automaticsheet metal cutting machine, a final year engineering project for small scale indutries.Includes design aspects and mechanism

1. INTR0DUCTION
 Nowadays, technological development demands efficiency of time and
energy in all fields in order to create a product that can compete in the
global market.
 Breakthrough innovations are needed to survive in global market.
 We all know about sheet metal working processes.
 Sheet metal contributes a wide range of applications in many industries,
one such example is automobile and aerospace industries.
 Also it is known that sheet metal has sharp edges which may tear off the
skin while working on it.
 Hence to avoid such kind of situation we have designed a automatic sheet
metal cutting machine.
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2. SHEET METAL MATERIALS
 Black Iron
 Galvanized Iron
 Copper Sheets
 Aluminium Sheets
 Tin Plates
 Stainless Steel
 Brass
 Lead
 Zinc
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3. Machines available in market
 Rack and pinion operated
 Pneumatically operated
 Hydraulically operated
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Fig 1 RACK AND PINION SHEARING
MACHINE
Fig 2 PNEUMATICALLY OPERATED
MACHINE
FIG 3 HYDRAULICALLY OPERATED

4.  It is observed that working with sheet metal is a tedious job for a
worker as it may tear of the skin of the worker.
 This machine is designed to overcome the above problem and to
reduce the labour cost.
 As it is said automatic, here the sheet metal role is fed at the sheet
metal holder and the machines automatically cuts the sheets for a
predetermined length.
 The machine works on 12 volt dc supply hence the power
consumption for the machine is less.
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4 ROLE OF OUR PROJECT

5. Objective
 The main objective is to design and fabricate the sheet metal
cutting machine for the mechanical basic workshop.
 To minimize human effort.
 Minimum power consumption.
 Implementing automation to reduce the time.
 For precise operation of cutting.
 To provide automation so as to reduce labor cost.
 To obtain perfect finished cutting edges on the sheet.
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6. Components Of Machine
The main components of the machine are:
Frame
Blades
Conveyor
Motors
Crank and link mechanism
Electronic circuit
Sensor
Battery
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7. PROCESS CARRIED OUT
• Sheet metal role
fed from the
holder
conveyor
• The conveyor
stops
• Blade motor
sensor
• The blade carries
the cutting
operation
Cycle repeats
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8. DEVELOPMENT OF IDEA
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9. PRELIMINARY DESIGN
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BLADE MOTOR
CAM
CONVEYOR
MOTOR
FRAME
CONVEYOR
BLADE

10. FINAL DESIGN
1. FRAME
2. BLADE
3. CONVEYOR
4. MOTOR
5. SWICH BOX
6. CRANK AND LINK
MECHANISM
7. SHEET METAL HOLDER
8. SENSOR
9. BATTERY MOUNTING
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3
8
6
7
45
2
1
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11. 2D VIEWS
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Side view Isometric view

12. CATIA MODELING
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FINAL DESIGN [CATIA MODEL]

13. DESIGN AND CONSTRUCTION
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14. FRAME
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 The rigid frame is fabricated by arc welding
 Cast-iron c-member is been used to build this
frame
 Dimensions:
 Length L: 1000mm
 Width B: 650mm
 Height H: 750mm
 Function:
 To provide a rigid support and mounting facility for
various components, to provide a safety and to
absorb vibrations made by blade and motor.

15. UPPER BLADE [MOVING BLADE] :
 It is pivoted to crank and link mechanism so as to obtain a
cutting forces transmitted by a link.
 Grinding operation is done on the blade surface to obtain
perfect mating between two blades
 An angle of 8 degree is provides to get a sharp edge
 Dimensions:
 Length L =731.5mm
 Width B =71.2mm
 Thickness T= 10mm
 Function:
 To obtain a cutting operation
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Figure 1 UPPER BLADE [CATIA MODEL]
Figure 2 FRONT VIEW

16. LOWER BLADE [STATIONARY BLADE]:
 Grinding operation is done on the blade surface to obtain
perfect mating between two blades
 It is fixed to the frame rigidly
 Dimensions:
 length L = 670.5mm
 Width B= 71.2 mm
 Thickness T= 10mm
 Function:
 To provide a sharp cutting edge
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Figure 1 LOWER BLADE
Figure 2 FRONT VIEW

17. CONVEYOR:
 It is assembled to the frame with the help of
fasteners.
 It is an assembly of plumber blocks, pvc
pipes, and rubber mat
 specifications:
 Length: 280 mm
 Width: 406 mm
 Speed: 4 m/min
 Function:
 To feed the sheet metal to the predetermined
length.
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18. Figure 5.4.2 PVC ROLLER
Pipe 1
Reducer coupling
Pipe 2
Conveyor assembly
 PLUMMER BLOCK:
 Internal diameter =25.4mm
 Function:
 To provide a mounting for a conveyor and to provide
frictionless rotation to rollers.
 ROLLERS:
 Pipes
1. Diameter =19.05mm
 Function: To connect reducer coupling to the Plummer block
2. Diameter =38.1mm
 Function: It helps to roll the mat over this pipe.
 Reducer coupling
 Outer diameter =25mm
 Inner diameter=47mm
 Function: It helps to connect the Plummer block and
roller pipe.
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Figure 1 PLUMBER BLOCK

