HARAMAYA UNIVERSITY

HARAMAYA INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

Thesis project on Design and analysis of automatic shearing machine for

circular and straight profile.

Submitted to Department of mechanical engineering HIT in partial fulfillment for the

requirement of the degree of BSc in mechanical engineering

Prepared by:
o Hanan Mohammed
o Kalid Haji
o Moibon Mengestu
o Natnael Tilahun
o Yeabsira Tesfahun

Advisor: MR. Addis A.

Submission Date; May, 2023
To: Department of mechanical engineering

Haramaya institute of technology

Haramaya University

DECLARATION

We hereby declare that the thesis paper titled by Design and analysis of automatic
shearing machine for circular and straight profile. Submitted by us is based on actual
and original work carried out by our own. Any reference to work done by any other
person or institution or any material obtained from other sources have been duly cited
and references. We further certify that the project paper has not been published or
submitted for publication anywhere else nor it will be send for publication in the future.

Advisors Name; Mr. Addis A.

_____________________________

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 ACKNOWLEDGMENT
We would like to express our deepest gratitude to our creator, to our beloved family and advisor,
Mr.Addis A .for his continual encouragement and patient guidance throughout the course of this
project. His deep insight into the subject of Fracture Mechanics, material handling, its many
applications and his communicable interest, his tolerances in helping our project design, and his
endless supplying of interesting ideas, have all greatly enriched our experience as a graduate
student.
Next thanks to all academic instructors who help us on how we can do any project successfully
and what procedures must be included in organized project. Beside this, thanks to all mechanical
engineering teachers those help us through different activities that approach to our project. Our
thanks and appreciations also go to our college in developing the project and people who have
willingly helped us with their abilities.

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 ABSTRACT

Shearing machine is a device used to cut sheet metals in any shape and size needed using a pair
of blades, by applying shear stress along the thickness of the sheet. This project presents Design
of shearing machine for circular and straight profile sheet metal using motor operated. Shearing
machines available at the market have some disadvantages such as requiring more energy to
operate, and not being able to cut in both linear and circular direction. The purpose of this project
is to modify the design of the existing shearing machine in terms of its functionality and also
human factors considerations. In this project, the scopes of research were on the designing.

Keywords: Shearing machine, circular profile sheet metal, straight profile sheet metal

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 Table of Contents
ACKNOWLEDGMENT....................................................................................................................................I
ABSTRACT....................................................................................................................................................II
LIST OF FIGURES..........................................................................................................................................V
LIST OF TABLES...........................................................................................................................................VI
CHAPTER ONE..............................................................................................................................................1
1. INTRODUCTION.......................................................................................................................................1
1.1. Background and Justification........................................................................................................1
1.2. Statement of the problem............................................................................................................1
1.3. Objectives.....................................................................................................................................2
1.4 Scope of the project.......................................................................................................................2
1.5 Significance of the Project Introduction.........................................................................................2
CHAPTER TWO.............................................................................................................................................4
2. LITERATURE REVIEW............................................................................................................................4
2.1. Introduction..................................................................................................................................4
2.1. Literature survey...........................................................................................................................8
CHAPTER THREE.........................................................................................................................................14
3. METHODOLOGY.................................................................................................................................14
3.1. Planning methods.......................................................................................................................14
3.2. Data collection methods.............................................................................................................14
3.3. Analysis methods........................................................................................................................15
3.4. Idea generation methods............................................................................................................16
3.5. Evaluation methods....................................................................................................................18
3.7. Research & Analysis....................................................................................................................21
3.8. Function and Task Analysis.........................................................................................................21
CHAPTER FOUR..........................................................................................................................................23
4. DESIGN PROCESS...............................................................................................................................23
4.1. Recognition of need....................................................................................................................23
4.2. Definition of problem..................................................................................................................23
4.3. Design calculation and specification...........................................................................................23
CHAPTER FIVE............................................................................................................................................78

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 5. RESULT AND DISCUSSION..................................................................................................................78
5.1 Results.........................................................................................................................................78
5.2. DISCUSSION................................................................................................................................79
CHAPTER SIX..............................................................................................................................................80
6. CONCLUSION AND RECOMMENDATION................................................................................................80
6.1. Conclusion..................................................................................................................................80
6.2 Recommendations.......................................................................................................................80
6.3 Future scope in future.................................................................................................................80
REFERENCES..............................................................................................................................................81
Appendices................................................................................................................................................83

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 LIST OF FIGURES
Figure 1 Universal scissors to cut sheet metal and profiling iron.................................................................4

Figure 2 Us patents 1...................................................................................................................................7

Figure 3 US patents 2..................................................................................................................................8

Figure 4. The effects of shearing on the material.........................................................................................9

Figure 5 Mechanical shearing machine.....................................................................................................10

Figure 6 Pneumatic Shearing Machine......................................................................................................10

Figure 7 Rotary Shearing Machine...........................................................................................................11

Figure 8 shearing machine.........................................................................................................................12

Figure 9 Function and task analysis...........................................................................................................22

Figure 10 Cutting die clearance................................................................................................................27

Figure 11 Pulley........................................................................................................................................53

Figure 12 Open belt drive..........................................................................................................................60

Figure 13 shaft...........................................................................................................................................64

Figure 14 motor.........................................................................................................................................65

Figure 15 Efficiency of worm gear Drive..................................................................................................71

Figure 16 Length of the worm...................................................................................................................72

Figure 17 Case depth vs Module graph.....................................................................................................73

Figure 18 Moment of inertia for rectangular beam....................................................................................77

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 LIST OF TABLES
Table 1. Concept screening........................................................................................................................19

Table 2. Concept scoring...........................................................................................................................20

Table 3 Heat treatment column..................................................................................................................29

Table 4 Young's modulus..........................................................................................................................30

Table 5 Value of σ－1...............................................................................................................................31

Table 6 Materials for gears........................................................................................................................32

Table 7 Stress concentration factor............................................................................................................33

Table 8 Life factor for bending..................................................................................................................33

Table 9 Design surface stress.....................................................................................................................34

Table 10 Life factor for surface strength....................................................................................................35

Table 11 Load concentration factor...........................................................................................................36

Table 12 Design twisting moment.............................................................................................................37

Table 13 Comparison between cylindrical and bevel gear.........................................................................38

Table 14 Recommended series of modules................................................................................................39

Table 15 Dynamic load factor...................................................................................................................42

Table 16 Bending strength formula...........................................................................................................43

Table 17 Form factor.................................................................................................................................45

Table 18 Basic dimensions of externally meshing standard cylindrical gears............................................47

Table 19 Standard width of pulley.............................................................................................................49

Table 20 V-belt..........................................................................................................................................54

Table 21 Recommended series & pulley diameter & tolerance.................................................................54

Table 22 Nominal pitch length for type C.................................................................................................55

Table 23 Correction factor for individual service......................................................................................57

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Table 24 Formulae for transmitting capacities...........................................................................................58

Table 25 Design bending stress.................................................................................................................66

Table 26 Recommended series of modules................................................................................................68

Table 27 Formula based on surface stress..................................................................................................69

Table 28 leg on the project is both ends are fixed......................................................................................75

Table 29 Properties of mild steel...............................................................................................................76

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NOTATION
Symbols Descriptions
W Weight
F Force
Rpm revolution per minute
𝜎𝑏 Bending stress
𝜎𝑐 Compressive stress
𝜎𝑡 Tensile stress
𝜎𝑟 Radial stress
𝜎𝑦 Yield stress
D1 diameter driving pulley
D2 diameter of driven pulley
Mb Bending moment
I Moment of inertia
Z Section modulus
ω angular speed
N speed of the pulley
V poison’s ratio
C clearance
Ƞ shear strength of stock material
E young’s modulus
M module
mx axial module
K load concentration factor
Kd dynamic load factor
ko shock loading
kbl life factor for bending
k𝜎 fillet stress concentration
HB surface hardness
𝑐𝑅 Coefficient depending on the surface
Hardness
Mt nominal twisting moment

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 [Mt] design torque
i standard ratio
a center distance
z1 no of teeth in driven gear
z2 no of teeth in driving gear
h tooth depth
y form factor
𝐹𝑝 Height factor
𝐹𝑐 Correction factor
𝐹𝛼 Service factor
dc tip diameter
df root diameter
Kw power capacity
S belt speed
τ Shear stress
T torsion
ρ Density
B width of pulley
b width of belt
n number of arms
WT tangential load per arm
L nominal pitch length
μ efficiency
Vs sliding velocity
V1 pitch line velocity of rack
γ Lead angle
ψ constant

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 CHAPTER ONE

1. INTRODUCTION

1.1. Background

Shearing machine is a machine with blades or rotary disks for cutting sheets, plates, or bars (as of
metal). Sheet Metal Cutting is a very important process in many Industry segments. Fast growing
industries segments like automotive have fueled the growth opportunities of sheet metalworking.
Sheet metal can be cut and bend into a variety of shapes finding numerous applications in car
bodies, airplane wings, medical tables, roofs for buildings and many other things. Almost all
machine manufacturing houses- textile, plastic processing machines, printing machines,
packaging machines, pharmaceutical machines, chemical plants, distilleries, breweries project
etc. are building main frame and majority parts from the sheet metal.

Rotary Cutting Machine is one of the principal machines in sheet metal industry. It is mainly
used as the name indicates to cut circles and straight of sheet material. There are many machines
in the industry which are able to cut sheet metal plate in a circular shape. Like cnc machine, Nc
machine and hand operated machines etc. Sheet 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 most
common cutting processes are performed by applying a shearing force, and are therefore
sometimes referred to as shearing processes. When a great enough shearing force is applied, the
shear stress in the material will exceed the ultimate shear strength and the material will fail and
separate at the cut location. This shearing force is applied by two tools, one above and one below
the sheet.

1.2. Statement of the problem

Now days, sheet metal industry sector is growing from small scale to large scale .One of the
products used is a mild steel as a main constitute which must be sheared to a desired shape and
size . Because it is done manually without much assistance from machines, this process is
orderly, tiresome, and time-consuming. The lack of easiness while shearing a sheet metal is a
serious issue of concern to many local metal industries, since the local metal shearing system and
mechanism is time consuming and requires high labor force. Its dimensional accuracy is low and
applicable for one activity (either for straight or circular shearing mechanism). Therefore, this
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study focuses

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On solving the stated problem by designing a simple and efficient design of sheet metal
cutting machine.

