply aailably aailable as compared to their manufacturing cost

*- Hydraulic cylinder J *@FF;'

- (5= 6nit J $FFF;'

0- &elding rod J *F;'

2- Color Imaroon, yellow, blac!, blue- J FF;'

8- NutsL bolt I2- J *8F;'

Total cost of the finished components J 1s @>F;'

iii- =abor cost)'

Table) 0. =abor cost

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Hence the total labor cost incurred J 1s. *098;' (rom the aboe we can calculate the total

manufacturing cost, i.e.

Hence the total manufacturing cost J A I i K ii - K 3 K C

J I*88 K @>F- K *92F K*098

J 1s.0>$F;'

3. MACHINING TIME ESTIMATION

This machining cost estimation gies us time re%uire machining a particular component

on machine. This gies us an estimation of how much time will be re%uired to hire the

machine for that particular component. This is done for all components e4cept standard parts

3..1 PROCEDURE FOR CALCULATING MACHINING TIME

*- After the machining time has been calculated including allowance for each component

because a component can hae more than one operation to be carried out. Hence, rates of

machine are different.

- The machining time is calculated using standard wor!ing rates.

0- The time re%uired to manufacture a gien component on a machine is multiplied by

machine rate to gie machine cost.

2- The estimation of machining cost for total number of components gies us machining

cost estimation.

8- 5achining time of components are estimated in order to !now total manufacturing cost

of component.

Total time includes basic time and arious factors which are ta!en into consideration and

they are)'

*- 6p time and down time J *FF of basic

Transportation time J *F min

Centrime time J F min

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"nspection time J F min

Other allowances ta!en into consideration are)'

*- /ersonal allowance J 8 of basic time

- (atigue allowance J > of basic time

0- Contingency allowance J 8 of basic time

3..2 TIME ANALYSIS

A- Turning Operation

The machining time in a lather wor! can be calculated for particular operation. "f speedof job food and length of job is !nown as M.C. Then,

Time ta!en for complete cut J * min J s 4 n

&here,

s J feed per reolution

n J No. of reolution ; min of job

l J =ength of job to be m;ced

3- haping operation

"f length of cutting sto!es, breadth of job feed and cutting speed are !nown time re%uired

to complete job may be calculated as

T J = 3 I* K m-;*FFF 1 4 .

&here,

T J Total time ta!en to complete cut.

= J length of sto!e in mm

1 J the ratio of return time to cutting time

J the cutting speed e4pressed in m;min

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J (eed e4pressed in mm;per double stro!e

C- 5illing operation

Time re%uired to mill any component surface can be gien as,

T J A;s# 4 # 4 n

&here,

T J Time re%uired to complete cut in min

= J =ength of table trael to complete cut in mm

P J (eed per tooth in mm

P J No. of teeth of cutter

n J No. of reolutions of cutter per minute

+- +rilling operation

5achining time in drilling operation can be determined by formula. T J *;sr 4 n mm.

&here,

T J 5achining time in min.

.l J =ength of trael of drill per min.

.n J No. of reolutions of drill in mm.

3..3 TIME REUIRED FOR MACHINING TIME COMPONENTS

*- (rame

Angle measuring J 0F min

Angle cutting J 28 min

&elding J *F min

Total time J *98 min

- =in!age

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5easurement J *8 min

Cutting J *8 min K *F min J 8 min

+rilling J F min

&elding J *F min

0- Hydraulic cylinder

(acing J F min

Turning J 8 min

+rilling J *F min K F min J 0F min

3oring J F min

Total time J 98 min

2- Casing

Cutting J *F min

3ending J 2F min

+rilling J 0F min

1ieting J 8 min

Total time J **8 min

8- lots

Cutting J *8 min

5illing J *@F min

3oring J *8 min

Total time J *F min

$- 1est plates

Cutting J *8 min

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3ending J *F min

&elding J 8 min

Total time J 8F min

3. MATERIALS

3..1 MILD STEEL

The three most common steel grades aailable in sheet metal are 0F2, 0*$, and 2*F.

• ?rade 0F2 is the most common of the three grades. "t offers good corrosion resistance

while maintaining formability and weld ability. Aailable finishes are Q3, Q0, and Q2.

Note that grade 0F0 is not aailable in sheet form.