19. MOTORS
 Two motors are being used in this machine, one for the
conveyor and second for the blade movement
 specifications:
 DC motor
 Voltage: 12V
 Power: 17 watts
 Current: 7.5Ah
 Speed: 60rpm
 Functions:
 First motor is used to operate the conveyor belt with suitable
arrangement.
 Second motor is used to drive the crank and link mechanism,
which interns drive the upper blade to perform cutting
operation of a sheet metal.
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Figure 2 WIPER MOTOR
Figure 1 WIPER MOTOR [CATIA MODEL]

20. Motor Calculation:
 Torque obtained:
 T= 60*P/2πN where; P= power of motor
 T=
60∗17
2𝜋∗60
N=speed of the motor
 T=2.7056 N-m
 Force obtained:
 F=T/R R= Radius of the crank
 F=
2.7056
0.1
= 27.05N
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21. LINK
Dimensions:
Length =259mm
Diameter =12mm
 Function: To connect crank and blade, and also helps to convert
rotary motion of the motor to reciprocating motion
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Figure 1 LINK
CRANK
Dimensions:
Length =172mm
Diameter =12mm
 Function: To convert the rotary motion of the motor into
oscillating motion of the link
Figure 2 CRANK

22. FIGURE 3 sensor
Figure 2 sensor isometric view
SHEET METAL
HOLDER
 It is a device which senses the sheet and sends the
signal to the controller.
 It is mechanical contact type sensor
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Figure 1 sheet metal holder
SENSOR
 Dimensions
 Length =555mm
 Diameter of the rod= 6mm
 FUNCTION:
 To hold the sheet metal roll

23. ELECTRONIC CIRCUIT
 RELAY
 A relay is an electrically operated switch
 Relays are used where it is necessary to
control a circuit by a low-power signal.
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24. ELECTRONIC CIRCUIT
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R2 R3
R5
R1
R4
BATTERY
M2
M1
MOTOR 1 SENSOR
MOTOR 1
OFF
MOTOR 2
ON
MOTOR 2
OFF
RELAY 3
NC
CYCLE
REPEATES
[WHERE]
R4 AND R5 IS USED
FOR AUXILARY
SWITCHING

25. APPLICATIONS
1. Can be used in various institutions, mechanical basic
workshop.
2. Can be used in hardware shops to provide service to the
customers.
3. By increasing length of blade the machine can be used in
various automobile industries.
4. Can be used in printing presses for cutting of paper.
5. Can cut aluminum foil, sun mica etc.
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26. ADVANTAGES AND DISADVANTAGES
 ADVANTAGES
 Easy to maintain and repair.
 Cost of the unit is less when compare to other machine.
 No fire hazard problem due to overloading.
 Comparatively the operation cost is less.
 Continuous operation is possible without stopping.
 Machine is mobile.
 Reduced labor charge.
 LIMITATIONS
 High torque cannot be obtained.
 There is a limitation for cutting width of sheet metal.
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27. SCOPE FOR FUTURE WORK
Microcontroller can be used to make it more versatile and to
achieve higher productivity.
Turning table can be provided to cut the sheets at a different
angle.
Increase cutting or shearing force by using powerful motors for
cutting thicker sheets.
DC adapter can be provided for direct AC power supply.
Sheet metal collecting box and packaging system can be
provided to make it ready for transportation.
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28. CONCLUSION
 When we say that it is automatic machine, we need to incorporate mainly the comfort in
usage of machine and the cost of the product.
 In this case it is necessary to make use of the product very comfortable, the cost of the
product is restrict below ₹ 15,000/-. Hence cost economic.
 Further the labour problem can be overcome as the machine can run for hours together.
 The sheet rolls once installed on the roller the cutting operation carries on automatically. In
other words no further human observation on the machine is required.
 The finished edges on the sheets are obtained by this machine.
 Also the length of the sheets to be cut can be adjusted as per the need. All these facts make
the machine very user friendly. This meets the objective of the project.
 The machine needs to be improved by implementing microprocessor so as to get faster
response of the system and the various sensors can be used so to sense the sheet metal. This
throws lot of scope for the improvement in future.
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29. REFERENCES
 Ajit Kumar Singh, Harpreet Singh and Dharmendra Sharma, “Design and Fabrication of Pneumatic
Auto Sheet Metal Cutting Machine Using Solar Energy”
 Bram Armunanto, Yudit Cahyantoro NS, Kaleb Priyanto (IJEAT), “A Circularity Analysis Of
Different Clearances In The Sheet Metal Punching Process”
 Dr. K.U Leuven “Research on sheet metal cutting machine construction”
 Indrajeet Chaudhary, Pradeshi Ram and Dinesh Kumar “Using Advanced Pneumatics Automation of
Conventional Sheet Bending Machine”
 Komanduri, R. “Machining and grinding: A historical review of the classical papers”
 Kerim Isik, Maria B Silva, Paulo AF Martins, and AE Tekkaya, Failure by fracture in sheet– bulk
metal forming “The Journal of Strain Analysis for Engineering Design,”
 Shubhkumar Bhandari “Methodology of Special Purpose Sheet Metal Cutting Machine”
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30. THANK YOU
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