1.3. Objectives

1.3.1. General Objective

The main objective of this project is to design and analysis of automatic shearing machine for circular and
straight profile.

1.3.2. Specific Objective

 Selection criteria of suitable material for shearing machine

 Design of shearing machine components like shaft, blade,
 Selection suitable motor for the shearing machine
 3D geometry generation of shearing machine using solid works V12
 Speed reducing mechanism

1.4 Scope of the project

The scope of this project significantly, to make shearing machine design understandable
basically, the project study limited or extended to cover the design development of a shearing
machine through complete material selection, force analysis, detailed drawing and 3D model
(solid work) software. This project does not include prototype.

1.5 Significance of the Project Introduction

This paper discusses in detail the design and implementation of such a low cost automatic metal
sheet cutting machine that is used for straight as well as circular cutting.

In a production environment where time is very important, a rotary shear is able to increase
productivity by cutting much faster and with less waste. Making more exacting cuts equals less
discarded material and thus, more profits for the company. The rotary shear is able to offset any
increased initial cost by generating a healthier bottom line in production costs.Increased speed,
safer cutting methods and a cleaner work space are just some of the benefits of working with a
rotary cutting tool. The shear also remains very sharp for a very long time; should the need arise
to replace the blade; however, it is a simple process. By replacing blades and not entire cutting
units, an additional savings is made which equates to increased profits over the long
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 Run. When operated with all of the special protective guards in place, the rotary cutters are
much safer than scissors and result in fewer worker accidents and injuries.

Problem identification Explanation of a need for Design analysis and

and data collection shearing machine material selection

No 3D geometry preparation
Stress analysis using
mathematical using solid works V 2020
Yes calculation

Result and discussion Conclusion

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 CHAPTER TWO

2. LITERATURE REVIEW

2.1. Introduction

In the history of metallurgy sheet metal work is without doubt highlighted. Since prehistoric
times, man has sought to develop increasingly sophisticated tools, utensils and machines to shape
metals. The progress of the civilization imposed new requirements in the area of the boiler, the
technology offers new possibilities. When, in the 19th century, the development of new systems
of inland and maritime transport raised in sheet metal forming requirements, technology gave a
turn radical allowing machining effectively processes until then entirely manuals.[1]

Figure 1 Universal scissors to cut sheet metal and profiling

Catalogue of machine tools 1913 General Alfred H. Schütte

Work in cold and hot sheet has been made for centuries by blacksmiths and metalworkers of
entirely manually. Tools like the Mezzaluna, the tranchet of Anvil, the cortafríos or the punches
were the only help of artisans from the cutting and deformation of sheet metal, although over
time were incorporating more advanced tools, such as the lever shears or the press of rocker at
the end of the Middle Ages.

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The breakthrough of the boiler does not occur until the last decades of the 18th century when the
advent of the steam engine revolutionizes the industry in general and especially shipbuilding and
land transport. Steamer with metallic helmet or the development of the railway, between other
breakthroughs, imposes the need to build large steel structures for buildings, bridges, or boilers.
This drives a real technological revolution in all processes related to the work of the sheet:
cutting, punching, bending, riveting, etc.

Existing patent

Manik et. al [1] has worked on Metals play a major role in the industrial and everyday life of
human beings. Hundreds of welded metal objects and parts are used in engineering and
household applications. Thus, the study of stress, strain & hardness in the welded area are so
much important. This paper focuses on the study of mechanical properties of mild steel & cast
iron before and after welding. It was seen that the stress of mild steel &cast-iron bar decreased
after welding for any cross-section due to heat treatment of metal. After welding the hardness of
the mild steel & cast iron increased because of rapid cooling. During experiment it was seen that
the proportional limit of the specimens decreased due to effect of welding. It was also observed
that the strength of the specimens decreased but hardness increased. Thus, the property of the
specimen can be changed due to welding effect.

B. KIM [2] has worked on improving the durability of an automotive V-belt pulley, which is
commonly used in an automotive powertrain to transfer power to other parts, is discussed.
Fatigue life of the original V-belt pulley is predicted based on damage analysis by finite element
analysis (FEA). Stress history of the pulley during operation was found by performing
consecutive static analyses on the pulley as the pulley rotates.

T. C. Firbank et [3] at has worked on the mechanics of the belt drive is considered when the belt
possesses a soft pliable envelope to grip the pulley and strong tension members to transmit the
power. It is concluded that shear strains in the belt envelope are a large factor in determining
drive behavior. This is in contrast to the Elastic Creep Theory which explains the traditional belt
drive in terms of longitudinal strains.

B. Sivakumar et.at [4] has worked on a gear or “gear wheel” is a rotating machine part having
cut teeth, or cogs, which mesh with another toothed part in order to transmit power. Two or more

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gears

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Working in tandem are called a transmission and produce a mechanical advantage through a gear
ratio and thus may be considered a simple machine.

Berna Balta et.at [5] has worked on One of the concerns in belt drive transmissions is the relative
sliding (slip) of the belt with respect to the pulley, which results in speed loss, i.e., decrease in
the angular velocity of the driven pulley. In this study, the slip behavior of a V-ribbed belt drive
with two equal-sized pulleys is investigated by utilizing several experimental methodologies.
The individual effects of belt-drive parameters on speed loss are determined using one-factor-at-
a-time (OFAT) test method. The relation between the belt drive parameters and the speed loss is
found using response surface method (RSM).

Hydraulic sheet-metal shearing machine comprising a movable apron pivotally mounted about an
eccentric axis of rotation of adjustable angular position permit ting of modifying at will the initial
clearance between the blades. The support of the sheet abutment device is hinged mounted to the
movable apron about an axis shifted in relation to the pivotal axis thereof, and which has
likewise an eccentric position. The shafts materializing these two axes are operatively
interconnected through means capable of correcting the position of said abutment device when
the clearance between the blades is modified by pivoting the eccentric hinge shaft of said
movable apron.

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FIG. 2 us patents 1

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FIG. 3 US patents 2

Inventor: Paul Cailloux, Le Perreux, France

2.1. Literature survey

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 most common cutting processes are performed by
applying a shearing force, and are therefore sometimes referred to as shearing processes. When a
great enough shearing force is applied, the shear stress in the material will exceed the ultimate
shear strength and the material will fail and separate at the cut location. This shearing force is
applied by two tools, one above and one below the sheet. Whether these tools are a punch and
die or upper
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And lower blades, the tool above the sheet delivers a quick downward blow to the sheet metal
that rests over the lower tool. A small clearance is present between the edges of the upper and
lower tools, which facilitates the fracture of the material. The size of this clearance is typically 2-
10% of the material thickness and depends upon several factors, such as the specific shearing
process, material and sheet thickness. The effects of shearing on the material change as the cut
progresses and are visible on the edge of the sheared material. When the punch or blade impacts
the sheet, the clearance between the tools allows the sheet to plastically deform and "rollover"
the edge. As the tool penetrates the sheet further the shearing results in a vertical burnished zone
of material. Finally, the shear stress is too great and the material fractures at an angle with a
small burr formed at the edge. The height of each of these portions of the cut depends on several
factors, including the sharpness of the tools and the clearance between the tools.

Figure. 4. The effects of shearing on the material

Types of Shearing Machines

1. Mechanical Shearing Machine

Mechanical shear machine consist of flywheel, motor, worm shaft which is gear driven by
flywheel, a ram actuated with the help of driven shaft by connecting links and eccentrics, a
clutch which is used for connecting the worm gear drive with driven shaft. In comparison with
hydraulic

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Shear, in many operation condition mechanical shear deliver more spm (strokes per minute).
Sometime cycle of mechanical shear is around 100 strokes per minute.

In mechanical shear, small motors are also used for the purpose of intermittent shearing due to
the energy stored in flywheel.

Figure 5 Mechanical shearing machine

2. Straight Knife Shearing Machine

In this type of shearing the work piece is placed in between movable upper knife and the
stationary lower knife. When upper knife is forced in downward direction then the upper knife
cuts metal in two parts. This type of shearing is economical for cutting of straight sided blanks
from strip, plate and sheet of thickness less than 50 mm. This process is used for cutting of sheet
in blanks which is subsequently drawn or formed.

3. Pneumatic Shearing Machine

Pneumatic shearing machines are most widely used for the shearing of thin metal which is less thick than
1. 50 mm and short pieces but less long than 1. 5 m. Shear blade beams are moved by the
activation of air cylinder for making cut. Free standing air or shop compressed air is used for
Providing power to the cylinder.

Figure 6 Pneumatic Shearing Machine

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4. Rotary Shearing Machine

Circle shearing or rotary shearing are cutting process of plate and sheet in contours or in straight
lines using two revolving and tapered circular cutters. The shearing by rotary shearing machine
needs holding fixtures for allowing rotation to the work piece for generating desired circle. In
rotary shearing machine, for straight line cut, a straight edge fixture is required which is mounted
in throat of machine behind cutter head.

Figure 7 Rotary Shearing Machine

5. Alligator Shearing Machine

Shearing action of alligator shearing machine is similar to that of pair of scissors. The upper
knife is held in arm securely and moves around the fulcrum pin and the lower knife is kept
stationary. Alligator shearing machines are generally used in shearing bar sections and bar and
for scrap preparing

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6. Hydraulic Shearing Machine

The actuation in hydraulic shearing machine is done by motor driven pump which forces the oil
in cylinder against piston. The piston movement energizes the ram which is holding upper knife.
Hydraulic shearing machines are able to take longer stokes as compared to mechanical shearing
machine. They are designed for fixed load capacity.

Figure 8. shearing machine

Operation of Shearing Machine

Punching is the most common operation of shearing machine in which sheared slug are scrapped.
Shearing is also done in between a die and punch. Shearing operation includes punching,
piercing, blanking, trimming, notching and nibbling.