• ?rade 0*$ offers more corrosion resistance and strength at eleated temperatures than

0F2. "t is commonly used for pumps, ales, chemical e%uipment, and marine

applications. Aailable finishes are Q3, Q0, and Q2.

• ?rade 2*F is a heat treatable stainless steel, but does not offer as good corrosion

resistance. "t is commonly used in cutlery. The only aailable finish is dull.

(ig) 0.0 5icrostructure of teel

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3..2 PROPOSED WOR

To prepare any machine part, the type of material should be properly selected, considering

design, safety and following points)'

The selection of material for engineering application is gien by the following (actors)'

*- Aailability of materials.

- uitability of the material for the re%uired components.

0- uitability of the material for the desired wor!ing conditions.

2- Cost of the materials.

"n addition to the aboe factors the other properties to be considered while selecting the

material are as follows)'

P+)i,#' 6"76!"i!))'

These properties are color, shape, density, thermal conductiity, electrical conductiity,

melting point etc.

M!,#8i,#' 6"76!"i!))'

The properties are associated with the ability of the material to resist the mechanical

forces and load.

The arious properties are)'

i- S"!89) "t is the property of material due to which it can resist the e4ternal forces

without brea!ing or yielding.

ii Si;;8!))) "t is the ability of material to withstand the deformation under stress.

iii- D$,i'i+) '"t is the property of material due to which it can be drawn into wires under

tensile load.

i- M#''!#


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T7$98!))) ' "t is the property of a material to bear the load acting on it.

i- B"i'!8!))) "t is the property of material due to which it brea!s into pieces with little

deformation.

ii- H#"(8!))) "t is the property of material to resist wear, deformation and the ability to

cut another material.

iii- R!)i'i!8,!) "t is the ability of the material to store energy and resist the shoc! and

impact loads.

i4- C"!!6) "t is the slow and permanent deformation induced in a part subjected to a

constant stress at high temperature. &e hae selected the material considering the aboe

factors and also as per the aailability of the material.

The materials which coer most of the aboe properties are)'

MILD STEEL

&hy steel, in particular

imply because, in my humble opinion, it is the greatest material man!ind has for

construction. "t is cheap, strong, readily aailable, easily cut, joined, and formed. &ood can

be light and stiff, but not ery strong. The best aluminum is strong and light, but ery difficult

to join. Titanium is superb in terms of strength to weight ratio and stiffness but its incredibly

e4pensie, difficult to obtain, and een more difficult and e4pensie to machine properly.

There is no way youre eer going to perform a battery'weld field'fi4 on a part made from

>F>8'T$ aluminum or titaniumR "n the end we come bac! to steel from mild carbon to some

of the more e4otic alloy steels pound for pound it is the most righteous material aailable for

our needs.

&here does steel come from

teel is not a naturally occurring substance ' it is entirely man made.

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teel is chiefly a combination of two naturally occurring elements) iron and carbon

Ialong with small amounts of other elements ' depending on the steel in %uestion-. The

process, by which man ma!es steel, would again fill seeral olumes. Here is my amateur

synopsis)

"ron is mined from the ground in the form if a reddish'brown roc! called iron'ore.

This ore is then smashed up, strained, filtered, chemically treated etc, until ultimately it is

melted in huge blast furnaces into something called pig iron. The process uses co!e Ia type of

coal-, which in turn imparts large amounts of carbon to the pig iron. As a result, pig iron itself

is full of impurities, brittle, and unmachinable ' practically useless.


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*. 5ild steel is readily aailable in mar!et

. "t is economical to use

0. "t is aailable in standard si#es

2. "t has good mechanical properties i.e. it is easily machinable

8. "t has moderate factor of safety, because factor of safety results in unnecessary wastage

of material and heay selection.

