Cutting Roller Ms 2007

DOCUMENT NO.
TITLE
Cutting Roller Design
STATUS
IFA
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DATE
25-02-2014
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Table of Contents
Table of Contents .........................................................................................................1
I.
BRIEF OF PROPOSAL .....................................................................................2

1.General.................................................................................................................2
2.Purpose.................................................................................................................3
3.Notice....................................................................................................................3
II.
DESCRIPTION OF PROPOSAL .....................................................................4

1. Design ..................................................................................................................4
2. Design Reference ................................................................................................4
3. Structure Calculation ........................................................................................4
4. Actual Equipment ..............................................................................................4
III. ADVANTAGES AND BENEFITS ....................................................................7

1. Attachment .........................................................................................................4
DOCUMENT NO.
TITLE
I.
BRIEF OF PROPOSAL
1.
General
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Cutting and welding operations (commonly referred to as hot work) are

associated with fabrication, maintenance, and construction activities. In piping
fabrication, cutting process is a critical operation in workshop activity. There
are two kind of cutting process which is consisting of hot cutting and cold
cutting.
Hot cutting process is done by using a cutting tool like plasma cutter or cutting
hand and a holder.
Fig 1. Hand Pipe Cutting Machine
Usually, in hot cutting process the plasma cutter running on the path of pipe
circumferences. In this situation the operators have a difficulty on rotating the
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pipe and they solved it by cutting the pipe above their head and it takes longer
time to accomplish and it risks operator struck by fire sparks.
2.
Purpose
This condition brings PT Gearindo Prakarsa to develop a method how to make
it easier and faster and safer in processing the pipe cutting activity.
The rolling cutter is an innovation tool that PT Gearindo Prakarsa design and
build according to development of that method. The tool let the pipe rolling
freely around it axis with a fixed horizontal position while the plasma cutter
cut the pipe circumferences in its fix position, this way the cutting process
have more accuracy because of the position of the cutter does not have any
movement or displacement.
This tool also minimizes error that made by operator and also reduces risk of
being struck by fire spark. This tool will increase the efficiency of pipe cutting
operations which is the pace for all downstream operations. Speed, quality and
dimensional accuracy of cutting pipe will contribute to lower project labor
costs.
3.
Notice
This method also submitted by PT Gearindo Prakarsa to fulfill Innovation and
Technology criteria in KPI Score under PHE Contract number STC-0789.
DOCUMENT NO.
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II.
DESCRIPTION OF PROPOSAL
1.
Design
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This tool is designed as simple as possible and easier to build without reducing
the functionality and benefits of the equipment with consideration as a wellconceived cutting system will incorporate the following concepts:
Mechanizing the cutting operation results in repeatable, high quality

cuts free from human error.
This cutting roller is combined with Hand Pipe Cutting Machine so

that torch carriages remain in its fix position and allow pipe from
diameters 4 until 20 to be cut in length without interference
anywhere along the machine bed and in full view of the operator.
2.
Design Reference
Fig. 2 Reference Design
DOCUMENT NO.
TITLE
3.
Structure Calculation
Load calculation:
Torque calculation:
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Polar moment of inertia calculation:
Maximum shear stress calculation:
The cutting roller materials is ASTM A36 with yield strength 250 MPa, so
its concludes that the maximum shear stress is bellow the yield strength of the
material.
4.
Actual Equipment
Fig.3 Cutting Roller in Action (a)
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Fig.3 Cutting Roller in Action (b)
III.
Advantages and Benefits

During operation of cutting roller is observed and obtained the following
results:
Activity
1
Cutting
Position
Before use of Cutting

Roller
Upper head cutting
position
After use of
Cutting Roller
Lower head cutting
position
Cutting Result
Rough pipe surface result
Pipe surface
relatively smoother
Cutting Time
For 20 pipe cutting

duration = 6.05 min
For 20 pipe cutting

duration = 6.38 min
Operator
Need 3 person or more

simultaneously
during
cutting operation
Preparation
Takes 5 minutes or more
Need only 2 persons

for first time setting
then 1 person after
setting
Takes only 2-3
minutes
Advantages
Reduces risk of being
struck by fire spark
Reduces risk of head
getting hit by pipe
Small
portion
of
grinding activity for
reducing rough surface.
Repeatable
cutting
result
with
higher
quality
Reduces cutting time,
increasing production
efficiency
Effective working time
Effective
preparation
time will increase more
production
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Attachment
Attachment 1
Assembly Drawing
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Attachment 2
3D Mechanical Drawing
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Attachment 3
Cutting Roller 2D Layout
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Cutting Roller Ms 2007

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DOCUMENT NO.

Cutting Roller Design

BRIEF OF PROPOSAL .....................................................................................2

DESCRIPTION OF PROPOSAL .....................................................................4

III. ADVANTAGES AND BENEFITS ....................................................................7

Cutting Roller Design

Cutting and welding operations (commonly referred to as hot work) are

Fig 1. Hand Pipe Cutting Machine

Cutting Roller Design

Cutting Roller Design

Mechanizing the cutting operation results in repeatable, high quality

This cutting roller is combined with Hand Pipe Cutting Machine so

Fig. 2 Reference Design

Cutting Roller Design

Cutting Roller Design

Polar moment of inertia calculation:

Maximum shear stress calculation:

Fig.3 Cutting Roller in Action (a)

Cutting Roller Design

Fig.3 Cutting Roller in Action (b)

Advantages and Benefits

Before use of Cutting

Rough pipe surface result

For 20 pipe cutting

For 20 pipe cutting

Need 3 person or more

Takes 5 minutes or more

Need only 2 persons

Cutting Roller Design

Cutting Roller Design

Cutting Roller Design

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