1. Blanking or Punching

Blanking or punching is defined as the process in which punch is used for removing a portion of
material from strip of sheet metal or from the larger piece. When small piece is being removed
then the operation is known as punching and if small removed piece is useful part and the left
over are scrap then this operation is known as blanking.

2. Trimming

When parts are produced by drop forging or by die casting, very less amount of extra metal are
spread out on parting plane and the extra metal which is known as flash are cut off from the part

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Before it is used, by the trimming operation. Trimming is quite similar to the blanking and the
dies used in trimming are also similar to the dies used in blanking.

3. Piercing

Piercing is defined as the process in which a hole is torn in metal. Piercing is different from the
punching because in piercing slug do not get generated. Pierced hole is quite similar to the bullet
hole in metal sheet.

4. Nibbling

Nibbling is a different variety of notching in which overlapping notches are cut in the metal.
Nibbling are resorted for producing any required shape such as collars, flanges.

5. Perforating

It is defined as the operation where various uniform spaced holes are made in the sheet of metal
and holes can be of any shape or size and cover complete sheet of metal.

6. Notching

Notching is defined as the operation in which small amount of metal is cut from the blank.
Notching is different from the punching operation because in notching the cutting line of slug
touches one edge of strip or blank. Notches are made of any shape

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 CHAPTER THREE

3. METHODOLOG

3.1. Planning methods

Product planning is the process of creating a product idea and following through on it until the
product is introduced to the market. A small company must also have an exit strategy for its
product in case the product does not sell. Product planning in marketing includes managing the
product throughout its life using marketing strategies such as product improvements,
differentiated distribution, price changes and promotions.

The first step of product planning is identification of the project mission. The Mission of the
project to consider alternative product concepts that employs conventional brush cutter as the
simple, flexible and economical technology. This work develops the detail design of the product
to make easy for mass production. It will be settled the method of fabrication.

3.2. Data collection methods

3.2.1 Primary data collection method

3.2.1.1 Gathering information with interview

The basic information to be gathered from the customer is the tool suitability to use and its
application to their work. However, have to make sure this method are reliable to get appropriate
customer. In the process of the project is focused on the basic specifications are settled to satisfy
the need customer.as stated above the basic method is used for gathering information is interview
and outdoor observation. The resulting customer needs are used to guide the team in establishing
product specification, generating product concepts, and selection a product concept for further
development. After organizing the needs of the customer, it is needed to make hierarchy. The
objective of the customer needs when the target specification. The questions for interview are
stated at appendix 1.

The respondent can be selected from the users of this design. The peoples who owned a company
they also gave appropriate answers for the question. The interview is undertaken to each
respondent to make sure the data is reliable from each respondent. The basic design and

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Manufacturing specifications are recommended from the skilled man powers who worked in the
company.

3.3. Analysis methods

This is the way of identifying problems, design of device, specify the process, selecting the
proper materials that are suitable for the device and determine the simplified way of fabrication
and methods of using developed SOLIDWORK 2020 software.

After some small observation, it was discovered that the combination of both straight and
circular sheet metal cutting machine eliminates the use of manual labor that goes with the
circular sheet metal cutting machine alone. The next step was choosing the appropriate
dimensions for pulleys to transmit power from motor to gearbox, after that some safety
considerations were taken.

Selection of suitable material must to be considered in account. The suitable of material with the
process of fabrication as well as the compatibility of the material with the environment. The
selection of proper material for engineering the best material is one with which save design
objective let the maximum cost.

Different manufacturing factor have been consider selecting material is the first target for
designing or manufacturing one machine. The process responsible for their commanding material
that will be suitable for process consideration.

Selecting material must consider the requirement or the material properties, sufficient strength
and easily workable. The most economical material that satisfy both processes and mechanical
requirements should be considered.

The material properties are very important in the selection of the material. Some important
mechanical properties which are considered in material selection are: -

 Cost
 Availability
 Suitability of the materials for the working condition.
 Literature review

But the following factors should be considered, which the material is: -
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  Availability of the material,
 suitability of material for the working consideration service and
 The cost of the material and easily fabrication.

3.4. Idea generation methods

Product concept is an approximate description of the technology, working principles and the
form of the product. It can be expressed in a sketch or rough 3D design with a brief text
description the successfulness of the product is basically influenced by the development of
quality concept by this design.

The basic steps to generate concepts

 Clarify the problem  Explore systematically
 Search externally  Reflection of generated product
 Search internally

3.4.1. External search result of sheet metal cutting machine

The search externally technique includes the literature reviewed types of sheet metal cutting
machine. External search is aimed at finding existing solutions to both the overall problem and to
the sub problems identified during the problem clarification step. This search is ongoing
throughout the development process. Implementing an existing solution is usually less expensive
and quicker than developing a new solution. There are some externally observed results of the
product. These are:

 Mechanical Shearing Machine

Mechanical shear machine consist of flywheel, motor, worm shaft which is gear driven by
flywheel, a ram actuated with the help of driven shaft by connecting links and eccentrics, a
clutch which is used for connecting the worm gear drive with driven shaft.

 Straight Knife Shearing Machine

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In this type of shearing the work piece is placed in between movable upper knife and the
stationary lower knife.

 Pneumatic Shearing Machine

Pneumatic shearing machines are most widely used for the shearing of thin metal which is less
thick than 1. 50 mm and short pieces but less long than 1. 5 m.

 Rotary Shearing Machine

Circle shearing or rotary shearing are cutting process of plate and sheet in contours or in straight
lines using two revolving and tapered circular cutters.

 Alligator Shearing Machine

Shearing action of alligator shearing machine is similar to that of pair of scissors.

 Hydraulic Shearing Machine

The actuation in hydraulic shearing machine is done by motor driven pump which forces the oil
in cylinder against piston.

3.3.2. Internal search on the sheet metal cutter

In this section developing the product concept to by considering the major effects found on the
general lawn mower and brush cutting systems. To satisfy the specific targets, there was made a
meeting on this concept to put additional features in order to manage the customer need.
Different ideas were raised to fulfill the design as the customers mentioned earlier. This are:
adjustment, ergonomics, adjustment for surface profile, easy for operation, have good stability
and maneuverability, flexible, and multi-purpose.

 Adjustment

This specification is the basic criteria for this project. Most of the customer recommended that
there should be some kind of adjustment with the diameter of circular cut by using rack and
pinion.

 Ergonomics

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These criteria focused on the correlation of the human and machine. This design should make the
product easy to operate with no physical damage on the human body. The when the operator
operates the machine it should meet the available position of working.

 Ease of operation

The next qualification to be taken for the product is that it should not be difficult to operate. In
this case it should be easy to carry and start operation. Every process didn`t need skilled man
power. In addition to that it easy to maintain when some defects are found on the product. The
operator did only have to turn on the switch to start cutting process. The machine should be easy
to disassemble and assemble because of the customer need.

 Stability and maneuverability

The motion of the carriage should have stable movement without any vibration. It may not be
able to damp all vibrational effect. It also should be easy to maintain the direction of motion. In
that case the caster wheels are used for this purpose.

 Stability and maneuverability

At this point of view the usability of the product should be simple and multi-dimensional.

 Multi-purpose

As the name indicates the multipurpose value is the main focus of this study. It will be used for
cutting of sheet metals in straight and circular profile.

3.5. Evaluation methods

Concept Selection is the process of evaluating concepts with respect to customer needs and other
criteria, comparing the relative strengths and weaknesses of the concepts, and selecting or more
concepts for further investigation or development.

There are two major steps of concept selection

 Concept screening
 Concept scoring

Page | 20
3.5.1 Concept screening

Concept Screening is alone may suffice for simple design decisions. This is a quick, approximate
evaluation aimed at producing a few viable alternatives. Rough initial concepts are evaluated
relative to a common reference concept using the screening matrix.

Selection criteria and concepts are used to provide the basic rows and columns of matrix.
Concepts should be presented at similar levels of detail for meaningful comparison and unbiased
selection.

We first screen the three concepts to drop one of them. The following table shows our criteria
and value given to screen out the best two. We use around ten criteria to select the two concepts.

Table 1 Concept screening

Concepts

Shearing for Shearing for Manual Motorized

straight and only circular or shearing shearing
circular cut. straight cut. machine machine

Ease of Manufacture + 0 + -
Service life + + - +
Cost - 0 0 -
Simplicity 0 + + +
Operating mechanism + + - +
Weight 0 + + 0
Portability + + + +
Ease of Handling + + + +
Work rate + 0 - +
Ease of maintenance + - + +

Sum +’s 7 6 6 7
Sum 0’s 2 3 1 1
Sum – ‘s 1 1 3 2

Page | 21
 Net Score 6 5 3 5
Rank 1 2 3 2
Continue? Yes Yes No Yes

3.5.2 Concept scoring

It is the final stage that is used for the selection of the final mechanism. As earlier explained the
three generated concepts have been screened by the former method. Here we are going to
compare the rest generated concepts by other system

Table 2 Concept scoring

Concepts

Shearing machine Shearing machine Motorized

for straight and for only circular or
circular cut. straight cut. Shearing machine

Selection criteria Weight Rating Weighted Rating Weighted Rating Weighted

score score score

Ease of Manufacture 10% 4 0.40 3 0.30 4 0.40

Service life 15% 5 0.75 5 0.75 4 0.40
Cost 10% 3 0.30 4 0.40 3 0.30
Simplicity 7% 3 0.21 4 0.28 4 0.40
Operating mechanism 12% 4 0.48 3 0.36 4 0.40
Weight 9% 3 0.27 4 0.36 3 0.30
Portability 10% 4 0.40 3 0.30 4 0.40
Ease of Handling 6% 4 0.24 3 0.18 4 0.40
Work rate 10% 4 0.40 3 0.40 4 0.40
Ease of maintenance 11% 4 0.44 3 0.33 4 0.40

Page | 22
 Total 3.89 3.66 3.8
Score
1 3 2
Rank

Continue Yes No Yes

?

The final concept section is settled as when selecting a multi-purpose cutting machine with
angular and surface profile adjustment. This result can be able to meet the above criteria’s. In
this case the handling can be solved by the adjustments and angular bends. The height
adjustment also used for the available human interaction and ergonomics.

