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1.1 ABSTRACT
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1.2 INTRODUCTION
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CHAPTER 2
Electric power
Ac motor
CUTTING TOOL
Handle Roller
BED
GRASS
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2.2WORKING PRINCIPLE
• Abrasive saw
• Axe
• Blade
• Bandsaw
• Chainsaw
• Circular saw
• Cutting tool (machining)
• Diamond blade
• Diamond tool
• Drill bit
• File
• Front teeth
• Glass cutter
• Hacksaw
• Hand saw
• Hole saw
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• Knife
• Lesar
❖ Higher safety
❖ To reduce manpower
❖ Less Maintenance
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CHAPTER 3
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• Verify the clearance between cutting punch and die. There should
be a clearance of at least one sheet thickness+10% of Sheet
Thickness between cutting punch and die.
• Provide adequate cutting radius and polish it to high surface finish.
Cutting radius is the radius on the cutting die on which the sheet
material flows to form the desired profile. Hence it is important to
have very good surface finish at this area for smooth flowing of
material.
• Use corner setting if possible. In case of 90° cutting, it is a good idea
to provide corner setting to eliminate spring back. Corner setting is
the process of coining the material to a small depth along the cutting
line to overcome spring back. Please note that corner setting may
not be possible on very think sheet materials and grass with very
high hardness.
• Brass • Steel
• Bronze • Tin
• Copper • Titanium
• Magnesium • Zinc
• Nickel
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3.4 Deformation processes
Grass can be cut, bent, and stretched into a nearly any shape. Material
removal processes can create holes and cutouts in any 2D geometric shape.
Deformation processes can cut the sheet numerous times to different
angles or stretch the sheet to create complex contours. The size of grass
parts can range from a small washer or bracket, to midsize enclosures for
home appliances, to large airplane wings. These parts are found in a variety
of industries, such as aircraft, automotive, construction, consumer
products, HVAC, and furniture.
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3.6 Types of tool fabrication
• Forming
• Cutting
• Roll forming
• Spinning
• Deep Drawing
• Stretch forming
• Shearing
• Blanking
• Cutting
• Plasma cutting
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3.7 TOOL FORMING PROCESS
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Also, lubricant can allow for a higher production rate, which will
also depend on the material thickness, number of roll stations, and radius
of each cut. The roll forming line can also include other grass fabrication
operations before or after the roll forming, such as Cutting or shearing.
The roll forming process can be used to form a sheet into a wide
variety of cross-section profiles. An open profile is most common, but a
closed tube-like shape can be created as well. Because the final form is
achieved through a series of cuts, the part does not require a uniform or
symmetric cross-section along its length. Roll forming is used to create
very long grass parts with typical widths of 1-20 inches and thicknesses of
0.004-0.125 inches. However wider and thicker sheets can be formed,
some up to 5 ft. wide and 0.25 inches thick. The roll forming process is
capable of producing parts with tolerances as tight as ±0.005 inches.
Typical roll formed parts include panels, tracks, shelving, etc. These parts
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are commonly used in industrial and commercial buildings for roofing,
lighting, storage units, and HVAC applications.
3.9 SPINNING
Spinning, sometimes called spin forming, is a metal forming process
used to form cylindrical parts by rotating a piece of grass while forces are
applied to one side.
A grass disc is rotated at high speeds while rollers press the sheet
against a tool, called a mandrel, to form the shape of the desired part. Spun
metal parts have a rotationally symmetric, hollow shape, such as a
cylinder, cone, or hemisphere. Examples include cookware, hubcaps,
satellite dishes, rocket nose cones, and musical instruments.
Spinning is typically performed on a manual or CNC lathe and
requires a blank, mandrel, and roller tool. The blank is the disc-shaped
piece of grass that is pre-cut from sheet stock and will be formed into the
part.
