UNIVERSAL NIBBLING MACHINE

Need of Project
In many industries it is required to cut complex contours on sheet metal , as they are the
part of sheet metal components that are in their ‘development form’, (see fig.). These
contours due to their odd shape and size , also low quantity of production cannot be
produced as pressed components. Hence the only solution in such cases is cut the contours
by chisel and file the given profile. This method requires extensive labor and skill and so
also it is extremely time consuming….hence the need of a special purpose machine for fast
production and accuracy.

INTRODUCTION
The Sheet Metal Nibbling Machine is a rugged, sturdy and
reliable multipurpose machine capable of sheet cutting &
forming operations. Its verstility is best expressed by terming it
the Sheet Metal Workers lathe. The working principle on which
nibbling operates is the sheet is cut or formed between the fast
reciprocating motion of an upper tool (powered by an electric
motor and driven by an ecentric crank) and a stationery lower
tool, by progressive punching, as the sheet is fed.
This machine is best suited for small batch production or
when cost of press tools and dies is prohibitive. It enhances
quality and productivity by doing such jobs which used to be
done by skilled men and hand tools. The machine has eliminated
expensive trimming dies in many modern workshops.
Fabricators, Control panel manufacturers, cabinet & vehicle body
makers, fan & impeller industry in addition to many others find it
a most valuable asset. While the capacities indicated below are
for mild steel, the machine is often used for many other materials
as well.
CONSTRUCTION
The nibbling machine consists of the following parts,
1. Motor (0.25 Hp) 12. Frame

2. Motor pulley 13. Motor Plate

3. Input shaft 14.Belt

4. Lower arm . 15.Ball Bearings

5. Upper arm. 16. Hinge shaft.

6. Eccentric. 17. Upper tool holder

7. Main shaft. 18. Lower tool holder.

8. Main shaft pulley . 19. Tool blades

9. Jockey 20.Belt tension adjuster

10. Ball screw.

11.Ball Socket.
WORKING
(Refer work motions shown in the construction figure:)
Profile to be cut is first marked on the sheet metal component, and the sheet
is introduced between the pair of reciprocating tools mounted on the upper and
lower arms respectively.
Motor is started which drives the main shaft by an open belt drive
comprising of the motor pulley , belt and main shaft pulley. Main shaft is keyed to
the eccentric which acts like an cam to impart reciprocatory motion to the jockey
and ball screw arrangement.

Ball screw engages in the ball socket mounted on the upper arm, this makes the
upper arm to hinge and oscillate about the hinge shaft. The tools for nibbling are
mounted in tool holders on the face of lower and upper arm. The tools are provided
with single cutting edge with shear angle. The lower arm is fixed where as the
upper arm oscillates to provide a virtual reciprocating up-down motion to the upper
tool which shear the sheet metal between the two tools.
Sheet metal is cut to given profile by guiding it by hand, shear force required
for cutting is minimal due to shear on blade, so also the method of cutting is point
to point which enables to generate precise countours.
 DESIGN

Design consists of application of scientific principles, technical information and

imagination for development of new or improvised machine or mechanism to perform a specific
function with maximum economy & efficiency .

Hence a careful design approach has to be adopted . The total design work , has been split
up into two parts;

 System design
 Mechanical Design.

System design mainly concerns the various physical constraints and ergonomics, space
requirements, arrangement of various components on main frame at system, man + machine
interactions, No. of controls, position of controls, working environment of machine, chances of
failure, safety measures to be provided, servicing aids, ease of maintenance, scope of
improvement, weight of machine from ground level, total weight of machine and a lot more.

In mechanical design the components are listed down and stored on the basis of their
procurement, design in two categories namely,
 Designed Parts
 Parts to be purchased

For designed parts detached design is done & distinctions thus obtained are compared to next
highest dimensions which is readily available in market. This amplifies the assembly as well as
postproduction servicing work. The various tolerances on the works are specified. The process
charts are prepared and passed on to the manufacturing stage.
The parts which are to be purchased directly are selected from various catalogues & specified so
that any body can purchase the same from the retail shop with given specifications.