$. =ow factor of safety results in unnecessary ris! of failure

>. "t has high tensile strength

@. =ow co'efficient of thermal e4pansion

/roperties of 5ild teel)

5.. has carbon content from F.*8

BRIGHT MATERIAL)

"t is a machine drawned. The main basic difference between mild steel and bright

metal is that mild steel plates and bars are forged in the forging machine by means is not

forged. 3ut the materials are drawn from the dies in the plastic state. Therefore the material

has good surface finish than mild steel and has no carbon deposits on its surface for e4trusion

and formation of engineering materials thus giing them a good surface finish and though

retaining their metallic properties A poor, but perhaps useful metaphor may be the use of

fibre'mat and resin in fibre glass wor!. The bul! raw material of fibreglass is the fibre

matting Ias iron is to steel- ' but by itself the matting is of no practical use. Not until we add

the resin to it to ma!e fibre glass Ias we add carbon to iron to ma!e steel-

+o we get a useful product

"n both cases, neither raw material is much use alone, but combines them nor do we

really hae something. imilarly, though carbon may only be present in small %uantities,

Mustas the amount of hardener added to fibre glass resin has a profound effect on the material,so does the small amount of carbon present in useful metallic iron and steel

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Composition) Carbon F.F

/roperties) Tensile strength 22.82 !gf;mm

Sield stress) @ !gf;mm

Hardness) *>F 3HN

6ses) ?eneral purpose steels for low stressed components

Table) 0.0 /roperties of 5aterials

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3.11 SPECIFICATIONS

Hydraulic jac!) ' capacity '0 ton

5inimum height '*98 mm

=ift height '*8 mm

Adjustment height ' $F mm

5a4imum height '0@F mm

Net weight ' 0.8 !gs

heet cutter)'6pper blade length '2F mm

=ower blade length '2F mm

Thic!ness of blades '* mm

&eight of cutting machine) ' *0.8 !gs

&idth of sheet to cut) ' F.FF8 to F.F8 mm

3.12 CALCULATIONS

Cylinder specification) 3ore diameter J >$ mm

&all thic!ness J .@2 mm

=ength J *@$ mm

/iston thic!ness J > mm

/ump specification) 5a4. /ressure J *>84*F8 N;m

(orce calculation) Area, A J Pi 4 r

J2.804*F'0 m

(orce or load J / 4 A

J *>84*F842.804*F'0

J>9.>8 !N

Time ta!en to cut the sheet J 8.@ sec

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CHAPTER: 4

FABRICATION AND E&ECTUION OF

HYDRAULIC SHEET CUTTING

MACHINE

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4.1 FABRICATION OF HYDRAULIC SHEET CUTTING MACHINE

The sheet cutting machine is a main part of the all industries. Cutting processes are

those in which a piece of sheet metal is separated by applying a great enough force to cause

the material to fail. The hydraulic sheet metal cutting machine wor!s with the help of

hydraulic cylinder. The piston is connected to the moing cutting tool. "t is used to cut small

si#ed pieces of the sheet metal. The machine is portable in si#e, so easily transportable. The

hydraulic sheet cutting machine has a hydraulic cylinder piston attached to a sheet cutter

which has $mm thic! blades, used to cut the re%uired metal sheet into pieces .&hen the

hydraulic jac! is sealed and the leer arm is moed up and down, the pressure deeloped inthe cylinder reseroir leads to the lifting of the piston rod which cause for the cutting tool to

cut down the metal sheet.

The application of hydraulic to mechanical wor! helps for the reduction of human

wor! force and helps in the increase in productiity by reducing time re%uired. &hen the

hydraulic jac! is tightly air sealed, the fluid present in the hydraulic cylinder gets

compressed. &hen the leer arm is continuously moed, the pressure is applied in the

cylinder reseroir which leads to increase in internal pressure. +ue to this, the piston rod

moes upward which in turn moes the leer of the cutting machine. This leer moes in

upward direction which causes the blade to cut it down

4.2 PARTS PRESENT IN SHEET CUTTING MACHINE

The hydraulic sheet cutting machine consists of arious parts which help in the

cutting of the sheet material into arious small pieces. The sheet cutting machine is attached

to a hydraulic jac! who in turn helps the machine to moe ery easily without any e4cessie

force to add onto the sheet metal. The sheet cutting machine mainly consists of parts such as)'

*- B'#(!)) ' The blades area also called as !nies. They are the ery important parts of the

sheet cutting machine which helps in the process of cutting the sheet in arious small pieces

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(ig) 2.* 3lades

The upper !nife is attached to a handle which helps the gear to moe both upward and

down ward direction. The upper !nife has a bolts attached to it in either side which helps in

its moement as we can see in the pic , the bolt on the left acts as a fulcrum attached to the

frame where as the on the right helps for the motion transfer of the handle to the blade.