The mandrel is a solid form of the internal shape of the part, against
which the blank will be pressed. For more complex parts, such as those
with reentrant surfaces, multi-piece mandrels can be used. Because the
mandrel does not experience much wear in this process, it can be made
from wood or plastic.
However, high volume production typically utilizes a metal
mandrel. The mandrel and blank are clamped together and secured
between the headstock and tailstock of the lathe to be rotated at high speeds
by the spindle. While the blank and mandrel rotate, force is applied to the
sheet by a tool, causing the sheet to cut and form around the mandrel. The
tool may make several passes to complete the shaping of the sheet.
This tool is usually a roller wheel attached to a lever. Rollers are
available in different diameters and thicknesses and are usually made from
steel or brass. The rollers are inexpensive and experience little wear
allowing for low volume production of parts.
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FIGURE 3.9 Spinning Lathe
CHAPTER 4
• Construction
mechanical or hydraulic)
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• Force rating (for example, 20 tons)
• The type of tool shop and its capacity (e.g., store revolving type,
capacity 34 tool)
• Safety features
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4.2 Cutting Diagram
• Cut line - The straight line on the surface of the sheet, on either side
of the cut, that defines the end of the level flange and the start of the
cut.
• Outside mold line - The straight line where the outside surfaces of
the two flanges would meet, were they to continue. This line defines
• Mold line distance - The distance from either end of the sheet to the
• Setback - The distance from either cut line to the outside mold line.
Also equal to the difference between the mold line distance and the
flange length.
• Cut axis - The straight line that defines the center around which the
grass is bent.
• Cut length - The length of the cut, measured along the cut axis.
• Cut radius - The distance from the cut axis to the inside surface of
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inside cut radius. The outside cut radius is equal to the inside cut
• Cut angle - The angle of the cut, measured between the bent flange
grass. The outside portion of the sheet will undergo tension and stretch to
shortens. The neutral axis is the boundary line inside the grass, along which
length to the outside and inside surfaces can be related to the original flat
length by two parameters, the cut allowance and cut deduction, which are
defined below.
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Neutral Axis
• Neutral axis - The location in the sheet that is neither stretched nor
as the ratio of the distance of the neutral axis (measured from the
operation, cut angle, etc.) and is typically greater than 0.25, but
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• Cut allowance - The length of the neutral axis between the cut lines,
• The cut allowance added to the flange lengths is equal to the total
flat length.
piece of material has been stretched by cutting. The value equals the
difference between the mold line lengths and the total flat length.
FIGURE4.2.1AIR BENDING
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4.3 V CUTTING
cutting, sometimes called edge cutting. Wipe cutting requires the sheet to
The punch then presses against the edge of the sheet that extends
beyond the die and pad. The sheet will cut against the radius of the edge
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CHAPTER 5
5.1Design rules
• Cut location - A cut should be located where enough material
is present, and preferably with straight edges, for the sheet to be secured
without slipping. The width of this flange should be equal to at least 4
times the sheet thickness plus the cut radius.
• Cut radius
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CHAPTER 6
diameter
A full revolution clutch can only bring the ram to a stop at the same
location- top dead center. Newer presses are often "part revolution" presses
equipped with braking systems identical to the brakes on commercial
trucks. When air is applied, a band-type brake expands and allows the
crankshaft to revolve. When the stopping mechanism is applied the air is
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bled, causing the clutch to open and the braking system to close, stopping
the ram in any part of its rotation.
On its stroke from TDC to BDC, the punch enters the material,
pushing it through the die, obtaining the shape determined by the design
of the punch and die set.
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The piece of material (slug) cut from the workpiece is ejected
through the die and bolster plate and collected in a scrap container. [1] The
return to TDC signals to the control to begin the next cycle.
"V" Cutting
"L" Cutting
"U" Cutting
V Cutting Dies
V Cutting dies have the simplest cutting die design. The cutting die
have the shape of V with an included angle of 90° in most cases. The
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cutting punch is also in the shape of V, but with a lesser angle than the die.