SYSTEM DESIGN
In system design we mainly concentrated on the following parameters: -
1. System Selection Based on Physical Constraints
While selecting any machine it must be checked whether it is going to be used in a large-scale
industry or a small-scale industry. In our case it is to be used by a small-scale industry. So space
is a major constrain. The system is to be very compact so that it can be adjusted to corner of a
room.
The mechanical design has direct norms with the system design. Hence the foremost job is to
control the physical parameters, so that the distinctions obtained after mechanical design can be
well fitted into that.
2. Arrangement of Various Components
Keeping into view the space restrictions the components should be laid such that their easy
removal or servicing is possible. More over every component should be easily seen none should
be hidden. Every possible space is utilized in component arrangements.
3. Components of System
As already stated the system should be compact enough so that it can be accommodated at a
corner of a room. All the moving parts should be well closed & compact. A compact system
design gives a high weighted structure which is desired.
Man Machine Interaction
The friendliness of a machine with the operator that is operating is an important criteria of
design. It is the application of anatomical & psychological principles to solve problems arising
from Man – Machine relationship. Following are some of the topics included in this section.
 Design of foot lever
 Energy expenditure in foot & hand operation
 Lighting condition of machine.

4. Chances of Failure
The losses incurred by owner in case of any failure is an important criteria of design. Factor
safety while doing mechanical design is kept high so that there are less chances of failure.
Moreover periodic maintenance is required to keep unit healthy.

5. Servicing Facility
The layout of components should be such that easy servicing is possible. Especially those
components which require frequents servicing can be easily disassembled.
Scope of Future Improvement
Arrangement should be provided to expand the scope of work in future. Such as to convert the
machine motor operated; the system can be easily configured to required one. The die & punch
can be changed if required for other shapes of notches etc.
6. Height of Machine from Ground
For ease and comfort of operator the height of machine should be properly decided so that he
may not get tired during operation. The machine should be slightly higher than the waist level,
also enough clearance should be provided from the ground for cleaning purpose.

7. Weight of Machine
The total weight depends upon the selection of material components as well as the dimension of
components. A higher weighted machine is difficult in transportation & in case of major
breakdown, it is difficult to take it to workshop because of more weight.

MECHANICAL DESIGN
 Mechanical design phase is very important from the view of designer .as whole success
of the project depends on the correct deign analysis of the problem.

Many preliminary alternatives are eliminated during this phase. Designer should have
adequate knowledge above physical properties of material, loads stresses, deformation, failure.
Theories and wear analysis , He should identify the external and internal forces acting on the
machine parts

These forces may be classified as ;

1. Dead weight forces
2. Friction forces
3. Inertia forces
4. Centrifugal forces
5. Forces generated during power transmission etc

Designer should estimate these forces very accurately by using design equations .If he does not
have sufficient information to estimate them he should make certain practical assumptions based
on similar conditions
which will almost satisfy the functional needs. Assumptions must always be on the safer side.
Selection of factors of safety to find working or design stress is another important step in design
of working dimensions of machine elements. The correction in the theoretical stress values are to
be made according in the kind of loads, shape of parts & service requirements.
Selection of material should be made according to the condition of loading shapes of products
environment conditions & desirable properties of material.

Provision should be made to minimize nearly adopting proper lubrications methods.

In ,mechanical design the components are listed down & stored on the basis of their procurement
in two categories

 Design parts
 Parts to be purchased

For design parts a detailed design is done & designation thus obtain are compared to the next
highest dimension which is ready available in market.
This simplification the assembly as well as post production service work. The various
tolerance on the work are specified. The process charts are prepared & passed on to the work are
specified.
The parts to be purchased directly are selected from various catalogues & specification so that
any body can purchased the same from the retail shop with the given specifications.
 MOTOR SELECTION

3- PHASE INDUCTION MOTOR (2 POLE)

MAKE:-
415 VOLTS, 50 Hz,
POWER = 0.5Hp(0.185 Kw )
SPEED = 1440 rpm (Synchronous)
FRAME SIZE =70
CURRENT = 1.70 AMP
TORQUE= 0.17 Kg . M
TEFC CONSTRUCTION.

