ABSTRACT

In many industries it is required to cut complex contours on sheet metal, as they are
the part of sheet metal components that are in their ‘development form’. These
contours due to their odd shape and size, also low quantity of production cannot be
produced as pressed components. Hence the only solution in such cases is cut the
contours by chisel and files the given profile. This method requires extensive labor
and skill and so also it is extremely time consuming. Hence the need of a special
purpose machine for fast production and accuracy.

A machine named “UNIVERSAL NIBBLING MACHINE” which can cut the

sheet metal by nibbling action. Nibbling is a continuous punching operation with a
circular tool and is used for producing internal and external cut-outs of any shape.
The working principle on which nibbling operates is the sheet is cut or formed
between the fast reciprocating motion of an upper tool (powered by an electric
motor and driven by an eccentric crank) and a stationery lower tool, by progressive
punching, as the sheet is fed.

Keywords:

Universal, Nibbling, Sheet metal, Shearing

INDEX

1. PROJECT OVERVIEW…………………………….............................. 01
2. INTRODUCTION AND MOTIVATION………………….…………. 02

3. PROBLEM STATEMENT……………………………………………. 03

3.1. Shearing…………………………………………………………… 03

3.2. Nibbling…………………………………………………………… 03

3.3. Rectangular Notching……………………………………………….. 04

3.4. Inner Circular Cutting ………………………………………………. 04

4. REQUIREMENT ANALYSIS……………………………………….. 05

5. PROJECT DESIGN…………………………………………………… 06

5.1. System Design……………………………………………………… 07

5.1.1. System Selection Based on Physical Constraints…………………... 07

5.1.2. Arrangement of Various Components…………………………. 07

5.1.3. Components of System……………………………………… 07

5.1.4. Man Machine Interaction……………………………………. 07

5.1.5. Chances of Failure……………………………………………………. 08

5.1.6. Servicing Facility…………………………………………… 08

5.1.7. Height of Machine from Ground……………………………… 08

5.1.8. Weight of Machine…………………………………………. 08

5.2. Mechanical Design…………………………………………………. 09

6. IMPLEMENTATION DETAILS……………………………………. 11

6.1. Cutting Force………………………………………………………. 11

 6.2. Motor Selection…………………………………………………….. 11

6.3. Design of Belt Drive for Machine Spindle……………………………………. 12

6.3.1. Input Data……………………………………………………………. 12

6.3.2. Selection of Belt Section…………………………………………….. 12

6.3.3. Power Transmitting Capacity of Belt………………………………... 14

6.3.4. Length of Belt………………………………………………………… 15

6.3.5. Selection of Belt……………………………………………………… 15

6.3.6. Result Table………………………………………………………….. 15

6.4. Design of Main Shaft………………………………………………………….. 16

6.4.1. Selection of Intermediate Shaft Material…………………………… 16

6.4.2. Considering Pure Torsional Load…………………………………… 17

6.4.3. Check for Bending Failure of Shaft…………………………………. 18

6.5. Design of Bearing……………………………………………………………… 19

6.5.1. Selection of Bearing at ‘A’…………………………………………… 19

6.5.2. Selection of Bearing at ‘B’…………………………………………… 21

6.6. Design of Key………………………………………………………………….. 23

6.6.1. Check for Shear Failure of Key………………………………………. 23

6.6.2. Check for Crushing Failure of Key........................................................ 23

7. TECHNOLOGIES USE………………………………………………. 24

7.1. Bill of Materials……………………………………………………. 33

8. TEST CASES………………………………………………………….. 34
9. PROJECT TIME LINE………………………….................................. 35

10. TASK DISTRIBUTION ………………………………………………. 37

11. CONCLUSION AND FUTURE WORK…………………………….. 38

12. REFERENCES………………………………………………………… 39

LIST OF FIGURE
Fig.3.1: Shearing……………………………………………………………………….. 03

Fig.3.2: Nibbling……………………………………………………………………….. 03
Fig.3.3: Rectangular Notching…………………………………………………………. 04

Fig.3.4: Inner Circle Cutting…………………………………………………………… 04

Fig.6.3.1: V-Belt……………………………………………………………………….. 12

Fig.8.1: Square & Rectangular Test Cases…………………………………………….. 34

LIST OF TABLE
Table No:5.2.1. Belt Cross Section………………………………………………………………. 13

Table No: 5.2.1. Result Table…………………………………………………………………….. 15

Table No: 5.3.1. Material Selection………………………………………………………………. 16

Table No: 5.4.1. Material Selection………………………………………………………………. 19

Table No: 5.4.2. Material Selection………………………………………………………………. 21

Table No: 7.1.Tecnology Used …………………………………………………………………… 25

Table No: 7.2.Tecnology Used …………………………………………………………………… 26

Table No: 7.3.Tecnology Used …………………………………………………………………... 27

Table No: 7.4.Tecnology Used …………………………………………………………………... 28

Table No: 7.5.Tecnology Used …………………………………………………………………… 29

Table No: 7.6.Tecnology Used ……………………………………………………………………. 30

Table No: 7.7.Tecnology Used ……………………………………………………………………. 31

Table No: 7.8.Tecnology Used …………………………………………………………………..... 32

Table No: 7.1.1.Bill of Material ………………………………………………………………….. 33

Table No: 10.1. Task Distribution ………………………………………………………………… 37