CHAPTER.1

INTRODUCTION

The project work assigned here with us is of building a shearing m/c that is

capable of shearing PVC / plastic / rubber pipes up to 6 mm in dia. Also it is pre-

assigned work to furnish the same m/c along with an automation unit as previously

mentioned.

As simple layout and tricky operational enables this type of m/c to work

practically at low cost, low maintenance, low capital investment in less space. It may

be forecasted that in future this m/c may have its unparallel place in the industry

mentioned previously.

The work is carried out using MDF (Medium Density Fiber) core hardwood

plywood. Also some connecting components like studs are used the plunger is made

up of high density polymer pipe and the core of electromagnetic is made up of again

high density polymer pipe. Rest of the construction is made in MDF sheet cut to

requirement. It can be noticed that in the fabrication of the project many parts are

manufactured other than ferrous material. It is done so because ferrous is conductor of

magnetism and controller be magnetized very easily for avoiding the flux generated

for getting disturb with surrounding material. The mat in surrounding is used the non

ferrous. The only major component is the iron core which is needed to be made up of

ferrous to get attracted to electromagnet when live next part that is fabrication out of

ferrous is stud nut bolt. It is very necessary that for structural support that this part

should be made in strength and support for solving the problem. It has been allowed

to use ferrous material for the same. Also care have been taken to keep this ferrous

material part away from electromagnet as for as possible.

Whenever electromagnet is made live it sucks the iron core in between the

cavity of the Electromagnetic because of high flux generated. This iron core there by

pushes the plunger in the same direction which activates the cutter blade subassembly

forcing the same in the blade subassembly forcing the same in the direction of

material to be cut. This is simple procedure of cutting by this type of m/c.

Another part of the project includes development of automation unit for

running this m/c on automation mode for cutting the mat as per required. This part

include a Microcontroller a motor drives a relay driver etc.

CHAPTER.2

BACKGROUND

As various application for automation & machinery arise,

machinery is developed to meet the needs of the particular application .Recently there

has been an increase in the need for machinery which is small in scale. Small scale &

miniature machinery include the number of moving parts which can breakdown &

lubrication .Problem specific to miniature machinery include the difficulty of

lubrication on a small scale & the difficulty of adapting conventional size machines to

smaller scale. Another need exists for machinery of any size which can exhibit a fine

degree of adjustment. In many control system application accuracy of movement is

crucial & simple on-off control will not suffice. It is also desirable that any machine,

whatever its size, be efficient & require little or no maintenance.

CHAPTER.3

LITERATURE REVIEW

Mr. Scott Michael Golowin, B.S. The Ohio State University 2008 in his research

paper on “Path Actuators for Magnetic Pulse Assisted Forming and Punch-less

Electro-Magnetic Shearing” discussed that Electro Magnetic shearing offers a number

of advantages over traditional methods. It is much less equipment-intensive than laser

cutting or die cutting. It can deal well with very thin materials, whereas very precise

tooling is required to shear thin metals and can be very expensive. Also, there are

opportunities for integrating forming and shearing operations. Despite these

advantages, this method has not been well developed.

The Ohio State University research paper on “Punch-less Electro-Magnetic Shearing

(PEM)” resulted in the following preliminary conclusions. Electromagnetic shearing

capability for sheet metal cutting that should be cost effective and could find wide

application in both small precision applications, such as medical & micro devices, and

could also have significant applications in heavy-duty manufacturing, such as

automotive and truck manufacturing. The process can replace laser cutting of metal,

which involves large amount of capital investment and can also be applied to non-

metal cutting, such as foam. Furthermore, electromagnetic forming and cutting could

be integrated in a single step to save manufacturing cost. The work here will help

develop a new agile sheet metal shearing technique, for shapes not realistic by

conventional methods.

Hans Christian Orsted & Francis Bitter in his paper entitled “Electromagnets: Two

Forces Team Up” discussed that these electromagnets are called “resistive” magnets

because, as in any machine running on normal electricity, the electrons that make up

the current encounter resistance as they bump into atoms and other electrons along

their journey. This inefficiency costs when it comes time to pay the electric bill; in

fact, the Magnet Lab uses about 7 percent of the electricity consumed in Tallahassee,

a city of about 160,000 residents! If we didn’t have magnets to operate, our on-site

power source could light up some half-million 100-watt light bulbs – at the same

time! The Mag Lab also uses a considerable amount of water, which is forced through

the holes of the Bitter plates to prevent the magnets from getting too hot. So resistive

magnets eat lots of electricity and drink lots of water, two expensive habits. This is

where superconducting magnets, the next type of temporary magnet we will explore,

offer some advantages.