DETAILS OF FRAME SIZE : 80

(FOOT MOUNTED)
TORQUE ANAYSIS :-
Torque at spindle is given by;
P= 2N T
60
where ;
T= Torque at spindle (Nm)
P = POWER (Kw)
N = Speed (rpm)
T = 370 x 60
2 x 1440
 T = 2.45 N.m
 Tdesign = 2.45 N.m
 DESIGN OF BELT DRIVE FOR MACHINE SPINDLE

INPUT DATA
INPUT POWER = 0.18 KW
INPUT SPEED =1440RPM
CENTERDISTANCE = 300 MM
MAX BELT SPEED = 1600 M/MIN = 26.67 M/SEC
GROOVE ANGLE (2  ) = 400
COEFFICIENT OF FRICTION = 0.25
BETWEEN BELT AND PULLEY
ALLOWABLE TENSILE STRESS = 2.5 N/mm2

Section of belt section

Ref PSG DESIGN DATA (PG NO . 7.58)

C/S USUAL NOMINAL NOMINAL WEIGHT
SYMBOL LOAD OF TOP THICKNE DER
DRIVE WIDTH SS T mm METER
(KW) (Wmm) Kgf
A 0.75-5 13 8 0.106

Sin = 02M = R2-R1 = D 2 - D1

0102 x 2x

= 150 - 62
2 x 300
   = 8.430

Angle of lap on smaller pulley; ie; motor puller ;

0 = 180 - 2

= 180 - 2(8.43)
 = 163.14

  = 2.84c

Now;
Mass of betl /meter length = 0.106 kgf
Centrifugal Tension (Tc) = Mv2

Tc = 0.106 (26.67) 2

Tc = 75.397 N
Max Tension in belt (T) = f all x Area
= 2.5 x 104
=260 N/mm2

A) Tension in Tight side of belt = T1 = T-Tc

= 260 - 75 .397

T1 = 184 N
B) Tension in slack side of belt = T
2.3 log T1 =  x  x cos sec 
T2

= 0.25 x 2.84 x cosec 20

log T1 = 0.90
T2

 T1 = 7.99
T2

 T2 = 23 N
POWER TRANSMITTING CAPACITY OF BELT
P = ( T2 - T2) 

= (184-23) 26.67

P= 4.293 kw

 Belt can safely tansmit o.18 kw power

LENGTH OF BELT

L =  (R2 + R1) + 2(X) + (R2 – R1)2

X
2
150 - 62
= 150 + 62 +2 (300) + 2 2

2 2 300
L = 933 mm
 L = 37”
SELECTION OF BELT .
Selection of belt ‘A- 37’ from std manufacturers catalogue
MAKE: PIX
RESULT TABLE –
1. BELT SELECTED A - 38
2. Tight side Tension T1 ’ =184
3. Slack side Tension T2 ’ = 23.17 N
4. Pulley (B)diameter( D3 =62
 D3)
5. Pulley (C) diameter D2 =150
(D4)
DESIGN OF MAIN SHAFT
Tdesign = 2.45 N.m
Reduction ratio of belt drive = 150/60 =2.5
Tdesign = 2.45 x 2.5 =6.125N-m
Selection of intermediate shaft material
Ref :- PSG Design Data.
Pg No :- 1.10 & 1.12.
1.17

Designation Ultimate Tensile Yield strength N/mm2

Strength N/mm2
EN 24 (40 Ni; 2 cr 1 1100 880
Mo 28)

Using ASME code of design ;

Allowable shear stress;

Fsall is given stress ;
Fsall = 0.30 syt = 0.30 x 880
=264 N/mm2
Fsall = 0.18 x Sult = 0.18 x 1100
= 198 N/mm2
Considering minimum of the above values ;
fsall = 198 N/mm2

As shaft is provided with key way considering 25% reduction in strength

fsall = 198 x 0.75 =148.5 N/mm2
 a) Considering pure torsional load;
Tdesign =  fsall d3
16
 d3 = 16 x 3.1 X 103
 x 148.5
d = 4.8 mm

selecting minimum diameter of spindle = 16 mm from ease of

construction because motor is coupled to the shaft directly by means
of Lovejoy coupling (Id = 16 mm)

But
Shaft is also subjected to bending loads; due to eccentric mounted on
shaft
Ft =49.6 N

