PROJECT REPORT

On

DESIGN AND FABRICATION OF

COMBINED HYDRAULIC HAND SHEAR
AND BENDING MACHINE
Submitted on partial fulfilment of the requirements for
the award of the degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

Submitted by:
Soumen Kumar Mukherjee (20163022)
Koushik Mukherjee (20163083)
Mayank Nagle (20163103)

Under the guidance of

Dr. Manish Gupta
Associate Professor

DEPARTMENT OF MECHANICAL ENGINEERING

Motilal Nehru National Institute of Technology Allahabad
Prayagraj, Uttar Pradesh -211004
 DECLARATION

We hereby declare that that the project report entitled “Design & Fabrication
of Combined Hydraulic Hand-Operated Shear and Bending Machine”,
submitted to the Department of Mechanical Engineering, Motilal Nehru National
Institute of Technology Allahabad, Prayagraj, in partial fulfilment for the award
of the degree of Bachelor of Technology in Mechanical Engineering, is a record
of bona fide work carried out by is a record of original dissertation work done
by us, under the guidance and supervision of Dr. Manish Gupta, Associate
Professor, MechanicaL Engineering Department, Motilal Nehru National
Institute of Technology Allahabad, Prayagraj and it has not formed the basis for
the award of any Degree/Diploma/Associateship/ Fellowship or other similar
title to any candidate of any University.

Date: 28-11-2019
Place: Prayagraj, India
(Soumen Kumar Mukherjee)

(Koushik Mukherjee)

(Mayank Nagle)
 CERTIFICATE

This is to certify that the project report entitled “Design & Fabrication of
Combined Hydraulic Hand-Operated Shear and Bending Machine”, submitted
to the Department of Mechanical Engineering, Motilal Nehru National Institute
of Technology Allahabad, Prayagraj, in partial fulfilment for the award of the
degree of Bachelor of Technology in Mechanical Engineering, is a record of
bona fide work carried out by Soumen Kumar Mukherjee- 20163022, Koushik
Mukherjee- 20163083, Mayank Nagle- 20163103, under my supervision and
guidance. All help received by her from various sources have been duly
acknowledged. No part of this report has been submitted elsewhere for award of
any other degree.

Date: 28/11/2019 (Dr. Manish Gupta)

Place: Prayagraj, India Assistant Professor, MNNIT Allahabad
 CHAPTER-1
BACKGROUND

It was during 2nd, 5th, 6th semesters we had subjects related to Manufacturing and for
that we needed to go to the mechanical workshop for our practical. It was during
these labs that we understood that in the sheet metal cutting operations, it becomes
quite hard to cut the sheet with hand scissors. Also the bending operation was not
possible with accuracy. Thus we took motivation from there to make a machine
which cater both the problem in a single apparatus.
Also, our HOD A.D. Bhatt sir motivated us to do something which helps in the
betterment of the labs. This project was in line with his thought. It will be our sincere
practice to be successful in making it, under the guidance of our mentor Dr. Manish
Gupta sir, so that we can contribute slightly for the betterment of mechanical
workshop.
 CHAPTER-2
INTRODUCTION

2.1 Bending of Sheet Metals

Bending in sheet-metal work is defined as the straining of the metal around a straight axis. During
the bending operation, the metal on the inside of the neutral plane is compressed, while the metal
on the outside of the neutral plane is stretched. The metal is plastically deformed so that the bend
takes a permanent set upon removal of the stresses that caused it. Bending produces little or no
change in the thickness of the sheet metal.
V-BENDING AND EDGE BENDING
Bending operations are performed using punch and die tooling. The two common bending
methods and associated tooling are V-bending, performed with a V-die; and edge bending,
performed with a wiping die
In V-bending, the sheet metal is bent between a V-shaped punch and die. Included angles ranging
from very obtuse to very acute can be made with V-dies. V-bending is generally used for low-
production operations. Itis often performed on a press brake, and the associated V-dies are
relatively simple and inexpensive.
Edge bending involves cantilever loading of the sheet metal. A pressure pad is used to apply a
force Fh to hold the base of the part against the die, while the punch forces the part to yield and
bend over the edge of the die. Edge bending is limited to bends of 90 or less. More complicated
wiping dies can be designed for bend angles greater than 90. Because of the pressure pad, wiping
dies are more complicated and costly than V-dies and are generally used for high-production
work.
ENGINEERING ANALYSIS OF BENDING
The metal of thickness t is bent through an angle called the bend angle a. This results in a sheet-
metal part with an included angle a0, where a + a0 ¼ 180. The bend radius R is normally specified
on the inside of the part, rather than at the neutral axis, and is determined by the radius on the
tooling used to perform the operation. The bend is made over the width of the workpiece w.