The lower !nife is a stationary !nife which remains constant attached permanently to the

frame as it has no respectie use. The lower !nife has a ery sharp edge, same as the upper

!nife where the both !nies meet causing for the sheet to get cut. There is a small gap of

around F.FF* between both !nies when they meet as to get a perfect cut of the metal sheet

- G!#") ' The gear is a small attachment present to the handle and the upper !nife to

transmit the motion from handle to the upper !nife. "t is not a complete gear but only thegrooes of the gear which help on the transmission of motion.

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(ig) 2. ?ear grooes

0- F"#*!) ' The frame is the main part connecting the all the parts and causing the sheet

cutting to ta!e place. The frame is made out of mild steel as it re%uires a lot strength to hold

the motion caused by the machine to hold it together. The frame is attached to the base and

holds both the lower and upper !nife together. "t also holds the hydraulic jac! to the machine

to get the re%uired motion to ta!e place

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(ig) 2.0 (rame

2- H+("#$'i, -#, ) ' The hydraulic jac! is attached to the handle of the sheet cutting

machine. &hen the air loc! is sealed and leer of the jac! is pushed up and down the ram

piston is forced out or upwards as the main cylinder fills with pressuri#ed fluid. This causes

the handle to moe down causing for the upper !nife to moe and cut the sheet. After the jac!

has done its job the release ale is opened and the fluid is ported bac! into the reseroir so

the jac!ing cycle can be repeated.

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(ig 2.2 Hydraulic jac!

C7*6#"i89 ! +("#$'i, )!! ,$i89 *#,i8! %i 7"(i8#"+ )!! ,$i89 *#,i8!

There is a lot of ariance between ordinary sheet cutter and hydraulic sheet cutting

machine

The hydraulic sheet cutting machine is far better and easy to operate than compared to

ordinary sheet cutting machine as the hydraulic jac! ceases to produce a lift of 0 tons causing

the sheet cutting machine to cut more sheet of more thic!ness than compared to that of

ordinary sheet cutting machine ."t also reduces the human force as it is easy to operate the

hydraulic jac! than compared to other shearing machine as all the force applied on it is

produced by a single jac! which is operated ery easily

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CHAPTER: 5

CONCLUSION

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CONCLUSION

Now we !now that hydraulic heet cutting machine is ery cheap as compared to

other sheet cutting machine. The range of the cutting thic!ness can be increased by applying

pressure on hydraulic jac!. This machine is adantageous to small sheet metal cutting

industries as they do not hae rely on the e4pensie /neumatic shearing machine

This project has met its objectie to produce a Hydraulic sheet cutting machine and its

function is to cut metal sheet of arious width. &e designed a hydraulic sheet cutting

machine which costs less than that aailable in the mar!et. &e are ery good at what we hae

done and had fun doing it. Our hydraulic sheet cutting machine is useful to cut metal sheet

thic!er than the capacity of the ordinary shearing machine as it is has 0 ton capacity jac!. &e

can do simple operations li!e cutting and piercing, which is ery useful and helpful to do

small wor!s at our college. &e chose a simple frame which occupies less space which any

one can operate, and manufactured it at *;0rd of the original cost in the mar!et. &e tested our

project by producing small bits and stripes of sheet metal.. As our project is based on

manufacturing of hydraulic press and shearing machine, further modifications can be done to

increase its applications.

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CHAPTER: /

FUTURE SCOPE

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FUTURE SCOPE

&e engineers hae the ability to thin! and plan. 3ut due to some time constraints, we

only hae thought and put in the report, the following future modifications)'

*- "t can be made pneumatic operated type by replacing the hand leer by pneumatic cylinder and air compressor.

- The place where there is low atmospheric pressure, the hydraulic jac! can be replaced by

an ".C.


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REFERENCES

*U. Anthony @'@*'0*@'F@*8'0

0U. +r. 1.D. 1ajput IFF$- “trength of 5aterialsE .Chand, "3N @*'*9'892'F

2U. /? College of Technology “/? +esign +ata 3oo!EIF*-

8U. T.M. /rabhu IF**- “+esign of Transmission

Fabrication of sheet cutting machine

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