3.7. Research & Analysis

Structured development of the design concept is called embodiment design. In this design the
decisions are made on strength, material selection, size, shape, and spatial compatibility. Beyond
this design phase, major changes become very expensive. At this stage it has been set thing about
the size, structure, special compatibility.

The need for assessment to the detail design concept satisfies the given specifications. A set of
concepts has been evaluated to produce single concept.at this stages it is putted the final structure
of the design product. Then the shape and size of the product settled and final look out of the
product is stated. Thus, the complete design concept is stated back to the body of the product. In
the next section important design parameters are quantified to the dimension and tolerance and
material type.

3.8. Function and Task Analysis

Function analysis is a method for analyzing and developing a function structure. A function
structure is an abstract model of the new product, without material features such as shape,
dimensions and materials of the parts. It describes the functions of the product and its parts and
indicates the mutual relations. The underlying idea is that a function structure may be built up
from a limited number of elementary (or general) functions on a high level of abstraction. In
function

Page | 23
Analysis, the product is considered as a technical-physical system. The product functions, 16
because it consists of a number of parts and components which fulfill sub-functions and the
overall function. By choosing the appropriate form and materials, a designer can influence the
sub- functions and the overall function. The functional analysis of this project can be observed
from the basic componential structure of the parts and the specific objective of the machine.

Problem

Using different shearing

machine for different
Manual machine
cut

Consumption of time High labor force Ergonomics

Figure 9 Function and task analysis

Page | 24
 CHAPTER FOUR

4. DESIGN PROCES

4.1. Recognition of
need

Recognition of need is the first step in consumer buying behavior and is also called problem
identification. It occurs when a consumer discovers an unmet need that must be fulfilled.

The main thing for human being is health .Human health, is the complete state of physical,
social, and mental well-being and not merely the absence of illness, disease, or infirmity, and is
as vital a resource as water, food, or energy. This is why people have to keep themselves from
inappropriate body posture. When workers are working on manual shearing machine they use
their own energy and they become exposed to heavy loads. These will cause musculoskeletal
disorders particularly Back injury, to solve the above problems, we find this equipment very
important and became motivated to do it.

4.2. Definition of problem

Engineers solve problems by creating or modifying products, systems, or environments. Before

creating something, it is very important to define the problem.

One the product of used is mild steel as a main component, which needs to sheared to the desired
shape and size because it is done manually with little help from machines. This process is not
organized, tiring, and time consuming, and it requires a large work force. It only applies to one
activity and has poor dimensional precision. Therefore the call of this project is to develop a
sheet metal cutting machine that is both straight forward and effective at solving the stated
problem.

4.3. Design calculation and specification

Design calculations of various components and with the help of that calculations we have done
modeling of rotary sheet cutting machine solid works.

4.3.1 Selection of suitable materials for machine components

Page | 25
The selection of materials is based on four assumptions, which are as follows:

Page | 26
  Cost  Suitability of the materials for the
working condition.
 Availability
 Literature review

Cast iron IS an alloy of iron that contains 2 to 4 percent carbon along with varying amounts of
silicon and manganese and traces of impurities such as sulfur and phosphorus. It is made by
reducing iron ore in a blast furnace.

Mild steel is a low carbon steel type. Carbon steels are metals with a tiny amount of carbon
(maximum 2.1%) added to improve the characteristics of pure iron. The carbon content of steel
changes based on the steel's requirements. Carbon content in low carbon steels ranges from 0.05
to 0.25 percent. Corrosion resistance, wear resistance, and tensile strength are among the
qualities that are improved with the addition of other elements.

High carbon steel has a carbon content of 0.60– 1.25 wt. % and a manganese content of 0.30 –
0.90 wt. %. It has the highest hardness and toughness of the carbon steels and the lowest
ductility. High-carbon steels are very wear-resistant as a result of the fact that they are almost
always hardened and tempered.

Tool steels and die steels are types of high-carbon steels, which contain additional alloying
elements including chromium, vanadium, molybdenum and tungsten. The addition of these
elements results in the very hard wear-resistant steel, which is a result of the formation of carbide
compounds such as tungsten carbide (WC).

Stainless steel refers to a group of alloy steels that typically contain 10 to 30% chromium.
Chromium has a high resistance to corrosion and heat, thanks to its low carbon content. Other
elements, such as nickel, molybdenum, titanium, aluminum, niobium, copper, nitrogen, sulfur,
phosphorus, or selenium, may be added to improve corrosion resistance, boost oxidation
resistance, or impart particular properties.

Force needed to cut steel sheet

Shear force for cut is calculated by basic formula:

Where,

Page | 27
 Sheet thickness, t = 4 mm

Material, M.S (Component)

Shear Strength, η= 550 N/ mm2

Perimeter of component,

P=9000mm

Cutting Force,

𝐹 =η×P×t

𝐹 = 19,800,000𝑁

The friction between the work piece and the punch increases punch force. With punch force, a
force are needed for strip the punch from sheet while return stroke and the second force are
opposite in the direction of punch force and this second force are difficult in estimation due to
various factors in operation.

1.
Rotor blade (cutter) [3]

The rotational element of the machine is the blade made of hard steel. It's a rotary thin disc with
a 200mm outside diameter and a 10mm inner diameter and a 10mm thickness, and the cutting
device is a circular knife with a blade sharpened along one side. There are two principal stresses
in the rotating disk—the tangential stress Ϭt and radial stress Ϭr.

2.
Analysis of stress on the rotary blade [9]

The general equations for tangential stress Ϭt and radial stress Ϭr. are as follows

𝑜2 2
𝜎 = 𝜌𝜔2((3 + 𝑣))(𝑟2 + 𝑟2 + 𝑟𝑖 𝑟 − 1 + 3𝑣 𝑟2
𝑖 𝑜
𝑡
8 𝑟2 3+𝑣

2
𝜎 = 𝜌𝜔2((3 + 𝑣) )(𝑟 2 + 𝑟 2 − 𝑟𝑖 𝑟𝑜− 𝑟 2)
𝑟 𝑖 𝑜
8 𝑟2

Since the material is hard steel, density of the material (ρ) is 7850 kg/m3 and Poisson’s ratio (v)
is 0.27. Angular speed (ω) depends of the rpm of the motor which is 1480 rpm (AC motor rpm is

Page | 28
based on reference data that found from the 24-motor review). From this angular speed can be
calculated using the following formula:

2πN
ω=
60

ω = 154.99 rad⁄sec

Where

𝑟𝑜 = 100𝑚𝑚

𝑟𝑖 = 5𝑚𝑚

r = 10mm

Substituting the above values in to the first equation result is:

𝑜2 2
𝜎 = 𝜌𝜔2((3 + 𝑣))(𝑟2 + 𝑟2 + 𝑟𝑖 𝑟 − 1 + 3𝑣 𝑟2
𝑖 𝑜
𝑡
8 𝑟2 3+𝑣

𝜎𝑡 = 0.961MPa

Also substituting the above values in to the second equation result is:
2
𝜎 = 𝜌𝜔2((3 + 𝑣) )(𝑟 2 + 𝑟 2 − 𝑟𝑖 𝑟𝑜− 𝑟 2)
𝑟 𝑖 𝑜
8 𝑟2

𝜎𝑟 = 0.572𝑀𝑝𝑎

It can be said the design is safe because the calculated stress is substantially lower than the
tensile strength of hard steel.
The clearance, c, between the punch and the die
When the punch is inserted into the die hole, the cutting clearance is the distance between one
side of the punch and the corresponding side of the die opening. Cutting clearance should always
be expressed as the amount of clearance per side. For the tool's longevity, proper cutting
clearance is required. Cutting clearance is also important for the quality of the piece portion.

Page | 29
The quantity of clearance and whether the punch and die have optimum cutting clearance or
excessive clearance or misalignment can be determined by visually inspecting the punched
components.

Figure 10 cutting die clearance

Clearance Equation
The ideal clearance can be calculated using the following formula
η
Clearance=C × t×√
10

Where C=0.005 (accurate components)

=0.01 (normal components)
t=sheet metal thickness in mm

η=shear strength of stock material in N⁄mm2

η (for mild steel) = 400-550N⁄mm2

550N⁄
Clearance = (0.005) × (4mm) ×√ mm2
10

= 0.15 mm per side

Page | 30
1. DESIGN OF SPUR GEAR

[4] Design procedure for Spur Gear

Step 1: Selection of material

Step 2: Assume life of gear

Step 3: Calculate young u’s modulus, Bending stress, compressive stress

Step 4: Assume Kkd = 1.3

Step 5: Assume KO according to shock loading

condition Step 6: Compute the design torque [Mt]

Step 7: Calculate center distance (a), assuming φ=

Step 8: Check for Z1 according to given condition

Step 9: Calculate module (m) and standardization

Step 10: Revise the value of ‘a’

Step 11: Assume IS quality of gear

Step 12: Obtain new value for k & kd

Step 13: Check for value of induced stress

Additional information

From point 2:- assume anything between 10,000 - 20,000 hour

From point 5:- ko according to shock loading

ko ~ 1 if application not specified

ko~ 1.25 moderate loading

ko~ 1.5 heavy loading

From point 8:- Full depth (20°) - Z1≥ 17

Page | 31
 Stub teeth (20°) - Z1≥14

Full depth (14.5°)-Z1≥32 (special case)

Solution

 Power to be transmitted - 75kw  Angular velocity ratio - 1:1

 Speed of first gear - 1480rpm  Tooth profile 20° stub

Step 1: Selection of material [table 8.5] [4]

Table 3 Heat treatment column

Case Hared alloy steel (15 Ni2 Cr1 Mo15)

Step 2: assume life of gear =20,000 hours

Page | 32
Step 3: Calculate
 Young’s modulus

Table 4 Young's modulus [4]

‘E’ is always 2.15 × 106 𝑘𝑔𝑓 or 2.1×105 𝑁

𝑐𝑚2 𝑚𝑚2

i.
Bending stress (σb) [page - 8.18] [4]

Table: Design bending stress (Tension σb)

Page | 33
  Rotation in one direction -

𝑘𝑏 𝜎𝑜
σb = (σ－1)
𝑛 𝑘𝜎

Alloy steel

Table 5 Value of σ－1 [4]

𝑁
σ－1= 0.35 σu + 120
𝑚𝑚 2

For σu (15 Ni2 Cr1 Mo15)

The reading is 1040.