Bend Allowance If the bend radius is small relative to stock thickness, the metal tends to stretch
during bending. It is important to be able to estimate the amount of stretching that occurs, if any,
so that the final part length will match the specified dimension. The problem is to determine the
length of the neutral axis before bending to account for stretching of the final bent section. This
length is called the bend allowance, and it can be estimated as follows:
where Ab ¼ bend allowance, mm (in); a ¼ bend angle, degrees; R ¼ bend radius, mm (in); t ¼
stock thickness, mm (in); and Kba is factor to estimate stretching. The following design values
are recommended for Kba.
Springback
When the bending pressure is removed at the end of the deformation operation, elastic energy
remains in the bent part, causing it to recover partially toward its original shape. This elastic
recovery is called springback, defined as the increase in included angle of the bent part relative
to the included angle of the forming tool after the tool is removed. This is illustrated in Figure
20.13 and is expressed:

where SB ¼ springback; a0 ¼ included angle of the sheet-metal part, degrees; and a0 t ¼ included
angle of the bending tool, degrees. Although not as obvious, an increase in the bend radius also
occurs due to elastic recovery. The amount of springback increases with modulus of elasticity E
and yield strength Y of the work metal.
Compensation for springback can be accomplished by several methods. Two common methods
are overbending and bottoming. In overbending, the punch angle and radius are fabricated
slightly smaller than the specified angle on the final part so that the sheet metal springs back to
the desired value. Bottoming involves squeezing the part at the end of the stroke, thus plastically
deforming it in the bend region.

Bending Force
The force required to perform bending depends on the geometry of the punch-and-die and the
strength, thickness, and length of the sheet metal.

The maximum bending force can be estimated by means of the following equation:
Max. work load per unit width is given by:
Fmax= (M/l) × [1+cos (tan-1µ) +µ*sin (tan-1µ)]
We have,
σy1= σy0+n*εmax
σy2=σy0 + n*ln [1+ 1/ (272(rp/t) +1)]
And bending moment per unit width is given by:
M= (0.55t) 2{σy0/6 + σy1/3} + (0.45t) 2{σyo/6 + σy2/3}
Now, strain in the outer fiber is given by
εmax = ln[1+ 1/ (1.82(rp/t) + 0.82) ]

2.2 Shearing of Sheet Metals

Estimates of cutting force are important because this force determines the size (tonnage) of the
press needed. Cutting force F in sheet metalworking can be determined by
F=S*t*L
where S = shear strength of the sheet metal, MPa (lb/in2); t = stock thickness, mm (in), and L =
length of the cut edge, mm (in). In blanking, punching, slotting, and similar operations, L is the
perimeter length of the blank or hole being cut. The minor effect of clearance in determining the
value of L can be neglected. If shear strength is unknown, an
alternative way of estimating the cutting force is to use the tensile strength:

F=0.7*(TS)*t*L
TS = ultimate tensile strength MPa (lb/in2).

These equations for estimating cutting force assume that the entire cut along the
sheared edge length L is made at the same time. In this case the cutting force will be a
maximum. It is possible to reduce the maximum force by using an angled cutting edge on
the punch or die. The angle (called the shear angle), spreads the cut
over time and reduces the force experienced at any one moment. However, the total energy
required in the operation is the same, whether it is concentrated into a brief moment or
distributed over a longer time period.
 CHAPTER-3
SOFTWARE DESCRIPTION

3.1 Solidworks
SolidWorks is computer-aided design (CAD) software owned by Dassault Systèmes. It uses the
principle of parametric design and generates three kinds of interconnected files: the part, the
assembly, and the drawing. Therefore, any modification to one of these three files will be
reflected in the other two.

