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1
INTRODUCTION
The project work assigned here with us is of building a shearing m/c that is
capable of shearing PVC / plastic / rubber pipes up to 6 mm in dia. Also it is pre-
assigned work to furnish the same m/c along with an automation unit as previously
mentioned.
As simple layout and tricky operational enables this type of m/c to work
practically at low cost, low maintenance, low capital investment in less space. It may
be forecasted that in future this m/c may have its unparallel place in the industry
mentioned previously.
The work is carried out using MDF (Medium Density Fiber) core hardwood
plywood. Also some connecting components like studs are used the plunger is made
up of high density polymer pipe and the core of electromagnetic is made up of again
high density polymer pipe. Rest of the construction is made in MDF sheet cut to
requirement. It can be noticed that in the fabrication of the project many parts are
manufactured other than ferrous material. It is done so because ferrous is conductor of
magnetism and controller be magnetized very easily for avoiding the flux generated
for getting disturb with surrounding material. The mat in surrounding is used the non
ferrous. The only major component is the iron core which is needed to be made up of
ferrous to get attracted to electromagnet when live next part that is fabrication out of
ferrous is stud nut bolt. It is very necessary that for structural support that this part
should be made in strength and support for solving the problem. It has been allowed
to use ferrous material for the same. Also care have been taken to keep this ferrous
material part away from electromagnet as for as possible.
Whenever electromagnet is made live it sucks the iron core in between the
cavity of the Electromagnetic because of high flux generated. This iron core there by
pushes the plunger in the same direction which activates the cutter blade subassembly
forcing the same in the blade subassembly forcing the same in the direction of
material to be cut. This is simple procedure of cutting by this type of m/c.
Another part of the project includes development of automation unit for
running this m/c on automation mode for cutting the mat as per required. This part
include a Microcontroller a motor drives a relay driver etc.
CHAPTER.2
BACKGROUND
Mr. Scott Michael Golowin, B.S. The Ohio State University 2008 in his research
paper on “Path Actuators for Magnetic Pulse Assisted Forming and Punch-less
Electro-Magnetic Shearing” discussed that Electro Magnetic shearing offers a number
of advantages over traditional methods. It is much less equipment-intensive than laser
cutting or die cutting. It can deal well with very thin materials, whereas very precise
tooling is required to shear thin metals and can be very expensive. Also, there are
opportunities for integrating forming and shearing operations. Despite these
advantages, this method has not been well developed.
Blade Rake Angle No. of strokes Motor Dimensions (m) Net Weight
MODEL Length Variable Rake Angle (kW) LxWxH (kgs.)
(mm) (Degree) max min
CUTTING BLADE
MODEL CAP. IN STROKE FRONT REAR MOTOR LENGTH LENGTH HEIGHT
M.S. PER GUAGE GUAGE HP/KW x A B
LENGTH x MINUTE WIDTH
THICKNES x THICK
1525 x 2540 1525
MI - 1 1525 x 2 50 500 750 3/2.0 63 x 12
1525 x 2540 1525
MI - 2 1525 x 4 50 500 750 5/3.7 63 x 12
2030 x 3050 1525
MI - 3 2030 x 4 50 600 750 7.5/5.6 63 x 12
2540 x 3050 1525
MI - 4 2540 x 4 50 600 750 10/7.7 75 x 16
MODEL CPS-4H
Capacity Width (mm) 1250
Capacity Thickness in M.S. 18 Gauge (1.20 mm)
Motor 2.0 H.P. Double Geared, Clutch Type
Net / gross weight (Kgs.) 700 / 800
Shipping dimensions (m) 1.63 x 0.88 x 1.18
Shipping volume (m3) 1.70
Technical Specifications:
1.3 KW Shearing Motor
2 x 0.75 KW Vacuum Motors
380 Volt
Maximum Shearing Width:
Model KA65: 65 cm
Dimensions (cm): KA65: 100 x 100 x 150
6.1 CONTRUCTION:
The electromagnetic shearing machine consist frame on
which mechanical & automation unit are fixed. A machine consist a plunger in which
iron core is fixed which move from electromagnetic core ,at bottom of plunger a high
carbon hard steel tool is fixed for shearing purpose. The plunger assembly is
subtended with the help of rubber stand in such a way that only lower inch portion
allowed inside electromagnet The rubber strap also required to retract the blade also c
stroke is completed. At the bottom of machine feeder & extractor is present which
constitute 2 rollers, the smaller roller is driving roller & the bigger one is driven.
6.2 MAIN COMPONENTS:
Frame: A cast iron square pipe (2cm) is used to construct a frame which is used for
supporting purpose.
MDF sheet :MDF sheet (12mm thick) are used to built up top plat form & bottom
plat form also a supporting column for rollers & pipe.
Iron Core: Iron core (1inch dia. & 4 inch long) is use to cut emf produce by
electromagnet.
Plunger: It is the main part of machine which is made up of high density polymer
pipe ( ) on which cutting tool is fitted in y-fork at the bottom.
Cutting Tool: The high carbon hard steel (1mm thick) tool is used for shearing
purpose it is fitted in y-fork with the help of nuts & bolts.
Supporting Column: It is made up of MDF sheet (10cm long& 2cm breath) to avoid
bending of pipe at the time of shearing.
Feeder & Extractor: It consist two rollers this roller carries wooden axis & made of
15mm thick foam sheet. Feeder is used to feed pipe for shearing, & extractor is used
to remove pipe after shearing.
Gearboxes: The two gearboxes are used one for feeder & another for extractor to
control the motion of feeder & extractor.
6.2 ELECTRICAL COMPONENTS:
Transformer: The step-down transformer is used to convert 220volt A.C supply into
12 volt A.C
Bridge: The Bridge is used to convert A.C supply current to D.C from 12 volt A.C to
12volt D.C volt for microcontroller flash memory program.
DESIGN OF MODEL
The design of part model is done in CATIA V5 R17 (Computer Aided Three
Dimensional Interactive Application) which is a multi-platform CAD/CAM/CAE
commercial software suite developed by the French company Dassault Systems IBM.
Written in the C++ programming language, CATIA is the cornerstone of the Dassault
Systems product lifecycle management software suite. The user may create, edit, and
delete end cuts, and the end cut for a beam is integrated in the piece part engine
Translate a Structure Functional Design 2 (SFD) or Ship Structure Detail Design 2
(SDD) feature during the explode mode through piece part process define end cut
graphic replacement in drafting manage different graphic replacements for beam
pillars enhances technological results usage in tooling design.