A 62 67 B

 Fy = 0

FT = R A +R B

 (R A +R B ) = 49.6 N-----(A)

 MA = 0
RB x 129 = 49.6 x 67
  RB =25.76

 RA = 23.8 N

Max BM = 1725.92 N-mm

Equivalent Torque;

Te = M2 + T2

Te =  (1.24 x 103 )2+ (1.725 x 103) 2

Te = 2.13 x 103 Nm

Te =  fs act x d3
16

f s act = 16 x T

 d3
 fs act = 16 x 2.13 x 103
 x (16) 3
f s act = 2.648 N/mm2
 AS f s act < fs al

Shaft is safe under torsional load.

B) Check for bending failure of shaft

Max bending moment occurs at point ‘C’ , the section diameter at point ‘C’

Dc = 30 mm

Me = ½ (M )+ Te
= ½ ( 1.725 x 103) + 2.13 x 103

= 2.995 x 103Nm

Me =  fb act d3
32
fb act = 2.995 x 103 x 32
 x 303
= 1.12 N/mm2

As f b act < fb all

Shaft is safe under bending load

 Selection of Bearing at ‘A’

Spindle bearing will be subjected to purely medium radial loads; hence we

shall use ball bearings for our application.

Selecting ; Single Row deep groove ball bearing as follows.

Series 62

IsI No Bearing of d D1 D D2 B Basic

basic capacity
design No
(SKF)
25BC0 6205 25 31 52 46 15 1000 153
2 0 00

P = X Fr + Y F a
Neglecting self weight of carrier and gear assembly
For our application F a =0
P = X Fr
where Fr = Rb
As; Fr < e  X =1
P = 23.8 N
Calculation dynamic load capacity of brg

L= ( C ) p , where p= 3 for ball bearings

P
When P for ball brg

For m/c used for eight hr of service per day;

LH = 12000- 20000hr
But ; L= 60 n LH
10 6
 L= 600 mrev

Now;600 = (C) 3
(23.8) 3

C= 200.73 N
As the required dynamic capacity of brg is less than the rated dynamic
capacity of brg;

 Brg is safe

Selection of Bearing at ‘B’

Spindle bearing will be subjected to purely medium radial loads; hence we

shall use ball bearings for our application.

Selecting ; Single Row deep groove ball bearing as follows.

Series 62

IsI No Bearing of d D1 D D2 B Basic

basic capacity
design No
(SKF)
20BC0 6204 20 26 47 41 14 1000 655
2 0 0

P = X Fr + Y F a
Neglecting self weight of carrier and gear assembly
For our application F a =0
P = X Fr
where Fr = RB
As; Fr < e  X =1
Max radial load = Fr =25.76N.

 P= 25.76 N

Calculation dynamic load capacity of brg

L= ( C ) p , where p= 3 for ball bearings

P
When P for ball brg
For m/c used for eight hr of service per day;
LH = 12000- 20000hr
But ; L= 60 n LH
10 6

L= 600 mrev

Now;600 = (C) 3
(25.76) 3

C= 217.62 N
As the required dynamic capacity of brg is less than the rated dynamic
capacity of brg;

 Brg is safe

DESIGN OF KEY

Selecting parallel key (6x6x20.5)

Is 2048 – 1962.

BOTH ENDS ROUND

Ref :- PSG DESIGN DATA ;

MATERIAL OF KEY :- EN9

(C 45)

CHECK FOR SHEAR FAILURE OF KEY.

T = L x b x d/2 x f b act

 fb act = Te x 2

Lxbxd
 = 2.13 x 103 x 2
20.5 x 6 x6

= 5.77 N/mm2

 AS f s act < fs all

Key is safe under shear load.

CHECK FOR CRUSHING FAILURE OF KEY.

Te = L x t/2 x d/2 x f s act

fs act = 21.3 x 103 x 2x2

20.5 x 6 x6

fs act = 11.54 N/mm2

AS f s act < fs all

Key is safe under crushing failure.

 DESIGN OF ECCENTRIC

Outside diameter of hub =50mm

Inside diameter of hub =30 mm

Eccentric can be considered to be a hollow shaft subjected to torsional load.

Material selection.