SolidWorks software enables us to:

 design very precise 3D objects

 develop products

 double-check your file's design

 maintain a library of your 3D files

 create 2D drawings

 create images and animations of your 3D objects

 estimate the manufacturing cost of your 3D objects

According to MIT Survey, Solidworks selected as High productivity (Up to 95% than others)

CAD software. It provides better design visualization, design better products, faster design

iterations, improved communications, design with fewer errors, create more aesthetic design

&products and also meets the clients/customer requirements.

Currently, SolidWorks has largest share in market of about 19.6%.

Benefits of Solidworks: -

Some of these purposes are:

 1. Concurrent engineering (CE) – Engineering and manufacturing process are enabled
simultaneously from shared Solidworks data.
2. Higher quality – Due to increased efficiency resulting from the ability to explore a greater
number of design iterations during product development.
3. Lower unit costs – Due to reduced development and prototype expenses.
4. Rapid prototyping (RP) – Solidworks models can be used to produce prototypes from
Stereolithography and other RP technologies.
5. Personnel development – Solidworks technology provides a challenging environment
for employees.
6. Personnel advancement – A variety of positions regarding the management and
supervision of Solidworks become available to advance employee careers.
7. Identify and eliminate inefficiencies – Solidworks develops opportunities for the
elimination of inherent inefficiencies in existing work flows and/or practices.
8. Increased workload capacity – Efficient use of Solidworks allows the production of
more work while maintaining current staff levels.
9. Greater feedback and control of production operations – Solidworks enables NC tool
paths to be generated, updated, and verified automatically with little human intervention.
10.Improved overall communications – Solidworks enable a shift from the traditional
paper-based design and manufacturing system to an electronic paperless one.
11.Increased accuracy of MRP data – Solidworks data files can be easily linked and
managed by MRP software.
12.Increased design flexibility – Solidworks offers a more robust set of tools and methods
to modify designs.
13.Increased design data integrity – With a single Solidworks model supporting all
downstream processes, changes are reflected quickly and accurately.

Recent Advancements in Solidworks:

The latest version of Solidworks is 2020. It has the following unique features:-

 Drawings
o The new and improved mode lets you open your drawings in seconds while maintaining the ability
to add and edit annotations within the drawing. With graphics acceleration, SOLIDWORKS now
fully supports high-end graphics cards for drawings, which provides more responsive, real-time
display for large drawings.
 Assembly Envelopes
o Design speed is improved by the new Envelope Publisher which allows you to include components
from a top-level assembly as we as envelopes in a subassembly. This dramatically reduced the
amount of model data that needs to be loaded while working on large assemblies.

 SOLIDWORKS PDM Performance

o The increased performance of SOLIDWORKS PDM 2020 makes your day-to-day use faster than
ever before. You no longer have to wait for file contents and their details to load to browse to a
subfolder. PDM tabs load data in the background as well. Overall system efficiency is improved.
This includes the PDM Add-In for SOLIDWORKS CAD.
 Simulation Mixed Meshing
o Improved mesh formulation allows both draft and high quality solid elements to coexist in the same
simulation study. Draft is faster in solution time while high quality is more accurate. The result is
quicker solving time.

For example: To model a washer, sketch the inside and outside diameters then extrude the profile to
the thickness required.
3.2 Ansys
If you’ve ever seen a rocket launch, flown on an airplane, driven a car, used a computer, touched
a mobile device, crossed a bridge, or put on wearable technology, chances are you’ve used a
product where ANSYS software played a critical role in its creation. ANSYS is the global leader
in engineering simulation. We help the world’s most innovative companies deliver radically
better products to their customers. By offering the best and broadest portfolio of engineering
simulation software, we help them solve the most complex design challenges and engineer
products limited only by imagination.