F. Bioul, R.Rolinsky, N.Van denBogaert, V.Regnier, F.Dupret in their research

paper on” Free surface Shear Flows Induced by alternating electromagnetic forces

Application to liquid bridges in micro-gravity& to floating zone presses” discussed

that besides Joulean heating and free surface deformation caused by the Lorentz force

normal component, an additional effect resulting from the generation of

radiofrequency alternating magnetic fields in the vicinity of electrically conducting

liquid components is the creation of a free surface shear flow. This effect is generally

undesired, but could be used to improve convection control in some applications such

as the Czochralski or Floating Zone semiconductor crystal growth process. The

electromagnetic field distribution in planar and axisymmetric configurations, which

provides equivalent magnetic forces and heat flux to be applied along the conducting

free surface.

J.Rodney Schexnayder in his research paper on “Electromagnetic Machine”

discussed that machinery is developed to meet the needs of the particular application.

Recently there has been an increase in the need for machinery which is small in scale.

Small scale & miniature machinery must be simple & reliable. Another need exists for

machinery of any size which can exhibit a fine degree of adjustment. In many control

system applications accuracy of movement is crucial & simple on-off controls will not

suffice. The machine of any size is efficient & requires little or no maintenance. These

all properties is give up by electromagnetic machine which uses electromagnetic force

to do work & particularly to device which use electromagnetic force to move

magnetically permeable particles, using the movement of those particles to do work.

Object of machine is to use electric current as its power source & provide a machine

with an extremely fine degree of adjustment.

Joseph Henry in his research paper on “Electromagnetism” discussed that an

electromagnet is a large inductor, and resists changes in the current through its

windings. Any sudden changes in the winding current cause large voltage spikes

across the windings. This is because when the magnet is turned on, energy from the

circuit must be stored in the magnetic field, and when it is turned off the energy in the

field is returned to the circuit. If an ordinary switch is used to control the winding

current, this can cause sparks at the terminals of the switch. Large electromagnets are

usually powered by variable current electronic power supplies, controlled by a

microprocessor, which prevent voltage spikes by accomplishing current changes in

gentle ramps. It may take several minutes to energize or deenergize a large magnet.

The factor limiting the strength of electromagnets is the inability to dissipate the

enormous waste heat, so higher fields, up to 90 T, have been obtained from resistive

magnets by pulsing them. The highest magnetic fields of all have been created by

detonating explosives around a pulsed electromagnet as it is turned on. The implosion

compresses the magnetic field to values of around 1000 T for a few microseconds.

Francis Woodward Jessop, of Cleveland, OHIO in his research paper on

“Electromagnetic Metal working Machine” discussed that relates to metal working

machines such as shearing, forming & compressing & more particularly to machines

in which the metal working operation is effected by single stroke get more

maintenance to reduce the prone of this machine an electromagnet is used which gives

significant applications in heavy-duty manufacturing & forming and cutting could be

integrated in a single step to save manufacturing cost.

CHAPTER.4

SUMMARY OF LITERATURE REVIEW

The industrial demands increases day by day toward

the simplification & more innovative creation of work in mass production. For such

type of qualities & flexibility in the manufacture only create by replacing the existing

machinery process layout for such type of machinery which reduce the labor cost

material increases production in sheet & tin plate like plants & pipe industries. The

automatic shearing or electromagnetic shearing process will be one of the feasible

solutions for them.

Electromagnet is used which gives significant applications in

heavy-duty manufacturing & other products but none of this uses the electromagnetic

force in a way which is simple, efficient & controllable to the degree dicer for such

work a simple machine which required only power to operate or produce the emf is

feasible instated of heavy load of electricity given to the machinery for such cutting

work. The advancement in manufacturing process in industry toward the convectional

Processing uses convectional machinery for manufacturing such as hydraulic,

mechanical & Pneumatic type for such machine working principal.