And in some cases the cutting punches may have a relief after a straight
land to a certain length.
L Cutting Dies
L Cutting dies are used for 90° cutting. L cutting dies can produce
the presence of spring loaded clamping pads which will hold grass closer
to the cutting line and then the cutting punch pushes the grass into the
cutting die along the cutting line. L cutting dies can also be used for cutting
complex parts.
6.3DIE COMPONENTS
• Die block - This is the main part that all the other parts are attached
to.
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• Punch plate - This part holds and supports the different punches in
place.
• Blank punch - This part along with the Cutting Die produces the
curved part.
• Stripper plate - This is used to hold the material down on the Blank/
Pierce Die and strip the material off the punches.
• Guide / Back gage / Finger stop - These parts are all use to make
sure that the material being worked on always goes in the same
position, within the die, as the last one.
• Setting Block - This part is used to control the depth that the punch
does into the die.
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Generally a blanking die may only cut the outside contour of a part, often
used for parts with no internal features.
Three benefits to die blanking are:
1. Accuracy. A properly sharpened die, with the correct amount
of clearance between the punch and die, will produce a part that holds close
dimensional tolerances in relationship to the parts edges.
2. Appearance. Since the part is blanked in one operation, the
finish edges of the part produces a uniform appearance as opposed to
varying degrees of burnishing from multiple operations.
3. Flatness. Due to the even compression of the blanking
process, the end result is a flat part that may retain a specific level of
flatness for additional manufacturing operations.
Compound operations:
Compound dies perform multiple operations on the part. The
compound operation is the act of implementing more than one operation
during the press cycle.
Compound die:
A type of die that has the die block (matrix) mounted on a punch
plate with perforators in the upper die with the inner punch mounted in the
lower die set. An inverted type of blanking die that punches upwards,
leaving the part sitting on the lower punch (after being shed from the upper
matrix on the press return stroke) instead of blanking the part through. A
compound die allows the cutting of internal and external part features on
a single press stroke.
Curling:
The curling operation is used to roll the material into a curved shape.
A door hinge is an example of a part created by a curling die.
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Cut off:
Cut off dies are used to cut off excess material from a finished end
of a part or to cut off a predetermined length of material strip for additional
operations.
Extruding:
Extruding is the act of severely deforming blanks of metal called
slugs into finished parts such as an aluminum I-beam. Extrusion dies use
extremely high pressure from the punch to squeeze the metal out into the
desired form. The difference between cold forming and extrusion is
extruded parts do not take shape of the punch.
Forming:
Forming dies cut the blank along a curved surface.
Cold forming (cold heading):
Cold forming is similar to extruding in that it squeezes the blank
material but cold forming uses the punch and the die to create the desired
form, extruding does not.
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• Hydroforming: Forming of tubular part from simpler tubes
with high water pressure.
• Pancake die: A Pancake die is a simple type of
manufacturing die that performs blanking and/or piercing. While many
dies perform complex procedures simultaneously, a pancake die may only
perform one simple procedure with the finished product being removed by
hand.
• Piercing: The piercing operation is used to pierce holes in
stampings.
• Progressive die: Progressive dies provide different stations
for operations to be performed. A common practice is to move the material
through the die so it is progressively modified at each station until the final
operation ejects a finished part.
• Shaving: The shaving operation removes a small amount of
material from the edges of the part to improve the edges finish or part
accuracy. (Compare to Trimming).
• Side cam die: Side cams transform vertical motion from the
press ram into horizontal or angular motion.
• Sub press operation: Sub-press dies blank and/or form small
watch, clock, and instrument parts.
• Swaging: Swaging (necking) is the process of "necking
down" a feature on a part. Swaging is the opposite of bulging as it reduces
the size of the part. The end of a shell casing that captures the bullet is an
example of swaging.