ANSYS uses certain inputs and evaluates the product behaviour to the physics that you are testing
it in. It is a general purpose software used to simulate the interactions between various physics
like dynamics, statics, fluids, electromagnetic, thermal, and vibrations. ANSYS typically creates
the user an opportunity to create a virtual environment to simulate the tests or working conditions
of the products before manufacturing the prototypes. This would certainly reduce the cost of
producing prototypes and mainly the time. In this competitive world the accuracy and time are
the most deciding factors for the company or the organization to sustain. ANSYS helps in
increasing the accuracy and decreasing the time of outcome of the final product

Advantages:
 ANSYS can import all kinds of CAD geometries (3D and 2D) from different CAD
software's and perform simulations, and also it has the capability of creating one
effortlessly. ANSYS has inbuilt CAD developing software's like Design Modeler and
Space Claim which makes the work flow even smoother.
 ANSYS has the capability of performing advanced engineering simulations accurately
and realistic in nature by its variety of contact algorithms, time dependent simulations
and non-linear material models.
 ANSYS has the capability of integrating various physics into one platform and perform
the analysis. Just like integrating a thermal analysis with structural and integrating fluid
flow analysis with thermal and structural, etc.
 ANSYS now has featured its development into a product called ANSYS AIM, which
is capable of performing multi physics simulation. It is a single platform which can
integrate all kinds of physics and perform simulations.
 ANSYS has its own customization tool called ACT which uses python as a background
scripting language and used in creating customized user required features in it.

For example we can do a simple task to fill surface geometry in Ansys. The following
screenshot shows one view:-
 CHAPTER-4
PARTS DESCRIPTION

4.1 Square Pipe

A hollow structural section (HSS) is a type of metal profile with a hollow cross-section. The
term is used predominantly in the United States, or other countries which follow US construction
or engineering terminology.
HSS members can be circular, square, or rectangular sections, although other shapes such as
elliptical are also available. HSS is only composed of structural steel per code.
Square HSS is made the same way as pipe. During the manufacturing process flat steel plate is
gradually changed in shape to become round where the edges are presented ready to weld. The
edges are then welded together to form the mother tube. During the manufacturing process the
mother tube goes through a series of shaping stands which form the round HSS (mother tube)
into the final square or rectangular shape.
Required Dimensions: - cross-section- 1.5x1.5 inch
Length – 24 inch (approx.)
Material properties:-
The Square pipe is made of Mild steel
Use-
It will be used to make the supporting frame for holding the tool.
4.2 L-Section

Section Beams are made of steel and they have a specific lengths and shapes like I-beam, L, C-
channel and I flanged beam. These types of section are usually used in steel structures and it is
common to connect them with plates of steel.
Steel design, or more specifically, structural steel design, is an area of structural
engineering used to design steel structures. These structures include schools, Houses, etc. The
design and use of steel frames are commonly employed in the design of steel structures. More
advanced structures include steel plates and shells.
In structural engineering, a structure is a body or combination of pieces of rigid bodies in space
that form a fitness system for supporting loads and resisting moments. The effects of loads and
moments on structures are determined through structural analysis. A steel structure is composed
of structural members that are made of steel, usually with standard cross-sectional profiles and
standards of chemical composition and mechanical properties. The depth of steel beams used in
the construction of bridges is usually governed by the maximum moment, and the cross section
is then verified for shear strength near supports and lateral torsional buckling (by determining
the distance between transverse members connecting adjacent beams). Steel column members
must be verified as adequate to prevent buckling after axial and moment requirements are met.
Required Specifications:- Thickness- 3 mm
Cross-section- 2 inch
Material- Mild steel
Use-
The basic purpose of the L-section is to support the Hydraulic jack. Apart from
That it also forms the body of the setup.
4.3 Extension Springs

An extension spring’s close-wound design opposes extension between mechanisms. Extension

springs provide return force to components that extend in the actuated position. Extension spring
ends include threaded inserts, extended twist loops, crossover centre loops, hooks, expanded
eyes, reduced eyes, rectangular ends and teardrop-shaped ends. Hook ends limit an extension
spring’s performance when hooks sit higher than the spring body. Initial tension determines how
tightly an extension spring is coiled.

An extension spring’s ends attach between two mechanisms. The extension springs hooks and
loops store and absorb energy. Through hooks or loops, an extension spring provides return force
to connected mechanisms.
Tightly wound extension springs typically sit in the no-load position. More stress in the end
hooks—as opposed to the spring body—limits the performance of extension springs.