CHAPTER.5

SHEARING MACHINES

Mechanical power shears are self-contained machines with a ram that

moves a non-rotary blade (knife), at a constant rake, past the edge of a fixed blade to

perform shearing or cutoff operations. Shears may be mechanically, hydraulically,

hydra-mechanically, pneumatically, or manually powered and are used to perform

numerous functions such as squaring, cropping, and cutting to length. There are

various types of shearing machine which is used in industries for various purposes

some of main types of shearing machines are classified below.

5.1. MANUAL SHEARING MACHINES:

5.1.1. Foot operated Shearing Machine:

Foot Operated Shearing Machines and Treadle Shearing Machines are

essential in sheet metal industries as they have an edge amongst others on the basis of

adaptable design, stiff construction, and appearance. Such machines are specially

designed for quick and incessant cutting of steel sheets of varied widths and trimming

them in unlimited lengths. They come with some vital features and comprise high

tensile springs for quick return of treadle. They comprise four cutting edged hardened

and ground quality blades. With spring loaded sheet holding device, they are delight

to have and they also contain all steel fabricated construction body.

Figure No. 5.1. Foot operated Shearing Machine

MODEL CTS-0L CTS-1L CTS-2LL CTS-2L

Capacity Width

(mm)

305 450 610 650

Capacity

Thickness (mm)

1.25 1.00 0.90 1.20

Net weight

(Kgs.)

110 125 150 225

Dimensions (m) 0.61x0.6x0.92 0.76 x 0.69 x 0.92 0.92 x 0.69x0.92 1.10x0.69 x 1.00

Shipping

volume (m3)

0.39 0.49 0.59 0.76

Table No.5.1 Specifications of Foot operated Shearing Machine

5.2. HYDRAULIC SHEARING MACHINES:

Hydraulic Shearing Machine has wide applications. This Hydraulic Shearing

Machine inherits all the merits of Hydraulic Shearing Machine, enhanced by new

technology. Compared with other Shearing Machine, Hydraulic Shearing Machine

enjoys many advantages including: more reasonable structure, more compact

appearance, smoother operating, higher efficiency and is easy to operate and maintain.

Hydraulic Shearing Machine has wide adoptability, is an ideal Hydraulic Shearing

Machine for production.

Figure No. 5.2. Hydraulic Shearing Machine

5.2.1 Variable Rake Angle Hydraulic Shearing Machine:

It has Sturdy Welded Frame designed for maximum resistance to deflection &

Moving Beam is overdriven, with two cylinders operating in series for even cutting.

A monoblock DC solenoid valve ensures a smooth reversal hydraulic system & Rake

angle can be varied by pre-selection through a selector switch to permit shearing

higher thickness than normal capacity. Front operated, rake angle adjustment of 0.5 to

2.5 degrees allows the operator to set the optimum rake angle required to produce the

perfect cut with minimum twist and bow & Top beam is guided by four point roller

guides with replaceable hardened liners for minimum wear. The Quick and easy blade

clearance setting by calibrated levers & Individual hydraulic hold downs ensure

perfect cutting. The Shadow line indicator useful for cutting on scribed lines & Safety

finger guard allows the operator to safely cut the material close to the cutting edge

Precise and fast travel motorized back gauge with front readout is standard. It travels

over a range of 800 mm on precision lead screw .The low rake angle, correct knife

clearance and a rigid frame ensure bow free, camber free and twist free shearing.

Figure No.5.3 Variable Rake Angle Hydraulic Shearing Machine

Blade Rake Angle No. of strokes Motor Dimensions (m) Net

MODEL Length

(mm)

Variable

(Degree)

Rake Angle (kW) L x W x H Weight

(kgs.)max min

SVR 616 1600 0.5-2.5 12 20 7.5 2.15 x 1.7 x 1.8 4200

SVR 625 2650 0.5-2.5 12 22 11 3.05 x 1.7 x 1.8 5300

SVR 630 3150 0.5-2.5 10 20 11 3.55 x 1.7 x 1.8 6300

SVR 640 4150 0.5-2.5 12 22 15 4.60 x 1.7 x 1.9 8400

Table 5.2 Specifications of Variable Rake Angle Hydraulic Shearing Machine

5.2.2 Hydraulic Guillotine Shearing Machine (overcrank series):-

This machine is known for their modern designs and built to machine

tools standards. They are sturdy machines for robust construction in the design. With

careful attention to lubrication, blade and clutch adjustment they will give years of

trouble free service. Side Frame is of solid steel plates designed for maximum

strength and rigidity. The bed is of box type steel welded construction, additional rids

under the table adds to its strength. The rolling key is in two pieces made of EN-24

which is incorporated in the machine for ensuring easy and efficient working.

