Ironworker Prototype II Proposal
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by Brianna Kufa and Reid Enniss
Current Design Progress, 12/8/11
- I was far into a previous design, when I realized how foolish it was to be designing my own blade instead of purchasing and mimicking one that already has the proper dimensions and capacity. I am scrapping that design and beginning a new one similar to a Scotchman 120T.
Design Concept
The next design will mimic a Scotchman 120T.
- It will have an upper and lower arm, both attached to the cylinder.
- The upper arm will have the punch permanently attached, and will have a table below it onto which you can put various accessories, including an angle shear.
- The lower arm will have a shear blade attached.
- Accessory tools can be made as necessary. Possible tools include: brakes, tubing shear, notcher, rod shear, and more.
- If we can find the dimensions for a blade for a 120T flat shear, or the angle blade, we will build our own blades by machining the proper tool steel and getting it professionally hardened. If we can't find it, we will have to buy the blades and then copy them.
Dependencies
We need to know:
- How much force the cylinder is exerting on the lower arm, and how far from the lower pin it attaches.
- Blade location relative to the arm and the table.
- Blade dimensions.
Analysis of Industry Standards
See the Spreadsheat Comparison. (Note: If someone can figure out how to embed this, that would be fantastic! Google changed the "Share" menu.)
Summary
- The most common machines cost $18.5k-25k.
- They weigh between 4800 and 5500 lbs.
- The punch capacities are all at least 120 tons.
- All except the Uni-Hydro can flat shear up to 1"x12", and most have 24" blades.
- All can shear at least 1/2"x6"x6" angle.
- Most machines shear the flat by an "angular" cut, meaning that the blade is rotating about some point.
Findings:
Most machines shear the flat by an "angular" cut. The closest design to the OSE objective is the Scotchman. It has a relatively simple construction, and enables quick re-tooling. The center table is desirable as big (up to 24" wide) attachments can fit inside, enabling more diverse fabrication.