• Trimming: Trimming dies cut away excess or unwanted
irregular features from a part, they are usually the last operation performed.
Steel-rule die
Steel-rule dies, also known as cookie-cutter dies, are used to
cut grass and softer webs, such as plastics, wood, cork, felt, fabrics, and
cardboard. The cutting surface of the die is the edge of hardened steel
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strips, known as steel rule. These steel rules are usually located using saw-
cut grooves in plywood. The mating die can be a flat pieces of hardwood
or steel, a male shape that matches the workpiece profile, or it can have a
matching groove that allows the rule to nest into. Rubber strips are wedged
in with the steel rule to act as the stripper plate; the rubber compresses on
the down-stroke and on the up-stroke it pushes the workpiece out of the
die. The main advantage of steel-rule dies is the low cost to make them, as
compared to solid dies; however, they are not as robust as solid dies, so
they usually only used for short production runs.
Rotary die
In the broadest sense, a rotary die is a circular shaped die that may
be used in any manufacturing field. However, it most commonly refers to
circular shaped dies used to process soft webs, such as paper and
cardboard. Two dies are used, one has cutting and creasing rules, while the
other acts as the anvil. Rotary dies are faster than flat dies, but not as
accurate.
Wire pulling
Wire-making dies have a hole through the middle of them. A wire
or rod of steel, copper, other metals, or alloy enters into one side and is
lubricated and reduced in size. The leading tip of the wire is usually
pointed in the process. The tip of the wire is then guided into the die and
rolled onto a block on the opposite side. The block provides the power to
pull the wire through the die.
The die is divided into several different sections. First is an entrance
angle that guides the wire into the die. Next is the approach angle, which
brings the wire to the nib, which facilitates the reduction. Next is the
bearing and the back relief. Lubrication is added at the entrance angle. The
lube can be in powdered soap form. If the lubricant is soap, the friction of
the drawing of wire heats the soap to liquid form and coats the wire. The
wire should never actually come in contact with the die. A thin coat of
lubricant should prevent the metal to metal contact.
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For pulling a substantial rod down to a fine wire a series of several
dies is used to obtain progressive reduction of diameter in stages.
Standard wire gauges used to refer to the number of dies through
which the wire had been pulled. Thus, a higher-numbered wire gauge
meant a thinner wire. Typical telephone wires were 22-gauge, while main
power cables might be 3- or 4-gauge.
CHAPTER 7
• Cut radius
• Material factor
• Material Factor
• Material thickness
• Shear factor
• Die Clearance
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7.2 DESIGN CALCULATION
Cutting force,
F= A x Tß
F = Cutting force
S = Material thickness
L = Total cutting length
A = L x S = Shear area
Tß = Shear strength
Note : Shear strength = 80% of tensile strength
The required force to cut a piece of grass using V-cutting a process
in which a V-shaped punch presses the sheet into a V-die. The cutting
force can be calculated from the sheet thickness, die opening, cut length,
and the ultimate tensile strength of the material.
The die ratio may be entered to calculate the die opening, which is
typically 6 to 18 times the sheet thickness. The calculated tonnage can be
used for the selection of a machine, such as a press brake, to perform the
cutting operation.
F = BA x t x l x
Where
F = Cutting Force in Newton
l = Cutting length
t = Thickness of sheet
= Ultimate tensile strength
F = BA x t x l x
F = (1.2) x. 0.004 x 0.01 x 410 x 106 = 19680 N
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7.3ADVANTAGES
• Low cost .
• Less maintenance.
• Simple in construction
• Higher accuracy
7.4 DISADVANTAGES
2. Noisy operation
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FINAL LAYOUT
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CONCLUSION
CUTTER”. This project is very much A for Cutting the grass. Thus by
means of the Cutting machine, we can cut the grass. This is one of the most
reliable and simple machine in the machine shop in which many number
calculated.
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REFERENCES
Reference Guide
McGraw-Hill,
Industry,
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