Required Specifications- Material- Stainless Steel

Brand- ESS AAR
Style- Cylindrical
Material Grade- ASTM 228 Music wire
Use-
It will be used for lifting action of the hydraulic jack and Blade. It is extremely essential in order
to return the setup in the original position.
4.4 Horizontal Blade

A blade is the portion of a tool, weapon, or machine with an edge that is designed
to puncture, chop, slice or scrap surfaces or materials. Blades are typically made from materials
that are harder than those they are to be used on. Historically, humans have made blades from
flaking stones such as flint or obsidian, and from various metal such as copper, bronze and iron.
Modern blades are often made of steel or ceramic. Blades are one of humanity's oldest tools, and
continue to be used for combat, food preparation, and other purposes.
Blades work by concentrating force on the cutting edge. Certain blades, such as those used on
bread knives or saws, are serrated, further concentrating force on the point of each tooth.
A simple blade intended for cutting has two faces that meet at an edge. Ideally this edge would
have no roundness but in practice all edges can be seen to be rounded to some degree under
magnification either optically or with an electron microscope. Force is applied to the blade, either
from the handle or pressing on the back of the blade. The handle or back of the blade has a
large area compared to the fine edge. This concentration of applied force onto the small edge area
increases the pressure exerted by the edge. It is this high pressure that allows a blade to cut
through a material by breaking the bonds between the molecules/crystals/fibres/etc. in the
material. This necessitates the blade being strong enough to resist breaking before the other
material gives way.
Required Specifications- Blade Material- Tool Steel
Available sizes-250 to 260 mm Long x 80 x 9 mm
Blade type- Frame cutting (colour- Bright)
Use-
It will used for shearing of the sheet metal.
4.5 Hydraulic Jack

A hydraulic jack is a device that is used to lift heavy loads by applying a force via a hydraulic
cylinder. Hydraulic jacks lift loads using the force created by the pressure in the cylinder
chamber.
A hydraulic jack creates pressure by moving oil through two cylinders via a pump plunger. The
pump plunger is drawn back, which opens the suction valve and draws oil into the pump chamber.
As the plunger is pushed down, the oil is transported through an external discharge valve and
into the cylinder chamber. The suction valve then closes, resulting in pressure being built up
within the chamber; causing the piston in the chamber to rise and lift your heavy object. This
process can be repeated many times, allowing your load to be lifted higher, and higher.
Hydraulic jacks function based on a concept in fluid mechanics known as Pascal’s Principal.
Essentially, if two cylinders (a large and a small one) are connected by an incompressible fluid,
and a given amount of pressure is applied to one cylinder, that same pressure is imparted to the
second cylinder through the fluid connecting them. However, because pressure is equal to force
per unit area, the cylinder that has a larger area will experience a force multiplication effect. Even
though the pressure on both cylinders is the same, the force which is produced by the larger
cylinder will be higher, proportionally higher based on the area of the cylinder.
Specifications:- We are using a 3 ton-force generating hydraulic piston for both the shearing and
bending operation.
We know, 1 ton-force= 9806.65N, so, 3 ton-force= 3*9806.65= 29419.95 N = 29.419kN
Use-
It is the main component of our setup and it will be used to move the shearing blade
and bending tool.
4.6 J- Bolt

J-bolts are J-shaped fasteners, threaded on the flat side.

They are often used in structural applications like
securing walls to concrete foundations. The bent end
hooks around rebar for support, and may be cast in
concrete for use as an anchor bolt. They are designed
for household and industrial applications and each bolt
comes with a furnished hex nut. They are manufactured
from steel wire and mostly designed for home and farm
applications.
Specifications:-
Required specifications: - Size-1/2"-4", M5 - M64
Type of bolt- Hexagonal
Bolt type- J- shaped (Mild steel)
Thread- Metric thread

Use-
It will be used to support the springs.
 CHAPTER-5
SOLID MODELLING OF SETUP

All the models are made using Solidworks software and later the setups
are designed and analysed using Ansys software. Following are the
models of all the tools and setup.

