A

PROJECT REPORT
ON
AUTOMATED SHEARING MACHINE WITH ARDUINO

Submitted By
LAKSHMANA K
MANOJ HALLI
SHANKAR U
SHARAD V R

Under the Guidance of

HEMAVATHY S

DEPARTMENT OF MECHANICAL ENGINEERING

M S RAMAIAH INSTITUTE OF TECHNOLOGY,BANGALORE
2014-2015

ACKNOWLEDGEMENT
We are rather infused by the kind guidance of Prof. H. N.
Tikekar who put us in the cradle of our engineering studies and
evaluated us to this end and mean of our project without his
guidance, we are sure to be an orphan in the vast ocean of the
subject. Ultimately no tongue could describe the deep sense of cooperation and ready nature to help us even in minute details of our
write up this project report.
Thanks and gratitude goes to Prof. RAVI NADU Head,
Department of Mechanical Engineering Polytechnic Wing, who made
very valuable guidance and co-operation during our project.
Further we are thankful to all the staff and non-teaching
members of Mechanical Engineering Department for the cooperation during the project work. We are very grateful to those
who in the form of books had conveyed guidance in this project
work. Last but not the least we are thankful to our colleagues and
those helped us directly or indirectly throughout this project work.

INDEX

Synopsis
The objective of the project is to prepare a
machine which cuts sheet metal without human efforts
but operates pneumatically. Compressed air is used as
working media. The compressed air moves the blades
of machine to cut the sheet of metal.
The idea of the project generated due to a manual
sheet metal sheering machine in workshop of our
college. In that machine sheet metal is placed in
between the two sheering blades of machine and the
lever is pulled down to move the upper movable blade
and cut the work-piece.
But in that machine large force is required which
can make tire to a worker who continuously works on it
for mass production in large scale industry; so to
reduce the human efforts pneumatic machine should
chose. Also we tried out the mechanism for the sheet
metal to be dragged when the lever moves back to
original position. Hence for some development of
machine, we have chosen this subject for our project.
We hope that a good idea will develop and we can use
it in many industries in surrounding and our practical
knowledge, team-working skill, leadership skills will be
improved.

FIGURE OF PROJECT

Literature survey
In shearing or cutting operation as or blade
descends upon the metal, the pressure exerted by the
blade first cause the plastic deformation of the metal.
Since the clearance between the two blades is very
small, the plastic deformation takes place in a localized
area and the metal adjacent to the cutting edges of the
blade edges becomes highly stressed, which causes the
fracture to start on both sides of the sheet as the
deformation progresses and the sheet is sheared.

Prior concepts
Pneumatics, from the Greek (pneumatikos, coming
from the wind) is the use of pressurized gases to do
work in science and technology. Pneumatics was first
documented by Hero of Alexandria in 60 A.D., but the
concept had existed before then. Pneumatic products
represent a multi-billion dollar industry today.
Pneumatic devices are used in many industrial
applications. Generally appropriate for applications
involving less force than hydraulic applications, and
typically less expensive than electric applications, most
pneumatic devices are designed to use clean dry air as
an energy source. The actuator then converts that
compressed air into mechanical motion. The type of
motion produced depends on the design of the
actuator. Pneumatics is employed in a variety of
settings.
In dentistry applications, pneumatic drills are
lighter, faster and simpler than an electric drill of the
same power rating, because the prime mover, the
compressor, is separate from the drill and pumped air is

capable of rotating the drill bit at extremely high rpm.

Pneumatic transfer systems are employed in many
industries to move powders and pellets.
Pneumatic devices are also used where electric
motors cannot be used for safety reasons, such as
mining applications where rock drills are powered by air
motors to preclude the need for electric motors deep in
the mine where explosive gases may be present.

1. INTRODUCTION

1.1. SHEET METAL:

Sheet metal is simply a metal formed into thin and flat pieces. It is one of the
fundamental forms used in metal working and can be cut and bent into a
variety of different shapes. Countless everyday objects are constructed of the
material. Thicknesses can vary significantly, although extremely thin
thicknesses are considered foil or leaf, and pieces thicker than 6 mm
(0.25 in) are considered plate.
Sheet metal is available in flat pieces or as a coiled strip. The coils are
formed by running a continuous sheet of metal through a roll slitter.
The thickness of the sheet metal is called its gauge. Commonly used steel
sheet metal ranges from 30 gauge to about 8 gauge. The larger the gauge
number, the thinner the metal. Gauge is measured in ferrous (iron based)
metals while nonferrous metals such as aluminum or copper are designated
differently; i.e., Copper is measured in thickness by Ounce.
There are many different metals that can be made into sheet metal, such as
aluminum, brass, copper, steel, tin, nickel and titanium. For decorative uses,
important sheet metals include silver, gold and platinum (platinum sheet
metal is also utilized as a catalyst.)
Sheet metal also has applications in car bodies, airplane wings, medical
tables, roofs for buildings (Architectural) and many other things. Sheet
metal of iron and other materials with high magnetic permeability, also
known as laminated steel cores, has applications in transformers and electric
machines. Historically, an important use of sheet metal was in plate armor
worn by cavalry, and sheet metal continues to have many decorative uses,
including in horse tack. Sheet metal workers are also known as "Tin
Bashers",("Tin Knockers") which is derived from the hammering of panel
seams when installing tin roofs.
There are three primary procedures in Layout
1. Parallel
2. Radial
3. Triangulation

1.2. SHEET METAL CUTTING:

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
shear 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 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 these portions of the cut
depends on several factors, including the sharpness of the tools and the
clearance between the tools.
1.2 HAND SHEAR
Introduction and overview
Hand shearing machine is a type of machine, mainly used for shearing of
sheet metals, in 2 axes. Shearing machine is fixed to table. Before shearing
off, marking has to be done and should be fed manually. Manually feeding

in the hand shearing is not so easy. If the width of the sheet is more, operator
cannot feed the sheet metal with single hand, because sheet bends at the
centre. So he has to feed the sheet metal with both hands, hence one more
person is needed to operate the lever. If the length of sheet is more again one
more person is needed at the end to support the sheet to make it straight.
Sufficient high force has to be applied at the lever to shear off.