Designation Ultimate Tensile Yield strength

strength N/mm2 N/mm2
EN 24 1100 880

As Per ASME Code;

 fs max = 148.5N/mm2

Check for torsional shear failure:-

T=  x fs act x Do 4
– Di 4

16 Do
2.13 x 103 =  x fs act x 504 – 304
16 50
 fs act = 0.1/mm2
As; fs act < fs all

 Coupling is safe under torsional load.

ADVANTAGES
1) Operates at high speed , nibbling rate approx.,500mm/min
2) Two tool blades have a scissor like action ie, the action of cutting is point to
point, this reduces the cutting force required and there by the motor Hp(0.25
Hp)
3) The cutting action is point to point hence the quality of cutting is superior.
4) Quality of cutting is very high , and component conforms to the given
template to size.
5) Low cost of production, because it does not require any press machine and
tooling
6) Fast production rate.

APPLICATIONS
1) Nibbling of sheet metal for the production of automobile sheet metal parts.
2) Nibbling of sheet metal for the production of air conditioning ducts.
3) Nibbling of car body components.
4) Nibbling of polymer sheets for first time production of components.
5) Shearing or straight cutting
6) Inner circle cutting
7) External circle cutting
8) Rectangular notching.

 BILL OF MATERIALS:-
SR NO. PART CODE DESCRIPTION QTY MATERIAL

1. NM-1 MOTOR 01 STD

2. NM -2 MOTOR PULLEY 01 CI

3. NM -3 BELT 01 STD

4. NM -4 MAIN SHAFT PULLEY 01 CI

5. NM -5 MAIN SHAFT 02 EN24

6. NM -6 BRG_HOUSING 02 EN9

7. NM -7 LOWER ARM 01 MS

8. NM -8 UPPER ARM 01 MS
 9. NM -9 BASE PLATE 01 MS

10. NM –10 ECCENTRIC 01 EN24

11. NM –11 LOCK NUT 01 EN9

12. NM –12 BALL SCREW 01 EN24

13. NM -13 BALL HOLDER SHAFT 02 EN9

14. NM -14 BALL SOCKET 01 EN9

15. NM -15 TOOL HOLDERS 02 EN9

16. NM -16 TOOL BLADE 02 HSS

17. NM-17 WORK TABLE 01 MS

18. NM -18 JOCKEY 01 EN24

19. NM-19 HINGE SHAFT 01 EN24

20. NM-20 MOTOR PLATE 01 MS

21. NM-21 BELT TENSION ADJUTER 01 MS

22. NM-22 BALL BEARING 6005 ZZ 02 STD

PROJECT ACTION PLAN

PHASE 1 : DATA COLLECTION
Data collection phase involves the collection of reference material for project concept, the idea is
taken from website : www.atlasmachines.com
PHASE 2 : SYSTEM DESIGN
The system design comprises of development of the mechanism so that the given concept can
perform the desired operation. The system design also determines the system components and
their shape and overall dimensions , the parts are as shown in part list above.
PHASE 3 : MECHANICAL DESIGN
 The parts mentioned above in the part list will be designed for stress and strain under the given
system of forces, and appropriate dimensions will be derived. The standard parts will be selected
from the PSG design data handbook.
PHASE 4 : PRODUCTION DRAWING PREPARATION
Production drawings of the parts are prepared using Auto Cad ,with appropriate dimensional and
geometric tolerances. Raw material sizes for parts are also determined.
PHASE 5 : MATERIAL PROCUREMENT & PROCESS PLANNING
Material is procured as per raw material specification and part quantity. Part process planning is
done to decide the process of manufacture and appropriate machine for the same.
PHASE 6 : MANUFACTURING
Parts are produced as per the part drawings.
PHASE 7 : ASSEMBLY –TEST & TRIAL
Assembly of device is done as per assembly drawing ,and test and trial is conducted on device
for evaluating performance.
PHASE 8 : REPORT PREARATION
Report preparation of the activities carried out during the above phases is done .
Refferences :

1. HMT handbook
2. www.atlasmachines.com
3. Workshop technology- Hajra -Choudhary

PART NO : NB- 03 MATERIAL SPECIFICATION : EN 24

PART NAME : MAIN SPINDLE RAWMATERIAL SIZE: 50 X 120
QUANTITY :- 01 NO’S.