5.1 Bending Tool

5.2 Shearing Tool
5.3 Bending Setup
5.4 Shearing Setup
 CHAPTER-6
DESIGN OF COMPONENTS

6.1 Sheet Thickness

Standard sheet metal gauges available are as follows:-

Carbon Galvanized Stainless Steel
Gauge Steel Aluminium
Steel eh Steel Steel (mm)

07 0.179 - - - - 4.547

08 0.165 0.1644 0.1681 0.1719 0.1285 4.191

09 0.150 0.1495 0.1532 0.1563 0.1144 3.810

10 0.135 0.1345 0.1382 0.1406 0.1019 3.429

11 0.120 0.1196 0.1233 0.1250 0.0907 3.048

12 0.105 0.1046 0.1084 0.1094 0.0808 2.677

13 0.09 - - 0.094 0.072 2.286

14 0.075 0.0747 0.0785 0.0781 0.0641 1.905

15 0.067 - - 0.07 0.057 1.702

16 0.060 0.0598 0.0635 0.0625 0.0508 1.524

17 0.054 - - 0.056 0.045 1.372

18 0.047 0.0478 0.0516 0.0500 0.0403 1.1938

19 0.042 - - 0.044 0.036 1.067

20 0.036 0.0359 0.0396 0.0375 0.0320 0.9144

21 0.033 - - 0.034 0.028 0.838

22 0.03 - - 0.031 0.025 0.762

23 0.027 - - 0.028 0.023 0.686

24 0.024 - - 0.025 0.02 0.61

 25 0.021 - - 0.022 0.018 0.533

26 0.018 - - 0.019 0.017 0.457

27 0.016 - - 0.017 0.014 0.406

28 0.015 - - 0.016 - 0.381

29 0.014 - - 0.014 - 0.356

30 0.012 - - 0.013 - 0.305

31 - - - 0.011 - -

 Thickness is expressed in inches except for the mm column (1in = 25.4mm).

From the above table it is clear that 18 out of 25 types of sheet metal available are within 2 mm
for different types of steel and aluminium. Hence we take maximum sheet thickness for bending
to be 2 mm in our design as it covers 72% of the sheets as shown in the chart.

Sheet Range Chart

More than 2 mm
28% Within 2 mm

More than 2 mm

Within 2 mm
72%

For sheet cutting operation, we are going to use double bladed hand operated type shear machine
for which 2 mm will be a greater thickness as compared to bending operation. Hence we will
take maximum thickness for shearing to be 1.5 mm for all shearing design and calculations.
6.2 Bending Force

We know max. work load per unit width is given by:

Fmax= (M/l)×[1+cos(tan-1µ) +µ*sin(tan-1µ)]

And Bending moment per unit width is given by:

M= (0.55t) 2{σy0/6 + σy1/3} + (0.45t) 2{σyo/6 + σy2/3}
Now, strain in the outer fiber is given by
εmax= ln[1+ 1/ (1.82(rp/t) + 0.82) ]

Taking nose radius of punch rp=1mm and job thickness t=2mm,

We get εmax=ln[1+ 1/1.73]= 0.4561
Taking yield stress σy0= 345 N/mm2 and Strain hardening rate n= 517N/mm2
We have σy1= σy0+n*εmax= 345+517*0.4561= 580N/mm2
Also σy2=σy0 + n*ln [1+ 1/ (272(rp/t) +1)]
= 345 + 517*ln (1.4739)
=545.55N/mm2
Now the Bending moment M per mm width is (from the above formula)
M= 497.3899 N
Taking µ=0.1 and l=18mm

Fmax (per mm width) = (497.3899/18)*[1+0.99+0.00994]

= 55.264N/mm

So, actual maximum bending force= 55.264*304=16800.256N.

(Width of the sheet= 304mm)
Fmax=16800.256/9806.65= 1.71 ton-force
Taking Factor of safety= 1.2,
We have, Fmax = 1.71*1.2=2.052 ton-force
6.3 Shearing Force

Cutting force F in sheet metal working is given by:-

F= S*t*L
Where, S= shear strength of the sheet metal in MPa
t= Stock thickness in mm
L= length of the cut edge in mm
Taking shear strength S= 310 MPa and t= 1.5mm and L=40mm,
Cutting force F= 310*1.5*40=18600N
= 18600/9806.65
= 1.89 ton
Taking factor of safety as 1.2, Fmax = 1.89*1.2 = 2.27 ton

6.4 Hydraulic Jack

Now, since the maximum force for bending and shearing comes out as 2.05 ton force and 2.27
ton force respectively, we take a hydraulic jack of 3 ton for our purpose.