Pneumatically operated multi disc, friction clutch can also be offered. Upper Beam

(Cutter) is also of solid steel plates, carrying the upper knife. Its minimum weight

ensures lesser load on the bearings. The upper beam moves in fabric based Bakelite

guide plates to avoid deflections for smooth running and maintains the accurate

straightness of the knife. Steel fabricated spring loaded hold-down is provided for the

gripping of plates by means of plunger for effective gripping. Hydraulic hold-down

can also be provided. Drive is through v-belts on the flywheel and a chain of gears

made of cast iron, hob cut for smooth running and longer life. Constant spring loaded

adjustable brake is provided. In case of pneumatic clutch operated machine brake is

built-in. Single shot lubrication provided oil to all the lubrication points, where

necessary. Automatic Lubrications can be provided as an option. The rigid and

accurate construction of the back gauge provided with the machine ensures

parallelism in the widths of sheets being cut as per IS standards.

Figure No.5.4 Hydraulic Guillotine Shearing Machine

Model LSSCO-1 LSSCO-2 LSSCO-3

Shearing Length

Mm 2000 2500 3100

Shearing Capacity

Mm 8, 10- 13 8, 10- 13 8, 10- 13

Size of Blades

(Blade segments)

Mm 1015 x 100 x 22 1270 x 100 x 22 1050 x 100 x 22

Length of cut in

one Stroke Mm 2000 2500 3100

No. of Strokes per

minutes No. 40 40 30

Power Require Hp/rpm 15,20,25/1440 20,25,30/1440 20,25,30/1440

Floor Area L x B

x H approx

Mm 3000 x 2400 x

2400

3000 x 2400 x

2400

4100 x 2600 x

2600

Table No.5.3 Specifications of Hydraulic Guillotine Shearing Machine

5.2.3 Hydraulic Guillotine Shearing Machine (undercrank):

It has overall welded structure of the rack and the knife rest & is

equipped with the advanced integrated hydraulic system, which is of good reliability.

Blade gap adjustment is through a hand-wheel, rapid, accurate and convenient.

Rectangular blade, and the four blade cutting edge can all be used, thus to achieve a

long service life. Adjustable shearing angle to reduce the sheet distortion & equipped

with back gauge and digital displayer.

Figure No.5.5 Hydraulic Guillotine Shearing Machine (under crank)

MODEL

CUTTING

CAP. IN

M.S.

LENGTH x

THICKNES

STROKE

PER

MINUTE

FRONT

GUAGE

REAR

GUAGE

MOTOR

HP/KW

BLADE

LENGTH

x

WIDTH

x THICK

LENGTH

A

HEIGHT

B

MI - 1 1525 x 2 50 500 750 3/2.0

1525 x 63

x 12

2540 1525

MI - 2 1525 x 4 50 500 750 5/3.7

1525 x 63

x 12

2540 1525

MI - 3 2030 x 4 50 600 750 7.5/5.6

2030 x 63

x 12

3050 1525

MI - 4 2540 x 4 50 600 750 10/7.7

2540 x 75

x 16

3050 1525

Table No.5.4 Specifications of Hydraulic Guillotine Shearing Machine

5.3 MECHANICAL SHEARING MACHINES:

5.3.1 Light Duty Mechanical Guillotine Shear:

This machine has the low cutting angle and inclined shear direction reduces bowing

and twist to a minimum, Blade clearance is easily set by a manually operated quick

set device. It’s an ideal true-cut machining equipment of metal sheet and nonferrous

metal sheet. C.I body Supplied with built in finger guard with four edge blade &

double geared clutch type motor. Driven by motor with electromagnetic brake adopt

small shearing angle & inclined shearing direction blade clearance easily set by

manually operated quick set device.