𝑚𝑚2

Page | 34
Table 6 Materials for gears [4]

(15 Ni2 Cr1 Mo15)

𝑁
 the reading 900 (To be safe we choose 1040 )
𝑚𝑚2 𝑚𝑚2
 case hardened steel
 kb=1.2

Page | 35
  case hardened steel
 n=2.0

Table 7 Stress concentration factor

[4]

 steel (>350) → > 25×107 cycle [kbl=0.7]

Table 8 Life factor for bending [4]

Page | 36
 Life = 20,000 ×60×1480 rpm

= 177.6 × 107cycle

So 177.6 × 107 cycle > 25×107 cycle

 kbl=0.7 but due to note under the

table kbl=1.0
𝑁
σ－1= 0.35 σu + 120
𝑚𝑚 2

=0.35 (1040) + 120 𝑁

𝑚𝑚2 𝑚𝑚2

= 484 𝑁
𝑚𝑚2

Therefore,
𝑘𝑏 𝜎𝑜
[Σb] = (σ－1)
𝑛 𝑘𝜎

(1) (1.4) (484)

= (2) (1.2)

𝑁
=282.3
𝑚𝑚2

ii.
Compressive stress σc

Table 9 Design surface stress [4]

Choose formula with CR

[σc] =CR HRC kcl

Coefficient CR

Page | 37
 Alloy steel → case hardened

 HRC= 55 to 63 & CR=280

Life factor for surface strength

 steel (>350) → > 25×107 cycle

→kcl=0.585 Table 10 Life factor for surface strength [4]

Therefore, [σc] =CR HRC kcl

=280 × 60×0.585

=982.8 𝑵
𝒎𝒎𝟐

Step 4: Finding the value of Kd from [page 8.15] table 14

 Kd=1.3

Page | 38
Table 11 Load concentration factor [4]

Step 5: shock loading condition ko

 For Shearing machine ko=1.25

Step 6: compute the design torque [Mt]:- [table 8.15]

 [Mt]= Mt Kd ko

Page | 39
Table 12 Design twisting moment [4]

 𝟐𝝅 𝑵 𝑴𝒕
P= 𝟔𝟎

𝒑×𝟔𝟎
Mt = 𝟐𝝅 𝑵

𝟕𝟓𝒌𝒘 ×𝟔𝟎
= 𝟐𝝅 (𝟕𝟒𝟎 𝒓𝒑𝒎)

= 967.87 Nm

 [Mt]= Mt Kkd ko

=484.16 Nm ×1.3×1.25

=786.764 Nm

Step 7: calculate center distance ‘a’

Formula for spur gear

𝟑 𝟎.𝟕𝟒 𝟐 𝑬 [𝑴𝒕]
a≥ (i + 1) √( ) ( )
𝝈𝒄 𝒊𝑇

 i=standard ratio

i=𝑍2 = 1
𝑍1

Z1= no of teeth in driven gear

Z2= no of teeth in driving gear

Page | 40
From the [table 8.14]

 Ψ= 0.3

Therefore,

a≥ (1 + 1) √ 2.1× 10 𝑚𝑚2 × (786.764× 103

0.74) ( 1(0.3) )
(
982.8

= 111.01

Table 13 Comparison between cylindrical and bevel gear [4]

Step 8: Check for Z1 according to given condition, since tooth profile is 20o stub

 Z1≥14

Choosing Z1=16

Z2= i×Z1

= (1) × 16

Page | 41
 = 16

Step 9: calculate module (m) & standardize it [page 8.22 and 8.2]

Table 14 Recommended series of modules [4]

Formula from table 8.22 (part 26) [4]

2𝑎
m=𝑍1+𝑍2

2(111.01)
= (16+16)

= 6.94

Table recommended series of module preferred value

∴ m=8

Page | 42
Step 10: Revise the value of ‘a’ [table 8.22] [4]


From the new value of m=8

2a= m (Z1+Z2)

(𝑍1+𝑍2) 8(32)
a= 2 = 2 =128

i. Ψ=𝑏
𝑎

Page | 43
 b = Ψ×a

= 0.3 ×128

= 38.4≈ 39 mm

ii. From table 8.22

 Diameter of the gear

d1=m Z1

= 8 ×16

=128

iii. Pitch line velocity

𝝅 𝒅𝟏 𝑵
V=𝟔𝟎×𝟏𝟎𝟎𝟎

𝝅 𝟏𝟐𝟖 ×𝟏𝟒𝟖𝟎
= 𝟔𝟎×𝟏𝟎𝟎𝟎

=9.914𝑚 ≈ 10𝑚
𝑠 𝑠

iv. From [page 8.15]

𝒃
Ψp =
𝒅𝟏

𝟑𝟗
= 𝟏𝟐𝟖

= 0.305 ≈ 0.4

Table: Cylindrical gear (Bearing close to gear & symmetrical)

K=1

Step 11: From IS quality of gear [table 8.16]

 Take IS quality ‘8’ for cylindrical gear

Page | 44
Table 15 Dynamic load factor [4]

Step 12: obtain new value for k &kd [table 8.15-8.16]

Table 8.15

 k= 1 (found next to ψp=0.4)

Table 8.16

 kd=1.4
 For IS quality =8 & pitch line velocity = 10𝑚 , but from the table the
𝑠
𝑚
Value will be 12
𝑠

[Mt] with new value:

 [Mt] = Mt .k .kd. Ko

= 484.16 Nm × (1) ×1.4×1.25

=847.28 Nm

Step 13: check the value of induced stress [table 8.13 -8.13A]

1) Compressive strength [table 8.13]

Page | 45
  σ =0.74 𝑖+1 3 𝑖+1 (𝐸) [𝑀𝑡]
C ( ) √𝑖𝑏
1+1 3
=0.74( ) 1+1 (2.1 × 105)[847.28]
128 √
1 (39)

=34.93 𝑁
𝑚𝑚2
𝑁
From step 3: [σc ] = 982.8
𝑚𝑚2 > σc Induced

2) Bending strength table below give formula [4]

𝒊±𝟏
 σb=
𝒂×𝒎×𝒃×𝒚 [𝑴𝒕]

Table 16 Bending strength formula

y=form factor

Page | 46
 From table 8.18

 Z=16

The reading

 y=0.355,

For height factor

Fp= 0.8 (stub teeth), the above value divided by Fp

 y=𝟎.𝟑𝟓𝟓 = 0.44375
𝟎.𝟖

Page | 47
Table 17 Form factor [4]

 1±1
σb= (111.01)×8×39× (0.44375) [847.28 × 10 𝑁𝑚𝑚]
3


=110.3 𝑁
𝑚𝑚2
𝑁
Therefore [σb] = 282.3 > σb, Induced satisfied
𝑚𝑚2

Step 14: Design is satisfied then table 8.22

Page | 48
i. Bottom Clearance (c ) = 0.3 for stub teeth

ii. Tooth Depth (h) = 1.9 for stub teeth

iii. Tip Diameter (dc )

= Dc1= [Z1 +2fa]

= [16+2(0.8)] 8

=140.8mm

iv. Root Diameter (df)=

Df1 = [Z1－2fo] m－2c

= [16－2 (0.8)] (8) －2 (0.3)

=114.6mm

Page | 49
Table 18 Basic dimensions of externally meshing standard cylindrical [4] l gears

Page | 50
2. Design of Pulley system [2]
The pulleys are generally made of *cast iron, because of their low cost. The rim is held in place
by web from the central boss or by arms or spokes.
The arms may be straight or curved.
Design of Cast Iron Pulleys
The following procedure may be adopted for the design of cast iron pulleys.

Dimensions of pulley
i. Diameter of pulley

The diameter of the pulley (D) may be obtained either from velocity ratio consideration or
centrifugal stress consideration.

We know that the centrifugal stress induced in the rim of the pulley,
𝜎𝑡 = 𝜌 ∗ 𝑣
Where

ρ = Density of the rim material = 7200 kg/m3 for cast iron

ν = Velocity of the rim = πDN / 60,
D being the diameter of pulley and
N is speed of the pulley.
The following are the diameter of pulleys in mm for flat and V-belts. 20, 22, 25, 28, 32, 36, 40,
45, 50, 56, 63, 71, 80, 90, 100, 112, 125, 140, 160, 180, 200, 224, 250, 280, 315, 355, 400, 450,
500, 560, 630, 710, 800, 900, 1000, 1120, 1250, 1400, 1600, 1800, 2000, 2240, 2500, 2800, 3150,
3550, 4000, 5000, 5400.

The first six sizes (20 to 36 mm) are used for V-belts only.

ii. Width of pulley

If the width of the belt is known, then width of the pulley or face of the pulley (B) is taken 25%
greater than the width of belt.

∴ B = 1.25 b
B=1.25(85)
B=106.25mm

Page | 51
Where
b = Width of belt. According to Indian Standards, IS: 2122 (Part I) – 1973 (Reaffirmed
1990) , the width of pulley is fixed as given in the following table:

Table 19 Standard width of pulley

Belt width in mm Width of pulley to

be greater than Belt
width by (mm)
13
up to 125
25
125-250
38
250-375
50
475-500

The following are the width of flat cast iron and mild steel pulleys in mm: 16, 20, 25, 32, 40, 50,
63, 71, 80, 90, 100, 112, 125, 140, 160, 180, 200, 224, 250, 315, 355, 400, 450, 560, and 630.
iii. Thickness of pulley
The thickness of the pulley rim (t) varies
𝐷
From 200
+ 3𝑚𝑚 for single belt and
𝐷
200+ 6𝑚𝑚 for double belt.
Therefore, the thickness of the driver pulley is
𝐷
= + 3𝑚𝑚
20
0
12 + 3 = 4.25𝑚𝑚
5
=
20
0
The thickness of the driven pulley is
𝐷
= + 3𝑚𝑚
200
257
= + 3 = 5.5mm
200
The diameter of the pulley (D) is in mm.

