1. INTR0DUCTION
Nowadays, technological development demands efficiency of time and
energy in all fields in order to create a product that can compete in the
global market.
Breakthrough innovations are needed to survive in global market.
We all know about sheet metal working processes.
Sheet metal contributes a wide range of applications in many industries,
one such example is automobile and aerospace industries.
Also it is known that sheet metal has sharp edges which may tear off the
skin while working on it.
Hence to avoid such kind of situation we have designed a automatic sheet
metal cutting machine.
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2. SHEET METAL MATERIALS
Black Iron
Galvanized Iron
Copper Sheets
Aluminium Sheets
Tin Plates
Stainless Steel
Brass
Lead
Zinc
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3. Machines available in market
Rack and pinion operated
Pneumatically operated
Hydraulically operated
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Fig 1 RACK AND PINION SHEARING
MACHINE
Fig 2 PNEUMATICALLY OPERATED
MACHINE
FIG 3 HYDRAULICALLY OPERATED
4. It is observed that working with sheet metal is a tedious job for a
worker as it may tear of the skin of the worker.
This machine is designed to overcome the above problem and to
reduce the labour cost.
As it is said automatic, here the sheet metal role is fed at the sheet
metal holder and the machines automatically cuts the sheets for a
predetermined length.
The machine works on 12 volt dc supply hence the power
consumption for the machine is less.
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4 ROLE OF OUR PROJECT
5. Objective
The main objective is to design and fabricate the sheet metal
cutting machine for the mechanical basic workshop.
To minimize human effort.
Minimum power consumption.
Implementing automation to reduce the time.
For precise operation of cutting.
To provide automation so as to reduce labor cost.
To obtain perfect finished cutting edges on the sheet.
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6. Components Of Machine
The main components of the machine are:
Frame
Blades
Conveyor
Motors
Crank and link mechanism
Electronic circuit
Sensor
Battery
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7. PROCESS CARRIED OUT
• Sheet metal role
fed from the
holder
conveyor
• The conveyor
stops
• Blade motor
sensor
• The blade carries
the cutting
operation
Cycle repeats
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14. FRAME
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The rigid frame is fabricated by arc welding
Cast-iron c-member is been used to build this
frame
Dimensions:
Length L: 1000mm
Width B: 650mm
Height H: 750mm
Function:
To provide a rigid support and mounting facility for
various components, to provide a safety and to
absorb vibrations made by blade and motor.
15. UPPER BLADE [MOVING BLADE] :
It is pivoted to crank and link mechanism so as to obtain a
cutting forces transmitted by a link.
Grinding operation is done on the blade surface to obtain
perfect mating between two blades
An angle of 8 degree is provides to get a sharp edge
Dimensions:
Length L =731.5mm
Width B =71.2mm
Thickness T= 10mm
Function:
To obtain a cutting operation
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Figure 1 UPPER BLADE [CATIA MODEL]
Figure 2 FRONT VIEW
16. LOWER BLADE [STATIONARY BLADE]:
Grinding operation is done on the blade surface to obtain
perfect mating between two blades
It is fixed to the frame rigidly
Dimensions:
length L = 670.5mm
Width B= 71.2 mm
Thickness T= 10mm
Function:
To provide a sharp cutting edge
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Figure 1 LOWER BLADE
Figure 2 FRONT VIEW
17. CONVEYOR:
It is assembled to the frame with the help of
fasteners.
It is an assembly of plumber blocks, pvc
pipes, and rubber mat
specifications:
Length: 280 mm
Width: 406 mm
Speed: 4 m/min
Function:
To feed the sheet metal to the predetermined
length.
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18. Figure 5.4.2 PVC ROLLER
Pipe 1
Reducer coupling
Pipe 2
Conveyor assembly
PLUMMER BLOCK:
Internal diameter =25.4mm
Function:
To provide a mounting for a conveyor and to provide
frictionless rotation to rollers.
ROLLERS:
Pipes
1. Diameter =19.05mm
Function: To connect reducer coupling to the Plummer block
2. Diameter =38.1mm
Function: It helps to roll the mat over this pipe.
Reducer coupling
Outer diameter =25mm
Inner diameter=47mm
Function: It helps to connect the Plummer block and
roller pipe.
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Figure 1 PLUMBER BLOCK
19. MOTORS
Two motors are being used in this machine, one for the
conveyor and second for the blade movement
specifications:
DC motor
Voltage: 12V
Power: 17 watts
Current: 7.5Ah
Speed: 60rpm
Functions:
First motor is used to operate the conveyor belt with suitable
arrangement.
Second motor is used to drive the crank and link mechanism,
which interns drive the upper blade to perform cutting
operation of a sheet metal.