Figure No.4.6 Light Duty Mechanical Guillotine Shear

MODEL CPS-4H

Capacity Width (mm) 1250

Capacity Thickness in M.S. 18 Gauge (1.20 mm)

Motor 2.0 H.P. Double Geared, Clutch Type

Net / gross weight (Kgs.) 700 / 800

Shipping dimensions (m) 1.63 x 0.88 x 1.18

Shipping volume (m3) 1.70

Table No.5.5 Specifications of Light Duty Mechanical Guillotine Shear

5.3.2 Mechanical Guillotine Shears (Overcrank):

Rigid steel frame of shears are optimally designed to avid weak sections at load

supports and is of interlocked design. The ram is guided throughout its length by

hardened and ground guide ways ensuring proper clearance and clean cut. Spring

loaded mechanical hold-down pads hold the sheets securely to avoid slipping and

bowing result in clean square cut. Hold down units is provided with oversize pads to

avoid impression on sheet metal. Shear is provided with Four Edge, single & segment

ally High Carbon, Chromium Steel Blades suitable for M.S. &.S.S. Cutting and Extra

long life. All bearing parts and guide surfaces are lubricated through centralize hand-

operated lubrication system. This is standard equipment provided on all Shears. Scale

on the back gauge gives instantaneous reading of distance between shear and back

gauge, thus avoiding errors and maintenance encountered in electronic equipment.

Fitted in front of hold-down for operator safety without obstructing viewing.

Electrical System consisting of motor & Control Panel of Starter, Gear and wheel

guard, V-Belts, Hand operated back gauge, Manual Lubrication System, T-slot front

gauge, Front scale gauge, instruction Manual.

Figure No.5.7 Mechanical Guillotine Shears (Overcrank)

MODEL ROC 4/6 ROC 5/6 ROC 6/6 ROC 8/6

Capacity in M.S.

Max. Length (mm):

Max. Thickness

(mm):

1250

6

1500

6

2000

6

2500

6

Number of Strokes /

min 50 50 50 50

Motor (HP): 7.5 10 12.5 12.5

Net weight (Kgs.) 3200 3800 5000 6000

Shipping dimensions

(mm) 2250x1450x2100 2550x1500x2100 2800x1600x2100 3300x1600x2100

Shipping volume(m3) 6.90 8.10 9.40 11.10

Table No.5.6 Specifications of Mechanical Guillotine Shears (Overcrank)

5.3.3 Mechanical Guillotine Shears under Crank:

Rigid steel frame of shears are optimally designed to avid weak sections at load

supports and is of interlocked design. The ram is guided throughout its length by

hardened and ground guide ways ensuring proper clearance and clean cut.

Spring loaded mechanical hold-down pads hold the sheets

securely to avoid slipping and bowing result in clean square cut. Hold down units is

provided with oversize pads to avoid impression on sheet metal. Shears are provided

with Four Edge, single & segment ally High Carbon, Chromium Steel Blades suitable

for M.S. &.S.S. Cutting and Extra long life. All bearing parts and guide surfaces are

lubricated through centralize hand-operated lubrication system. This is standard

equipment provided on all Shears. Scale on the back gauge gives instantaneous

reading of distance between shear and back gauge, thus avoiding errors and

maintenance encountered in electronic equipment. Fitted in front of hold-down for

operator safety without obstructing viewing. Electrical System consisting of motor &

Control Panel of Starter, Gear and wheel guard, V-Belts, Hand operated back gauge,

Manual Lubrication System, T-slot front gauge, Front scale gauge, instruction manual

Figure No.5.8. Mechanical Guillotine Shears under Crank

MODEL RUC 4/3 RUC 5/3 RUC 6/3

Capacity in M.S. Max.

Length (mm): Max.

Thickness (mm):

1250

3

1500

3

2000

3

Number of Strokes /

min 60 50 50

Motor (HP): 3 3 5

Net / gross wt(Kgs.): 1500 / 1700 1600 / 1800 2200 / 2400

Shipping dimensions

(mm): 2550x1425x1450 2850x1425x1450 3300x1425x1450

Shipping volume (m3): 5.30 5.90 6.80

Table No.5.7. Specifications of Mechanical Guillotine Shears under Crank

5.4 PNEUMATIC SHEARING MACHINES:

The pneumatic snap shears is widely used for cutting squares, bars and other

similar products. The pneumatic cylinders of adequate capacity control shearing and

swiveling applications with precision. Frame of the shears are fabricated with relieved

structural sheet flats that provide ultimate stability and durability. Robust construction

with steel body fully automatic with pneumatic controls capable to cut hot ends

during rolling available in fixed and swiveling type high quality circular blades with

angular edge.