Page | 52
Dimensions of arms
(i) The number of arms may be taken as
 4 for pulley diameter from 200 mm to 600 mm and
 6 for diameter from 600 mm to 1500 mm.
Note: The pulleys less than 200 mm diameter are made with solid disc instead of arms.
The thickness of the solid web is taken equal to the thickness of rim measured at the center of
the pulley face. (720 „ A Textbook of Machine Design)
(ii) The cross-section of the arms(b & b/2)

The cross section of the arms is usually elliptical with major axis (a1) equal to twice the minor
axis (b1).

The cross-section of the arm is obtained by considering the arm as cantilever i.e. fixed at the
hub end and carrying a concentrated load at the rim end. The length of the cantilever is taken
equal to the radius of the pulley.

It is further assumed that at any given time, the power is transmitted from the hub to the rim or
vice versa, through only half the total number of arms.

3 aD
b = 2.94 √
4π

b = 40.57mm

Let

T = Torque transmitted,

R = Radius of pulley, and

n = Number of arms,

∴ Tangential load per arm,

𝑇
𝑊𝑇 =
𝑅 × 𝑛⁄
2

𝑊𝑇 = 1935.72𝑁

Page | 53
 Maximum bending moment on the arm at the hub end

2T
M=
n

For driver pulley

2 × 483.93Nm
M=
4

M = 241.97Nm

For driven pulley

M = 483.94Nm

And section modulus,

π
2
Z= × b1 (a1)
32
Z = 65,767.47mm3

(iii) Arms taper:

The arms are tapered from hub to rim.

The taper is usually 1/48 to 1/32. (A Textbook of Machine Design)

(iv) Radius of cross section of arms:

3b
r=
4
3 × 40.57mm
r=
4

r = 30.43mm

a) Dimensions of hub:

i. Diameter of hub

Page | 54
The diameter of the hub (d1) in terms of shaft diameter (d) may be fixed by the following
relation (A Textbook of Machine Design)

𝑑1 = 1.5𝑑 + 25𝑚𝑚

For driving pulley 𝑑1 = 27.25𝑚𝑚

For driven pulley 𝑑1 = 28𝑚𝑚

ii. Length of the hub,

π
L= ×d
2

For driving pulley L = 2.36mm

For driven pulley L = 3.14mm

Diameter of driver pulley is 125mm and Diameter of driven pulley is 257 mm.

RPM of Driver pulley is 1480 rpm.

We are calculating of Driven pulley using Equation of,

𝑁1𝐷1 = 𝑁2𝐷2

Where,

 N1 and N2 is RPM of pulley or

 D1 and D2 is diameter of pulle1y

Put Value N1, D1, D2 in Equation above

After put value we find rpm of Driven pulley is 720.

After rpm calculation we calculate torque for standard equation.

Driver pulley Torque is 483.917Nm and Driver pulley Torque is 994.72Nm.

Page | 55
 Figure 11 Pulley
3. V-Belt[4]
1) Selection of belt section
2) Selection of pulley diameter
3) Selection of center distance
4) Determination of nominal pitch length
5) Selection of load correction factor
6) Correction factor for arc of contact
7) Selection of service factor
8) Calculation of maximum power capacity
9) Determine of no of belts
10) Calculation of actual center
distance

11) Requirement
 Power to be transmitted: - 75kw
 Speed of driving wheel: -1480rpm
 Speed of driven wheel: - 720 rpm
 Diameter of driving wheel: - 235mm
 Center distance: - 800mm
 Service time: -?
Solution
Step 1: selection of belt selection [4]
Page | 56
  The selected belt type is c type b/c the power transmitted is
75kw. Table 20 V-belt

Step 2: according to (the above table)

Table 21 Recommended series & pulley diameter & tolerance

Given -125mm

𝑑2 𝑁1
𝑑1 = 𝑁2
𝑑2 1480
=
12 720
5

Page | 57
 1480×250
d2 = = 257mm
720

Step 3: selection of center distance (c = 800mm)

Step 4: Determination of nominal pitch length

[6]
(𝐷−𝑑) 2
L =2c+ 𝜋 (𝐷 + 𝑑) +
2 4𝑐

(257−125)2
L =2(800mm) + 𝜋 (257 + 125) +
2 4 (800)

=2205.2mm

For belt cross section c

Standardizing PGS value from [page 7.59-7.60] (table)

From standardizing the value (2205.2mm) is found between (2159-2286)

mm Nominal pitch lengths for type C will be 2342mm.

Table 22 Nominal pitch length for type C

Page | 58
Step 5: Selection of load correction factor: - According to [page

7.59] Belt cross section symbol C

Correction factor (Fc) = 0.91

Step 6: Correction factor for arc of contact - [page 7.68]

Arc of contact = 1800 －

𝐷−𝑑 ( × 600)
𝑐

257−125
= 1800 － ( 800𝑚𝑚 × 600)

= 170.50 ≈ 171o

Table: correction factor for arc of contact (Fd)

[9] V-v for 171 0 = 0.98

Fd=0.98

Page | 59
Table 23 Correction factor for individual service

Step 7: Selection of service factor [page - 7.69] [4]

Fα= Choosing medium duty

Fα=1.4

Step 8: Calculation of maximum power capacity [page - 7.62] [4]

Belt cross section symbol c type

Page | 60
 Kw= (1.47−0.08 − − 2.34 × 10−4 𝑠2) s
142.7

𝑑𝑒

Table 24 Formulae for transmitting capacities [4]

S =?

De=?

𝑑𝑁 𝜋 (125) (1480)
S=60 × 1000= 60 × 1000

=0.0097 𝑚
𝑠

𝐷 257
[𝐹𝑏 = = = 2.056] Therefore according to the table reading Fb = 1.13
𝑑 125

De= d× Fb= 125mm× 1.13

=141.25mm

But from the table: Maximum value of de = 300mm,

Page | 61
 Kw= (1.47−0.08 − − 2.34 × 10−4 (0.0097 ) ) (0.0097 )
𝑚 2 𝑚
142.7
𝑠 𝑠
300

= 48kw

Step 9: Determine no of belt

𝑃 ×Fα
Number of belt = 75 𝑘𝑤 ×1.4
𝑘𝑤 𝐹𝑐 𝐹𝑑
= (48 ) (0.91) (0.98)

=2.54 ≈ 3

Step 10: Actual center distance

C=A+√𝐴2 − 𝐵

𝐿 𝐷+𝑑 2342 257+125

A=4 − 𝜋 8 = 4 −𝜋 8

=533.69mm

(𝐷−𝑑) 2 (257−125)2
B= 8 = 8

=2178mm

Therefore, C =A+√𝐴2 − 𝐵= 533.69+√ (533.69)2 − 2178

= 1,065mm

Design for length of open belt drive

Page | 62
Figure 12 Open belt drive [4]

D and d = diameter of the larger and smaller pulleys

C= distance between the center of two pulley (i.e. o1

o) L = total length of the belt

Formulas
(𝑟1−𝑟2).....................
L =π(r1＋r)2 ＋ 2c ＋ (in terms of pulley radii)
𝑐
(d1−d2)2.......................................
L=π (d1 + d2) + 2c + (In terms of diameter)
2 4c

The Accorded values from the above calculation

D 2=257mm
d1=125mm
Center distance (C) = 1200mm
Solution
(d1−d2)2
L=π (d1 + d2) + 2c +
2 4c
(257−125)2
= π (257 + 125) mm + 2(1065mm) +
2 4(1065)

= 2734mm =2.4m

4. Design of Circular shaft [2]

Material Used for Shafts
The material used for shafts should have the following properties:
1. It should have high strength.
2. It should have good machinability.
3. It should have low notch sensitivity factor.
4. It should have good heat treatment properties.
5. It should have high wear resistant properties

The shaft is design based on strength and rigidity criteria.

Let

Page | 63
 τ = Shear stress induced due to twisting moment, and

σb = Bending stress (tensile or compressive) induced due to bending moment.

According to maximum shear stress theory, the maximum shear stress in the shaft,
1
𝑟 = √𝜎2 + 4𝑟2
𝑚𝑎𝑥 𝑏
2
𝜋
𝑇𝑒 = √𝑀 + 𝑇 =
2 2
∗ 𝑟 ∗ 𝐷3
16

Where, at the section under consideration:

τ=Allowable combined shear stress for bending and torsion

=40MPa for steel shaft with keyway.

Mb=Bending moment (Nm)

T=Torsional moment (Nm) = 994.7183

D=Diameter of solid shaft

The bending load is due to the weight of the pulley, the summation of Tensions on the belts
acting vertically downward, and the weight of the threaded shaft

 Torque transmitted by the shaft,

P × 60
T=
2πN
75000 × 60
T=
2 × π × 720

T = 994720N_mm

Let T1 and T2 = Tensions in the tight side and slack side of the belt on pulley A. Since the
torque on the pulley is same as that of shaft (i.e. 994.720 × 103 N-mm), therefore are

T
1
2.3log ( ) = μθ
T
2

Page | 64
 29.875 π
) = 0.25 × 145 × ⁄180O
O
Log (
T2 2.3

29.875
𝑇2 = 1.884

𝑇2 = 15.86𝑁

∴ Total vertical load acting downward on the shaft at A

𝑇1 + 𝑇2 + 𝑊𝐴

= 29.875 + 15.86 + 63.765

= 109.5N

Assuming that the torque on the blade B is same as that of the shaft, therefore the tangential force
acting vertically upward on the blade B,

