Ironworker Prototype II Geometry

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See the OSE Ironworker Prototype II for other details. Prototype II has the following geometries:

  1. The cylinder has a 5" bore, 16" stroke, 2.5" shaft thickness
  2. The upper shear blade is in line with the line from the main pivot
  3. The end of the upper shear blade closest to the main pivot is 19" away from the main pivot
  4. The blade is approximately 14.5" long
  5. At full open shear position, the end of the blade closest to the pivot is open 1.5" wide, and the end farther away from the pivot is open 3" wide
  6. In the fully closed shear position, the upper blade edge closer to the pivot is about 1/4" below the edge of the lower blade, while the far end is just closed
  7. In the 1" open position of the blades closer to the pivot, the farther end of the blades from the pivot is 1.5" open
  8. When just closed at the position closest to the pivot, the end of the blades farther from the pivot is 5/16" open
  9. Conclusions: the far end of the blade from the pivot travels a total of 3" vertical motion; the close end of the blade travels 1-5/8" vertically
  10. End point of shear blades closest to the pivot has a mechanical advantage of (cylinder travel/ blade travel) = 16/1.6 ~ 10
  11. End point of shear blades farthest from pivot has a mechanical advantage of 16/3 ~ 5.3
  12. To obtain 10x mechanical advantage with a simple lever design ironworker machine - if we use a 5" cylinder - then we need to use a cylinder with a stroke of 12 inches to travel 1.2 inches. An 8" cylinder gets us a ~7x mechanical advantage.

Conclusions: we can likely shear 10" slabs with the 7x mechanical advantage - 140 tons at the beginning of cut. Need to figure out mechanical advantage at end of cut based on geometry of having a 1" opening at the end closer to the pivot. We want to have the farther end of blades be about .5" higher than the closer end of blades (accprding to point 7 above). Thus, whatever location of blades we choose, we need to have far end .5" above the close end of the blades.