Figure No.5.9 Pneumatic shearing machines

5.4.1Pneumatic foot shear:

Machine has with 52 inch wide maximum shear length Maximum

material thickness: Mild steel - 16 gauge/.060 inch; Stainless steel - 20 gauge/.036

inch Operation capacity of 20 strokes per minute front and back gauge length is 24

inches Shear angle is 1 degree/40 ft. Shear is pneumatic (air powered) .Shear has high

carbon, high chromium blades. Have front support arms with squaring bar shipping

dimensions: 75 inches long x 36 inches wide x 53 inches high, weight is 1588 lbs.

Figure No.5.10 Pneumatic foot shear

5.5 OTHER SHEARING MACHINES:

5.5.1 TSOP Shearing Machine:

Shearing requires proper attention to each individual skin. TSOP

Shearing Machine offers the greatest quality by giving absolute control at the cutting

point. TSOP Shearing Machine adjustments are easy and quick and do not require a

high degree of expertise. It can shear down to 1mm from the skin. It has been

developed and tested in co-operation with highly skilled and experienced furriers until

reaching perfection. It is suitable for all kinds of skins and has been tested. It occupies

very little space and is very easily installed. TSOP Shearing machine offers a great

advantage to the modern furrier enabling you develop your unique shearing designs

and patterns.

Technical Specifications:

1.3 KW Shearing Motor

2 x 0.75 KW Vacuum Motors

380 Volt

Maximum Shearing Width:

Model KA65: 65 cm

Dimensions (cm): KA65: 100 x 100 x 150

Figure No.5.11 TSOP Shearing Machine

5.5.2 Nibbling Shearing machines:

Nibbling machines work on to shearing principles. They use a

relatively small shearing punch; with a particular geometric form (square, rectangular

or round) which shears the required form in a metal sheet with small individual cuts.

Balance may be made between hand-guided nibbling machines, and those with an

automatic relative movement between the tool and work. The application of these

machines is in the small quantity and 'one off' production field, where the provision of

press tools is uneconomic. In particular, nibbling machines provide an economic

solution to work requiring very long edges to be cut. For internal curves, and circular

and straight cuts, rectangular shearing punches are used. Figure 5.12 illustrates a

sheet-metal working centre which is able to perform other sheet-metal operations

besides nibbling. During nibbling, a vertically driven punch shears holes into the 68

metal sheets, which is guided in accordance with the contour required to be cut. The

smaller the advance of the metal sheet (which is moved during each return stroke of

the punch), the nearer Will be the shape of the cut line to the required contour. If the

cut edge produced is to be a functional surface with close dimensional tolerances, then

a finishing cut, using a different

Cutting action (e.g. milling), may be carried out on the same machine. The machine

shown in Figure 5.12 is capable of milling, thread cutting and deep-drawing

operations, in addition to nibbling. With the use of automatically interchangeable

specialized tools, a wide range of sheet-metal working operations (e.g. extruding, the

cutting of vent louvers, etc.) are possible. The movement of the work is under

numerical control.

Figure 5.12 Nibbling Shearing machines

CHAPTER.6

ELECTROMAGNETIC SHEARING MACHINE

6.1 CONTRUCTION: The electromagnetic shearing machine consist frame on

which mechanical & automation unit are fixed. A machine consist a plunger in which

iron core is fixed which move from electromagnetic core ,at bottom of plunger a high

carbon hard steel tool is fixed for shearing purpose. The plunger assembly is

subtended with the help of rubber stand in such a way that only lower inch portion

allowed inside electromagnet The rubber strap also required to retract the blade also c

stroke is completed. At the bottom of machine feeder & extractor is present which

constitute 2 rollers, the smaller roller is driving roller & the bigger one is driven.

6.2 MAIN COMPONENTS:

Frame: A cast iron square pipe (2cm) is used to construct a frame which is used for

supporting purpose.