Sr. Description of Tools Time in minutes

No Operation
Jigs & M/c Cutting Measuring Settin M/c Total
Fixture Tools Tools Instrumen g Time Time
t Time
 1. Clamp stock Three jaw Lathe - - 15 - 15
chuck
2. Facing B/S to --”-- --”-- Facing Vernier 5 14 19
total length tool &
110mm & center
center drilling drill
3. Clamp stock Center --”-- --”-- --”-- 25 25
between center support &
carrier
4. Turning OD Ø --”-- Turning --”-- - 13 13
40 mm through tool
out length
5. Step turning Ø --”-- --”-- - --”-- - 9 9
25 to 24mm
length
6. Step turning Ø --”-- --”-- Twist drill --”-- - 7 7
30hrough 82
length
7. Step turning Ø --”-- --”-- --”-- --”-- - 7 7
20 through 69
length
8. Step turning Ø --”-- --”-- --”-- --”-- - 8 8
24through
57mm length
9. Step turning --”-- --”-- --”-- --”-- 7 7
OD Ø 24 mm
through 22mm
10.Step turning Ø --”-- --”-- --”-- --”-- - 7 7
20 through 10
length
11.Milling key way M/c vice Milling End mill --”-- 25 17 42
6x3x20mm m/c
1no’s
12.Milling key way M/c --”-- --”-- --”-- -- 21 21
6 x 3 x 27
mm1No’s

PART NO : NB-06 MATERIAL SPECIFICATION : EN 9

PART NAME : BEARING HOUSING-01 RAWMATERIAL SIZE: 80X30X120
QUANTITY :- 01 NO’S.

Sr. Description Tools Time in minutes

No of
Operation
Jigs & M/c Cutting Measuring Settin M/c Total
Fixture Tools Tools Instrumen g Time Time
t Time
1. Clamp stock M/C Vice Milling - - 15 - 15

2. Facing All --”-- --”-- Facing Vernier 5 14 19

Sides Sq. to cutter
total length
75x25x109
mm
3. Clamp stock 4 jaw Lathe - - 25 25
on lathe chuck
4. Drilling Ø 25 --”-- --”-- Twist drill Vernier 15 10 25
through
thickness
5. Boring Ø --”-- --”-- Boring Vernier 15 10 25
48through tool
thickness
6. Counter --”-- --”-- Boring Vernier 15 10 25
Boring Ø 55 tool
through
13hickness
7. Milling flat vice milling Facing vernier 20 60 80
as per cutter
profile
PART NO : NB-07 MATERIAL SPECIFICATION : EN 9
PART NAME : BEARING HOUSING-02 RAWMATERIAL SIZE: 80X30X120
QUANTITY :- 01 NO’S.

Sr. Description Tools Time in minutes

No of
Operation
Jigs & M/c Cutting Measuring Settin M/c Total
Fixture Tools Tools Instrumen g Time Time
t Time
1. Clamp stock M/C Vice Milling - - 15 - 15

2. Facing All --”-- --”-- Facing Vernier 5 14 19

Sides Sq. to cutter
total length
75x25x109
mm
3. Clamp stock 4 jaw Lathe - - 25 25
on lathe chuck
4. Drilling Ø 25 --”-- --”-- Twist drill Vernier 15 10 25
through
thickness
5. Boring Ø --”-- --”-- Boring Vernier 15 10 25
36through tool
thickness
6. Counter --”-- --”-- Boring Vernier 15 10 25
Boring tool
Ø42through
12hickness
7. Milling flat vice milling Facing vernier 20 60 80
as per cutter
profile
PART NO : NB-08 MATERIAL SPECIFICATION : EN 9
PART NAME : HINGE BLOCK RAWMATERIAL SIZE: 60X40X50
QUANTITY :- 01 NO’S.

