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.
Basic Structure
- 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. There must be a blade gap adjuster.
- 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.
Non-Structural features
- Angle Shear Attachment- Similar to the one included with the scotchman. Angle Blade slides up and down in its casing, which contains lower blades and rails for it.
- Tables milled out so you can put on an adjustable fence.
- Adjustable Stripper
- Grease joints
- Rubber Clamp for flat shear (could be manual or hydraulic)
- Back gauge for repeated measurements
Useful, but not necessary, design features
- Foot Pedal
- Multiple controls
- Punch and Die rack
- Slug catcher
Possible Accessories
- Notcher
- Brake
- Channel Shear
- Rod Shear
- Tubing Shear
- Non-uniform angle shear
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
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
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.
Although the Edwards is a popular model, and there are many on the market which work similarly (Geka, Peddinghaus) this design is undesirable for OSE. They are a "closed off" design, and accessory tools cannot be as diverse as on a machine like the Scotchman.