MDF sheet :MDF sheet (12mm thick) are used to built up top plat form & bottom

plat form also a supporting column for rollers & pipe.

Iron Core: Iron core (1inch dia. & 4 inch long) is use to cut emf produce by

electromagnet.

Electromagnet core: Electromagnetic core of 20 gauge 1000 turn, insulated copper

wire is used to produce emf ( ) which attract iron core in cavity which helps to control

the motion of plunger.

Plunger: It is the main part of machine which is made up of high density polymer

pipe ( ) on which cutting tool is fitted in y-fork at the bottom.

Cutting Tool: The high carbon hard steel (1mm thick) tool is used for shearing

purpose it is fitted in y-fork with the help of nuts & bolts.

Supporting Column: It is made up of MDF sheet (10cm long& 2cm breath) to avoid

bending of pipe at the time of shearing.

Feeder & Extractor: It consist two rollers this roller carries wooden axis & made of

15mm thick foam sheet. Feeder is used to feed pipe for shearing, & extractor is used

to remove pipe after shearing.

Gearboxes: The two gearboxes are used one for feeder & another for extractor to

control the motion of feeder & extractor.

6.2 ELECTRICAL COMPONENTS:

Transformer: The step-down transformer is used to convert 220volt A.C supply into

12 volt A.C

Microcontroller: Microcontroller (AT89C52 6-12v) flash programmer type is used

to run the automation unit.

Bridge: The Bridge is used to convert A.C supply current to D.C from 12 volt A.C to

12volt D.C volt for microcontroller flash memory program.

L293d IC: It is used to

CHAPTER.7

DESIGN OF MODEL

The design of part model is done in CATIA V5 R17 (Computer Aided Three

Dimensional Interactive Application) which is a multi-platform CAD/CAM/CAE

commercial software suite developed by the French company Dassault Systems IBM.

Written in the C++ programming language, CATIA is the cornerstone of the Dassault

Systems product lifecycle management software suite. The user may create, edit, and

delete end cuts, and the end cut for a beam is integrated in the piece part engine

Translate a Structure Functional Design 2 (SFD) or Ship Structure Detail Design 2

(SDD) feature during the explode mode through piece part process define end cut

graphic replacement in drafting manage different graphic replacements for beam

pillars enhances technological results usage in tooling design.

The mold to cam function is enhanced to permit the creation of a

technological results report. Reporting of die/mold technological results is accessible

via the new command display technological results (available with Prismatic

Machining preparation assistant 2 (MPA) license). Any user of the tooling design 1

product who has an MPA license can benefit from this enhanced reporting command:

Create a report (*.csv) on the technological results existing in a given die define some

in house processes between the design and the manufacturing stage that provide the

user with a powerful tool to control the integrity of the die design and prevents costly

iterations between design and manufacturing Increases design productivity in sheet

metal design .The powerful extrusion explode improvement offers an explode mode,

which allows the user to generate an associative wall on edge. Creating an extrusion

becomes an accelerator of the design and exploding the extrusion allows user to

locally modify design while maintaining associations. Design performance for

innovation increases sales through on the plant, architecture, and construction

industries thanks to new capabilities in terrain modeling .These powerful

improvements include the ability to: Work with meshed surfaces and volumes

including tessellation and multi-slice commands Edit the meshes easily Create and

manage Z-Level curves benefit from dedicated improvements to the building

implantation and enhancements to the graphic performances.

The each part of model is design according initial line diagram from this line diagram

the improved sketch of model is design in the CATIAV5 as per the Following

dimensions:

Top plat form 30×28 cm 12mm thickness

Base plat form 30×28 cm 12mm thickness

Figure No.7.1 Electromagnetic shearing machine

Disc of 18.46 cm & smaller 6.8cm 12mm thick

Supporting column of 10cm height & 2cm breath 12mm thick

Y-fork 10cm × 8cm 6mm thick

Iron core 1inch dia. & 4inch length

Plunger support of elliptical shape

Plunger of 35cm

Electromagnet core at middle

Frame of total height 52 cm

Figure No.7.2 CATIAV5 Design of Mode

Figure No.7.3 CATIAV5 Draft mode

Figure No.7.4 Multi View