𝑇
𝐹𝑡 =
𝑅𝐵

967.87 × 103𝑁𝑚𝑚
𝐹𝑡 =
64𝑚𝑚

𝐹𝑡 = 15,122.97𝑁

 Taking moments about E, we get

𝑅𝐷 × 100 = 109.5 × 0.5 + 15196.545 × 0.34 + 0.5 × 19357.4

𝑅𝐷 = 149002.753𝑁

 For the equilibrium of the shaft

𝑅𝐵 + 109.5 = 𝑅𝐷 + 19357.4

𝑅𝐵 = 168,250.653𝑁

We Know that B.M. at A and B

=0

Page | 65
B.M at D
= 109.5 × 0.4 + 15,196.545 × 0.24

= 3,690.97Nmm

B.M at E
= 0.5 × 19,357.4

= 9,678.7Nmm

 The bending moment is maximum at E

∴ Maximum B.M M = MD = 9,678.7Nmm

 The equivalent twisting moment,

𝑇𝑒 = √𝑀2 + 𝑇2

𝑇𝑒 = √9,678.72 + 994,7202

𝑇𝑒 = 9,726.97𝑁𝑚𝑚

 The equivalent bending moment,

1
𝑀𝑒 = [𝑀 + √𝑀 + 𝑇
2 2

𝑀𝑒 = 9,702.837 𝑁⁄
𝑚𝑚2

 Allowable shear
stress;
τu
τ=
F. S
500
τ= = 83.3 N⁄
6 mm2

 The allowable tensile

stress
𝜎𝑡𝑢
𝜎𝑏 =
𝐹.
𝑆

Page | 66
 700
𝜎 = = 116.7 𝑁⁄
𝑏
6 𝑚𝑚2

 The Diameter of shaft from the equivalent twisting moment,

𝜋
𝑇𝑒 = 16× 𝑟 × 𝑑
3

d = 23.98mm

 The diameter of shaft from equivalent bending moment

𝜋
𝑀𝑒 = × 𝜎𝑏 × 𝑑
3

32
d = 27.3mm

 Taking the larger of the two values, we have

d = 27.3mm says 30mm

We design 1m length of MS circular shaft. Total Weigh of shaft is 3.85Kg.

Figure 13 shaft

5. Motor

 Model no : YE3-280S-4  Ac voltage: 380/400v

 Type: Asynchronous motor  Speed of motor is 1480rpm.
 Phase: three phases
 Output power: 75 kw

Page | 67
 Frequency: 50Hz

Figure 14 motor

6. Design procedure for rack and pinion

1. Select the material 5. Calculating the sliding velocity
2. Calculate center distance 6. Correcting compression stress
3. Calculation of axial module 7. Determine of induced stress
4. Revise a and obtain d1 8. Check the efficiency
9. Design of pinion

Solution
Step 1: select the material (page
8.45)
Rack - cast iron
Pinion - cast iron
𝑁
σu < 390
𝑚𝑚2
𝑁
σb =30
𝑚𝑚2 Rotation in one direction only)
(

Page | 68
Table 25 Design bending stress

Step 2: calculate center distance (page 8.44)

i. No of teeth on rack
Desired μ=0. 87
Z = 3 and 4
Z=3

 Velocity ratio i=18:1 (due to full rotation (complete revolution) 360o and the pinion
turning in degree is 20o)
i=360= 18
20

ii. Z= i z = 18×3
= 54

Page | 69
iii. Check whether Z lies between 25 and
85 So Diameter factor (q) = 11 [page
8.45]
𝑚
iv. Assume Vs =3
𝑠
𝑁
[σc = 159 ]
𝑚𝑚2

v. Assume initially Kkd =1 ( average person can produce 50 to 150 watt )

2 𝜋𝑁𝑀𝑡
vi. P = 60

𝑃 ×60 150 𝑊 × 60
Mt= 2𝜋𝑁 = 2(45.5 𝑟𝑝𝑚)
= 31.5 Nm
Design torque
[M t] = ko. Kkd. Mt
= 1. 1 (31.5 × Nm)
= 31.5 × 103 Nmm
Center distance formula

𝑧 2
540 [𝑀𝑡]
3
a= ( + 1) √ (𝑧 ) (To convert all the units in to one particular type (10) is added)
𝑞 [𝜎𝑐] 10
𝑞

54
+ 1) 3
2
540) [31.5 ×103]
=(
11 √ [159]
10
(54
11

= 67.76mm
Step 3: calculation of axial module [page 8.43]
2𝑎 2(67.76 𝑚𝑚)
= =
Mx = 2.1
𝑞+𝑧 (11) + (54)

Standard the module from [page 8.2]

Mx= 2.5mm

Page | 70
Table 26 Recommended series of modules

Step 4: revise a and obtain d1

𝑚𝑥 (𝑞 + 𝑧)
a= 2 2.5 (11 + 54) = 81.25
= 2

Pitch circular diameter of rack [page 8.43] (formula)

d1=q (mx) = 11(2.5)
= 27.5mm
Step 5: calculating the sliding velocity (formula)
𝑉1
Vs=
Cos 𝛾 [Tan γ = 𝑧
= 3
=0.2727
𝑞 11

γ = tan−1(0.2727) = 15.25o]
𝑚
1.18 𝑚
Vs= 𝑠 = 1.22 × 10−3 Lead
Cos [15.25] 𝑠

V 1= pitch line velocity of rack

𝑚
𝜋 𝑑1 𝑁1 𝜋 (27.5𝑚𝑚) (819 𝑟𝑝𝑚) = 1.1793 × 10−3
= 60 ×1000 = 60 ×1000 𝑠

Page | 71
Table 27 Formula based on surface stress [4]

Step 6: correct (σc) for actual VS [page 8.45] since VS < 4

𝒎 , the [σc] is correct revise k, Kkd
𝒔

And [Mt] for actual pitch line velocity of the pinion

𝑟𝑝𝑚 (𝑟𝑎𝑐𝑘 𝑠𝑝𝑒𝑒𝑑) × 𝑙𝑒𝑎𝑑

V2= 60 × 1000
Page | 72
 (819 𝑟𝑝𝑚) × (2 𝜋 𝑚𝑥) (819 𝑟𝑝𝑚) × (2 𝜋 =0.2144 𝑚
= 60 × 1000 =
×2.5) 𝑠
60 × 1000
Since V2 = 0.2144 < 3𝑚 , Kkd =1
𝑚
𝑠
𝑠

[Mt] = k. Kd. Mt= 31.5 Nmm

Step 7: Determine of Induced stress [σb and σc]

(Formula)[4]
540 𝑧 3 54
σc = √ [𝑞+ 1] 540 +1 3
𝑧
𝑀𝑡 = √ [ 11 ] 31.5 × 103
54
𝑎 (81.25) 10
10 11
𝑞

𝑁
= 121.11
𝑚𝑚2

Therefore 121.11 𝑁
𝑁
𝑚𝑚2 < [σc] = 159
𝑚𝑚2
1.9 [ 𝑀𝑡]
σb = 𝑚𝑥3 (𝑞) 𝑦 (z= 54...................yv = 0.490
1.9 [31.5 × 103 𝑚]
b
σ = (2.5)3 (11) (0.49) (54) = 13.16 𝑁
𝑚𝑚2
𝑁
Therefore 13.16 𝑁
𝑚𝑚2 < [σb] = 30 (Both are satisfied)
𝑚𝑚2

Step 8: check the efficiency [page

8.49] tan 𝛾
μ=
Tan (𝛾 =15.25o and p=friction angle degree)
(𝛾+𝑝)

Tan 𝑝= 0.03
P=tan−1(0.03) = 1.72o
tan 15.25
μ =tan = 0.89%
(15.25+1.72)

Page | 73
Figure 15 Efficiency of worm gear Drive [4]

Basic dimension
Rack:

L= (12.5 +0.09 Z) mx

Page | 74
 = (12.5 + 0.09 (54) (25)

= 434mm

L 1= L + 35 (GA) [page 2.12]

= 434 + 35(2)

= 504mm

Figure 16 Length of the worm [6]

Page | 75
Figure 17 Case depth vs Module graph
𝐿1
No of thread on the rack =
𝜋 𝑚𝑥 504
= 𝜋 (2.5)

= 65

Actual length of rack = 65 ×π × 5 = 1021 .0mm

Pitch diameter of rack = 27.5mm

Tip diameter (da) = d1 + 2mx

= 27.5mm +2(2.5)

= 32.5mm

Root diameter (df1) = d1 - 2mx - 2c

=27.5 - 2(2.5) - 2(0.3× 2.5)

= 24mm

Page | 76
Design of pinion

Face width of the pinion

b=0.75 d1

= 0.75(27.5)

= 21mm

Pitch circle diameter of pinion

d2=Z mx

= (54×2.5)

= 135mm

Tip diameter of the wheel

da2= (Z+2) mx

= (54+2)2.5

= 140mm

Root diameter pinion

df2= (Z-2) mx - 2c

= (54-2) (2.5) - 2(0.3)

=129.4mm

7. Buckling calculation [1]

Buckling load

The load, at which the column just buckles, is known as buckling load (critical just or crippling
load). The buckling load is less than the crushing load column. Actually, the value of buckling
load for long column is low, whereas for short column the value of buckling load is relatively
high.
Page | 77
End conditions for column

Page | 78
1) Both the ends of the column are hinged (or pinned)

2) One end is fixed and the other end is free

3) Both the ends of column are fixed

4) One end is fixed and the other is pinned

Table 28 leg on the project is both ends are fixed [1]

Cripple load when both the ends of the column are hinged

Assumption made in the Euler’s column theory

1. The column is initially perfectly straight and the load is applied axially

2. The cross - section of the column is uniform throughout its length

3. The column material is perfectly elastic, homogeneous and isotropic and obey Hooke’s law

4. The length of the column is very large as compared to its lateral dimension

5. The direct stress is very small as compared to bending stress

6. The column will fail by buckling alone

7. The self- weight of the column is negligible expression for cripple load when one end of the
column is fixed and the other end is free.