6.5 Design of Upper Support

The upper support takes all the force of hydraulic jack and in turn provides a reaction force for the
successive bending and shearing operation. It will be clamped to the upper part of frame with nuts
and bolts.

It is considered as a beam and the force that is applied by jack is considered as a point load.

Dimensions of the support:

Length (L): 139.70 mm
Cross section: 175 mm * 10 mm
Force applied by the jack (P) = 3 tons = 29430 N
Moment of inertia (I) = 𝑏ℎ3 /12
103
= 175 ∗
12
= 14580 mm4
Maximum bending moment = PL/4
= 29430*139.7/4
= 1027.84 kN-mm
σmax = M*ymax/I
= 1027.8*2.5/14580
= 176 MPa
Fos = 250/176
= 1.42

δ = PL3/48EI
= (29430*139.703)/(48* 200000* 14580)
= 0.5 mm
Hence, the design is safe.

6.6 Design of Lower Support for Hydraulic Jack

The lower support is extremely crucial part as it facilitates the following things:
i) Support the hydraulic jack and bears all of its weight.
ii) The bending setup and shearing setup is assembled with this.
iii) Springs are attached to this support which helps to take back the jack after operation.

It is considered as a beam and the weight of jack is considered as a point load.

Dimensions of the support:

Length (L): 336 mm
Cross section: 3 mm * 38.10 mm
Weight of jack (P) = 10 kg = 98 N

bh3
Moment of inertia (I) =
12
33
= 38.10 ∗
12
= 85.72 mm4
Maximum bending moment = PL/4
= 98*336/4
= 8232 N-mm
σmax = M*ymax/I
= 8232*1.5/85.72
 = 144 MPa
Fos = 250/144
= 1.73
δ = PL3/48EI
= (98*3363)/(48* 200000* 85.72)
= 4.5 mm
Hence, the design is safe.

6.7 Design of Bolts

The bolts are used in various place to assemble the setup. The bolts of the upper support and
base of the setup are taking all the force of bending and shearing. Hence these are critical bolts
and to be considered for design.

Selected bolt: M10 Hexagonal bolt.

Cross sectional area (A) = πD2/4
= 78.53 mm2
Since there are 4 bolts, the maximum force is shared by all of them equally.
So, F= Fmax/4
= 23430/4
= 7357.5 N

τ = F/A
= 7357.5/78.53
= 93.67 MPa
Fos = 200/93.67
= 2.13
Hence, the design is safe.

6.8 Design of Springs

The two springs which are attached to the lower support is to take the jack back after operation.
Dimensions: 15 mm Coil diameter and 2 mm wire diameter.
Material: ASTM 228 Music wire

The spring will undergo repeated cycles of expansion and contraction and hence will be
designed for fatigue.

Pmax = 98/2 = 49 N
Pmin = 0
Pm = (49-0)/2 = 24.5 N
Pa = (49+0)/2 = 24.5 N
C = D/d
= 15/2
= 7.5
Ks = (1+0.5/C)
= 1.06
τs = Ks*8PmD/(πd3)
= 123.99 MPa

4𝐶−1 0.615
K= +
4𝐶−4 𝐶
= 1.18
τa = 8KPaD/(πd3)
= 138.03 MPa
Sse = 0.21Sut
= 514.5 MPa
Ssy = 0.42Sut
= 1029 MPa

The values of τs and τa are well within the endurance and yield strength of ASTM 228 Music
wire and hence the design of springs are satisfactory.

6.9 Ansys Simulation

6.10 Final Dimensions
Shearing Tool Dimensions

Bending Front View

Bending Right View
References:
1. Fundamentals of Modern Manufacturing, MP Groover.
2. Manufacturing Science, 2nd Edition, Ghosh and Mallik.
3. Mechanics of Materials, Gere and Timoshenko
4. Design of Machine Elements, Bhandari, Tata McGraw Hill
5. Shigley’s Mechanical Engineering Design, 10th Edition, Tata McGraw Hill
6. https://www.cableorganizer.com/learning-center/articles/gauge-metal-sheet.html
7. www.solidworks.com
8. www.ansys.com/en-in
9. www.wikipedia.org
10.www.indiamart.com