Problems
1. Problems associated with handling, marking and feeding of sheet
metal.
2. Manual force.
We made modification in the hand shearing machine and we can take this
problem as project.
What is the key observation ??
The lever operated downwards, sheet metal will be sheared off and
the lever will be moved back, doing no work. Thus the return motion
upward motion of lever is idle. So this motion is free, so we thought
to use this motion for some other purpose to obtain some useful work.
Then we planned to introduce feeding mechanism for feeding the
sheet metal, using this motion. As this mechanism runs on the motion
of lever during return stroke, hence it is auto feeding mechanism,
because it uses no other driving force to run.
To overcome the problem 1, we introduced auto feeding mechanism.
In order to avoid, manual force for shearing, we introduced pneumatic
cylinder. Now the problem converted to like this.
Now the machine can operate with only one operator, their operator is
required to operate the pneumatic valve to actuate cylinder. So I order
to eliminate complete man intervention or to make it automatic, we
introduced micro controller with c-programming. We got arduino
UNO work board in which, we got microcontroller, digital i/o pins,
analogue pins, capacitors crystal oscillators, usb port, power supply
connection etc. this is very much cheaper as compared to plc. and if is
for specific purpose. The operating voltage of au is 5 to 20v safer 5 to
12v. We chosen 5/2 solenoid spring dc valve so as to work compatible

with digital output (voltage) by microcontroller. Solenoid valve

operates at 24 volts, so has to synchronise the arduino solenoid valve
we used relay. Two power supplies of 12v and 24 volts are used . 12
volts for relay and AU and 24 volts for solenoid valve. This relay acts
as switching device.

ARDUINO
What is arduino ?
Arduino is a tool for making computers that can sense and control more of
the physical world than your desktop computer. It's an open-source physical
computing platform based on a simple microcontroller board, and a
development environment for writing software for the board.
Arduino can be used to develop interactive objects, taking inputs from a
variety of switches or sensors, and controlling a variety of lights, motors,
and other physical outputs. Arduino projects can be stand-alone, or they can
communicate with software running on your computer (e.g. Flash,
Processing, MaxMSP.) The boards can be assembled by hand or purchased
preassembled; the open-source IDE can be downloaded for free.
The Arduino programming language is an implementation of Wiring, a
similar physical computing platform, which is based on the Processing
multimedia programming environment.

Why Arduino?
There are many other microcontrollers and microcontroller platforms
available for physical computing. Parallax Basic Stamp, Netmedia's BX-24,
Phidgets, MIT's Handyboard, and many others offer similar functionality.

All of these tools take the messy details of microcontroller programming and
wrap it up in an easy-to-use package. Arduino also simplifies the process of
working with microcontrollers, but it offers some advantage for teachers,
students, and interested amateurs over other systems:
Inexpensive - Arduino boards are relatively inexpensive compared to
other microcontroller platforms. The least expensive version of the
Arduino module can be assembled by hand, and even the preassembled Arduino modules cost less than $50
Cross-platform - The Arduino software runs on Windows, Macintosh
OSX, and Linux operating systems. Most microcontroller systems are
limited to Windows.
Simple, clear programming environment - The Arduino programming
environment is easy-to-use for beginners, yet flexible enough for
advanced users to take advantage of as well. For teachers, it's
conveniently based on the Processing programming environment, so
students learning to program in that environment will be familiar with
the look and feel of Arduino
Open source and extensible software- The Arduino software is
published as open source tools, available for extension by experienced
programmers. The language can be expanded through C++ libraries,
and people wanting to understand the technical details can make the
leap from Arduino to the AVR C programming language on which it's
based. Similarly, you can add AVR-C code directly into your Arduino
programs if you want to.
Open source and extensible hardware - The Arduino is based on
Atmel's ATMEGA8 and ATMEGA168 microcontrollers. The plans for

the modules are published under a Creative Commons license, so

experienced circuit designers can make their own version of the
module, extending it and improving it. Even relatively inexperienced
users can build the breadboard version of the module in order to
understand how it works and save money.

Construction

Raw Material Used1. Mild Steel bars for base frame.

2. 35C8 material for shearing blades.
3. Cylinder fittings like fork end, base plates,
support links.

4. Angle section for blade fitting.

5. Connecting link.

6. Blade link.

Ready Items Used1. Pneumatic double acting cylinder.

2. Direction & flow control valves.
3. Pneumatic pipe & pipe fittings.
4. Bolts & nuts.

5. Antirust coat & paint.

Machines & Tools Used1. Cutting Machine.

2. Hacksaw Cutting Machine.
3. Sensitive Drilling Machine.
4. Horizontal Milling Machine.
5. Electric Arc Welding Machine.
6. Table Grinder.

7. Hand Grinder.
8. Surface Grinding Machine.
9. Tap & Tap Holder.