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Figure 2 WIPER MOTOR
Figure 1 WIPER MOTOR [CATIA MODEL]
20. Motor Calculation:
Torque obtained:
T= 60*P/2πN where; P= power of motor
T=
60∗17
2𝜋∗60
N=speed of the motor
T=2.7056 N-m
Force obtained:
F=T/R R= Radius of the crank
F=
2.7056
0.1
= 27.05N
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21. LINK
Dimensions:
Length =259mm
Diameter =12mm
Function: To connect crank and blade, and also helps to convert
rotary motion of the motor to reciprocating motion
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Figure 1 LINK
CRANK
Dimensions:
Length =172mm
Diameter =12mm
Function: To convert the rotary motion of the motor into
oscillating motion of the link
Figure 2 CRANK
22. FIGURE 3 sensor
Figure 2 sensor isometric view
SHEET METAL
HOLDER
It is a device which senses the sheet and sends the
signal to the controller.
It is mechanical contact type sensor
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Figure 1 sheet metal holder
SENSOR
Dimensions
Length =555mm
Diameter of the rod= 6mm
FUNCTION:
To hold the sheet metal roll
23. ELECTRONIC CIRCUIT
RELAY
A relay is an electrically operated switch
Relays are used where it is necessary to
control a circuit by a low-power signal.
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24. ELECTRONIC CIRCUIT
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R2 R3
R5
R1
R4
BATTERY
M2
M1
MOTOR 1 SENSOR
MOTOR 1
OFF
MOTOR 2
ON
MOTOR 2
OFF
RELAY 3
NC
CYCLE
REPEATES
[WHERE]
R4 AND R5 IS USED
FOR AUXILARY
SWITCHING
25. APPLICATIONS
1. Can be used in various institutions, mechanical basic
workshop.
2. Can be used in hardware shops to provide service to the
customers.
3. By increasing length of blade the machine can be used in
various automobile industries.
4. Can be used in printing presses for cutting of paper.
5. Can cut aluminum foil, sun mica etc.
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26. ADVANTAGES AND DISADVANTAGES
ADVANTAGES
Easy to maintain and repair.
Cost of the unit is less when compare to other machine.
No fire hazard problem due to overloading.
Comparatively the operation cost is less.
Continuous operation is possible without stopping.
Machine is mobile.
Reduced labor charge.
LIMITATIONS
High torque cannot be obtained.
There is a limitation for cutting width of sheet metal.
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27. SCOPE FOR FUTURE WORK
Microcontroller can be used to make it more versatile and to
achieve higher productivity.
Turning table can be provided to cut the sheets at a different
angle.
Increase cutting or shearing force by using powerful motors for
cutting thicker sheets.
DC adapter can be provided for direct AC power supply.
Sheet metal collecting box and packaging system can be
provided to make it ready for transportation.
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28. CONCLUSION
When we say that it is automatic machine, we need to incorporate mainly the comfort in
usage of machine and the cost of the product.
In this case it is necessary to make use of the product very comfortable, the cost of the
product is restrict below ₹ 15,000/-. Hence cost economic.
Further the labour problem can be overcome as the machine can run for hours together.
The sheet rolls once installed on the roller the cutting operation carries on automatically. In
other words no further human observation on the machine is required.
The finished edges on the sheets are obtained by this machine.
Also the length of the sheets to be cut can be adjusted as per the need. All these facts make
the machine very user friendly. This meets the objective of the project.
The machine needs to be improved by implementing microprocessor so as to get faster
response of the system and the various sensors can be used so to sense the sheet metal. This
throws lot of scope for the improvement in future.
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29. REFERENCES
Ajit Kumar Singh, Harpreet Singh and Dharmendra Sharma, “Design and Fabrication of Pneumatic
Auto Sheet Metal Cutting Machine Using Solar Energy”
Bram Armunanto, Yudit Cahyantoro NS, Kaleb Priyanto (IJEAT), “A Circularity Analysis Of
Different Clearances In The Sheet Metal Punching Process”
Dr. K.U Leuven “Research on sheet metal cutting machine construction”
Indrajeet Chaudhary, Pradeshi Ram and Dinesh Kumar “Using Advanced Pneumatics Automation of
Conventional Sheet Bending Machine”
Komanduri, R. “Machining and grinding: A historical review of the classical papers”
Kerim Isik, Maria B Silva, Paulo AF Martins, and AE Tekkaya, Failure by fracture in sheet– bulk
metal forming “The Journal of Strain Analysis for Engineering Design,”
Shubhkumar Bhandari “Methodology of Special Purpose Sheet Metal Cutting Machine”
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