Sr. Description Tools Time in minutes

No of
Operation
Jigs & M/c Cutting Measuring Settin M/c Total
Fixture Tools Tools Instrumen g Time Time
t Time
1. Clamp stock M/C Vice Milling - - 15 - 15

2. Facing All --”-- --”-- Facing Vernier 5 14 19

Sides Sq. to cutter
total length
47x32x40
mm
3. Clamp stock 4 jaw Lathe - - 25 25
on lathe chuck
4. Drilling Ø 15 --”-- --”-- Twist drill Vernier 15 10 25
through
thickness
5. Boring Ø --”-- --”-- Boring Vernier 15 10 25
18through tool
thickness
6. Drilling Ø --”-- Drillin Twist drill Vernier 15 10 25
6.8through g
15hickness
7. Tapping M8 vice Drillin tap vernier 20 60 80
threads g
PART NO : NB-08 MATERIAL SPECIFICATION : EN 9
PART NAME : HINGE PLATE RAWMATERIAL SIZE: 110X20X50
QUANTITY :- 02 NO’S.

Sr. Description Tools Time in minutes

No of
Operation
Jigs & M/c Cutting Measuring Settin M/c Total
Fixture Tools Tools Instrumen g Time Time
t Time
1. Clamp stock M/C Vice Milling - - 15 - 15

2. Facing All --”-- --”-- Facing Vernier 5 14 19

Sides Sq. to cutter
total length
40x12x98
mm
3. Clamp stock 4 jaw Lathe - - 25 25
on lathe chuck
4. Drilling Ø 15 --”-- --”-- Twist drill Vernier 15 10 25
through
thickness
5. Boring Ø --”-- --”-- Boring Vernier 15 10 25
26through tool
thickness
6. Drilling Ø --”-- Drillin Twist drill Vernier 15 10 25
8.5through g
15hickness
PART NO : NB-10 MATERIAL SPECIFICATION : EN 9
PART NAME : ECCENTRIC CAM RAWMATERIAL SIZE: 60X40X60
QUANTITY :- 01 NO’S.

Sr. Description Tools Time in minutes

No of
Operation
Jigs & M/c Cutting Measuring Settin M/c Total
Fixture Tools Tools Instrumen g Time Time
t Time
1. Clamp stock M/C Vice Milling - - 15 - 15

2. Facing All --”-- --”-- Facing Vernier 5 14 19

Sides Sq. to cutter
total length
50x34x50m
m
3. Clamp stock 4 jaw Lathe - - 25 25
on lathe chuck
4. Drilling Ø 15 --”-- --”-- Twist drill Vernier 15 10 25
through
thickness
5. Boring Ø --”-- --”-- Boring Vernier 15 10 25
24through tool
thickness
6. Step turning --”-- --”-- Turning --”-- 20 25 45
Ø 25 to tool
24mm
length
7. Groove --”-- --”-- Grooving --”-- 20 15 35
turning Ø tool
37.8 to
1.7mm
length
PART NO : NB-17 MATERIAL SPECIFICATION : EN24
PART NAME : HINGE PIN RAW MATERIAL SIZE: A/F 22X 70
QUANTITY :- 01 NO’S.

Sr. Description of Tools Time in minutes

No Operation
Jigs & M/c Cuttin Measuri Setti M/c Tot
Fixture Tools g ng ng Tim al
Tools Instrum Time e Tim
ent e
1 Clamp stock Three Lathe - - 20 - 20
jaw
chuck
2 Facing Both Three Lathe Facing Vernier - 5 5
side to total jaw tool
length chuck
67.5mm

3.. StepTurning Lathe Turnin Vernier - 14 14

OD to Ø g tool
18mm
through
length 62.5

4.. Drilling Ø5 - --”-- Twist Vernier 15 10 25

through drill
thickness20
5. Tapping M6 - --”-- Tap Vernier 15 10 25
PART NO : NB-18 MATERIAL SPECIFICATION : EN24
PART NAME : ROD EYE PIN RAW MATERIAL SIZE: A/F 22X 50
QUANTITY :- 01 NO’S.