Page | 79
E= Young’s modulus

P= crippling load

I = moment of Inertia

l=length of column
Formula for both ends of the column are hinged

P=

The selected Column material is mild steel: - its properties are on below table
Table 29 Properties of mild steel

Name Mild steel

Phase at STP Solid

Density 7850

Ultimate tensile strength 400 550 MPa

Yield strength 250 MPa

Young’s modulus of elasticity 200GPa

Brinell hardness 120 BHN

Melting point 1450 oc

Thermal conductivity
50

Heat capacity
510

Page | 80
 Moment of inertia for rectangular beam

Figure 18 Moment of inertia for rectangular beam [14]

For rectangular beam moment of inertia

b=70mm
d=70mm
Moment of inertia of the section about x-x axis

= 2.000833 × mm3
Moment of inertia of the section about y-y axis

= 2.000833 × mm3

Since IXX and Iyy are the same, the column it will tend to buckle in both direction,
and the value of I will be
I = 2.000833 × mm3
Therefore

P= = 0.0044799 × 109 = 44,799,978.972 N =44.8 MN

Page | 81
Page | 82
 CHAPTER FIVE

5. RESULT AND DISCUSSION

5.1 Results

5.1.1 Analytical (hand calculation) analysis result

Using analytical data, analytical analysis assures the material's safety. In Chapter 4, the major
components that require safety assurance were estimated. The table below shows the overall
numerical result.

Part Part name Dimension Selected material remark

no.

1 Rotary blades di=200mm Hard steel 𝜎𝑡 = 0.961MPa

do=10mm 𝜎𝑟 = 0.572𝑀𝑝𝑎
t=1mm

2 Main shaft d=2mm Mild steel τ = 83.3 N⁄

mm2
𝜎𝑏
= 116.7 𝑁⁄
𝑚𝑚2
FOS=6
𝑵
3 Spur gear d=128mm Case hardened alloy steel σc= 982.8
𝒎𝒎𝟐
𝑁
𝜎 = 282
𝑏 𝑚𝑚2
𝑁
4 Rack & pinon Cast iron 𝜎 = 13.16
𝑏 𝑚𝑚2
d=70mm
σ
=121.11 𝑁
L=1305mm c
𝑚𝑚2

5 Driver pulley d=125mm Cast iron

6 Driven pulley d=257mm Cast iron

7 Bolts d=10mm Carbon steel 𝜎𝑡 =365.7MPa

FOS=1.7

Page | 83
5.2. DISCUSSION

The most crucial priority for an engineer is safety. Stress analysis of metal sheet cutter
components ensures the machine's longevity and safety.

Based on numerical data and material parameters, a safety check is performed, and the material
is deemed safe. Safety can be assured if the primary shaft component is designed to a specific
size and material.

Failure of the rotatory blade to be manufactured with a specific dimension will not be an issue.
Also, the efficiency of Ac motor is calculated and based on actual power output it was possible
to find the centrifugal force acting on the blade.

Page | 84
 CHAPTER SIX

6. CONCLUSION AND RECOMMENDATION

6.1. Conclusion

The following findings were reached after doing various tasks:-

 This study focuses on the design and analysis of a multifunctional shearing machine that is
problem-solving, environmentally friendly, and does not require skilled people to operate, as
well as minimal initial and operational. This project is beneficial in reducing human labor
work.

 Major components such as main shaft, belt and pulley, gear, circular blade of force and
stress analyses were meticulously performed using manual calculations and solid works
simulation.it can be concluded from this section that the design is safe.

6.2 Recommendations

By designing this machine that can have standard component and other small unknown issues
that could only be found and fixed if a machine were built in Manufacture Company and further
time was spent on design and testing. Ideally, other designers would look at this model and
design determines a plan for the constructing of our design in manufacturing company level.

6.3 Future scope in future

This project can be improved to cut other metal types. The advanced shearing mechanism,
shearing material, and associated gear were utilized in this project.

As a result, this study is limited to a few scenarios; however, this paper can be expanded to
include the situations stated below.

 If the cutting capacity grows, all sections of the cutting accessories will be modified and
designed accordingly.

 This machine can be designed to be fully automatic for the sake of reducing labor force

Page | 85
 REFERENCES

[1] Strength of material by RK Bansal

[2] Machine design by R.S. Khurmi and J.K. Gupta

[3] Shigley‘s mechanical engineering design 15th edition by Richard G. Budynas and J. Keith
Nisbett

[4] Design data book of engineers by PSG COLLAGE OF TECHNOLOGY

[5] Hand book of mechanical engineers

[6] Designing of the rack and pinion gearbox for all terrain vehicles for the competition
BAJA SAE INDIA.

[7] Md Inaithul Rehaman, P Satish Reddy, Matta Manoj, N.Guru Murthy,” Design and
Analysis of Progressive Die for Chain Link Plate”, International Journal of

Science Engineering and Advance Technology, IJSEAT, Vol 2, Issue 11, ISSN 2321-6905
November- 2014.

[8] Ch.Mastanamma, K.Prasada Rao, Dr. M.Venkateswara Rao,” Design and Analysis
of Progressive Tool”, International Journal of Engineering Research &

Technology (IJERT) Vol. 1 Issue 6, August - 2012

ISSN: 2278-0181.

[9] Cyril Donaldson, George H LeCain, V C Goold, Tool design 3rd edition, Tata McGraw-Hill
Education, New Delhi.

[10] Jyothi Bhaskar, G Sathya Prakash,” Die design and analysis of progressive tool for can
lid lever”, IJREAT International Journal of Research in Engineering &

Advanced Technology, Volume 1, Issue 4, Aug-Sept, 2013 ISSN: 2320 – 8791.

[11] Ashwinchopane, shanugupta “Design and analysis of plastic gears in rack and
pinion steering system for formula supra car” materialstoday, vol.5, issue 2,

Page | 86
March 2018.

[12] Ajay M, Sanket P, “Design of rack and pinion steering for all terrain vehicle”
international research journal of engineering and technology” vol.6, issue 2, Feb 2019.

[13] DipalkumarKoladia, “Mathematical model to design rack and pinion Ackerman

steering geometry” international journal of science &

Engineering research, volume 5, issue 9, September 2014.

[14] Knight WA, Boothroyd G. Fundamentals of Metal Machining and Machining tools.
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 Appendices

Appendix 1: Shearing Machine for straight and circular profile Questionnaires

1. How many operators are there to operate?

2. How many meters of sheet metal can be cut per day?

3. What problems do you face while shearing the sheet metal?

4. Does the machine need skilled man power to operate?

5. How much labor force do the machine needs to operate?

6. Do you get enough of spare parts around your place?

Yes No

7. Is the machine helpful for other operation?

Yes No

8. Does the machine give you good cutting quality?

Yes No

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9. Do you get the machine helpful than manual cutting process?

Yes No

10. Does the machine save your time?

Yes No

11. What is the main problem with the machine?

12. Which parts of the machine have a problem of failure?

13. Do you have easy solutions for the problems of the machine?

Page | 89
Appendix 2: Bill of material

Item Part number Material QTY.

No.

1 RHS 1 Mild steel 1

2 RHS 2 Mild steel 1

3 RHS 3 Mild steel 2

4 Main shaft Mild steel 1

5 Ac Motor 1

6 M10 Bolt Plain carbon steel 6

7 M20 Bolt Plain carbon steel 6

8 M20 Nut Plain carbon steel 6

9 Knife type Blade High carbon steel 2

10 Driven Pulley Cast iron 1

11 Driving Pulley Cast iron 1

12 Spur Gear Case harded alloy 2

steel

13 Rack and pinion Gear Cast iron 1

14 V - Belt Rubber 3

15 Handle Mild steel 1

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 16 Key Mild steel 5

17 Roller Bearing Stainless steel 2

Appendix 3: Concept Screening Matrix

Concept
Selection criteria adjustable Tool Stationary Reference foldable Lay Foldable seat
head rest storage Feet ram flat

accuracy + + + 0 0 0 0

Cost 0 0 _ 0 0 _ 0
effectiveness

Durability + _ 0 0 + _ 0

Manufacturability + + 0 0 0 + +

Strength 0 + _ 0 0 _ 0

Sum +’s 3 3 1 0 1 1 1

Sum 0’s 2 1 2 5 4 1 3
0 1 2 0 0 3 1
Sum –’s
Net Score 3 2 -1 0 1 -2 0

Rank 1 2 5 3 6 4
Yes Yes No Combine Yes No Yes
Continue?

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 Appendix 4: Concept Scoring Matrix

Selection Concepts
criteria
Adjustable Tool storage Reference foldable ram Foldable seat
head rest

Weig Ratin Weigh Ratin Weigh Ratin Weigh Ratin Weigh Ratin Weigh
ht g ted g ted g ted g ted g ted
score score score score score
accuracy 20 4 0.8 3 0.6 3 0.6 3 0.6 3 0.6

Cost 15 3 0.45 3 0.45 3 0.45 3 0.45 3 0.45

effectiveness
Durability 25 4 1 3 0.45 3 0.78 4 1 2 0.5

Manufacturabili 20 4 0.8 4 0.8 3 0.8 4 0.8 2 0.4

ty
Strength 20 4 0.8 4 0.8 3 0.8 4 0.8 3 0.6

Total score 100 3.85 3.1 3.43 3.65 2.55

Rank 1 4 3 2 5

Continue? Yes Yes Yes No

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Appendix 5: Relative Importance of Need

Importance 1-5
1 2 3 4 5
Questions

 The shearing machine increased speed, safer cutting methods

and a cleaner work space.
 The shearing machine can creates clean cuts with smooth
edges.
 The shearing machine are going to let you cut the sheet in
straight and circular shape
 The shearing machine can be performed on sheet metal in a
variety of diameter sizes.
 The machine can be cost-effective for high-volume
manufacturing applications.
 Doesn't produce waste in the form of chips.

 replacing blades

1- Feature undesirable
2- Feature not important, but would not mind having it
3- Feature nice to have, but not necessary
4- Feature highly desirable, but not critical
5- Feature critical, would not consider without it
Rating

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Appendix 6: Marginal and Ideal value

No. Metric Metric unit Ideal value Marginal value

1 Human force applied

2 Blade maximum to 𝑁 2-15 0.961-14

minimum strength 𝑚𝑚2

3 Blade rotational speed rpm 1480 -

4 Mass of the cutter Kg 0.863 0.820

5 The maximum height of m 1.50 1.50

the machine

6 The minimum height of M 1.42 1.45

machine

7 The width of the M 2 00 2.10

machine

8 Ac motor specification V , rpm 380v , 1480 380v , based

rpm on the
available

9 Source voltage V 380 400

Page | 94
Page | 95