Sr. Description of Tools Time in minutes

No Operation
Jigs & M/c Cuttin Measuri Setti M/c Tot
Fixture Tools g ng ng Tim al
Tools Instrum Time e Tim
ent e
1 Clamp stock Three Lathe - - 20 - 20
jaw
chuck
2 Facing Both Three Lathe Facing Vernier - 5 5
side to total jaw tool
length chuck
45.5mm

3.. StepTurning Lathe Turnin Vernier - 14 14

OD to Ø g tool
16mm
through
length 40.5

4.. Drilling Ø5 - --”-- Twist Vernier 15 10 25

through drill
thickness20
5. Tapping M6 - --”-- Tap Vernier 15 10 25

OPERATIONS & APPLICATIONS :

The operations that can be performed on the nibbling machine

are as follows:

1. Shearing(straight line cutting)

Shearing tools are available for straight cutting, figure cutting

(contour cutting) and circle cutting operations. The shearing
length per cut is small and there is no wastage of materials.

2.NIBBLING
Nibbling is a continuous punching operation with a circular tool
and is used for producing internal and external cut-outs of any
shape. The workpiece does not warp but the edges produced may
require filing, depending on the end use. The fixed nibbling tool
is a. solid punch cutting at one side. The punch and die clearance
is provided to suit the sheet thickness and the feed is controlled
by the tool design. This tool, when used with the rotary nibbling
attachment, enables nibbling in any direction without turning the
sheet.

4. RECTANGULAR NOTCHING
Rectangular notching is a continuous punching operation with a square punch and die. It is
used mainly for producing internal rectangular cutouts. The tool cuts in the two
directions and the edges produced are clean.

5. Inner circle cutting Available for circles from 100 mm dia meter up to a maximum
circle dia meter-the size being 80% of throat depth of the corresponding model chosen. Pre-
hole in the centre is necessary for sheet thickness above 1.2 mm
BILL OF MATERIALS
SRN PART DESCRIPTION QTY MATERIAL
O CODE
1. NBM -1 MOTOR 01 STD

2. NBM -2 MOTOR PULLEY 01 CI

3. NBM -3 BELT 01 STD

4. NBM -4 REDUCTION PULLEY 01 CI

5. NBM -5 MAIN SHAFT 01 EN24

6. NBM -6 ECCENTRIC CAM 01 EN24

7. NBM -7 JOCKEY 01 EN9

8. NBM –8 LH_BRG_HOUSING 01 EN9

9. NBM –9 RH_BRG_HOUSING 01 EN9

10. NBM –10 POS BALL SCREW 01 STD

11. NBM –11 HINGE PIN-1 01 EN24

12. NBM –12 FORK 01 EN9

13. NBM –13 TOP ARM 01 EN9

14. NBM –14 BOTTOM ARM 01 EN9

15. NBM –15 HINGE PLATES 02 EN9

16. NBM –16 GM BUSH 02 EN9

17. NBM –17 HINGE PIN-2 01 EN9

18. NBM –18 TOOL HOLDER 02 EN9

19. NBM –19 TOOL 02 HSS

20. NBM -20 BASE FRAME 01 MS

21. NBM -21 BRG 6006ZZ 01 STD

22. NBM -22 BRG 6004 ZZ 01 STD

23. NBM -23 CIRCLIP 01 STD

  RAW MATERIAL COST
The total raw material cost as per the individual materials and their corresponding rates
per kg is as follows,
Total raw material cost = Rs 3450/-

 MACHINING COST
OPERATION RATE TOTAL TIME TOTAL
Rs /HR HRS COST Rs/-
LATHE 90 12 1080
MILLING 105 9 945
DRILLING 50 3.2 160
TAPPING 5 Rs/hole 16 80

TOTAL 2265
TOTAL MACHINING COST = Rs . 2265 /-

 MISCELLANEOUS COSTS

OPERATION COST(Rs)
Sawing 110
Fabrication 400
Total 510

 COST OF PURCHASED PARTS :-

 SR DESCRIPTION QTY COST
NO.
1. Motor 01 3650
2. Srdg Brg 6006zz 01 210
3. Srdg Brg 6004zz 04 185
4. POS unit 01 530
5. Tools 02 670
6. Slide bearing 02 690
7. Grub Screw M6 04 20
8. Bolts & Nut - 160
The cost of purchase parts = Rs 6115/-

 TOTAL COST

TOTAL COST = Raw Material Cost +Machine Cost + Miscellaneous Cost

+ cost of Purchased Parts +Overheads
= Rs 3450+2265+510+6115+400
Hence the total cost of machine = Rs 12740/-approx.