ME 6612 DESIGN AND FABRICATION PROJECT

DESIGN AND FABRICATION OF sheet metal CUTTING

MACHINE USING GENEVA MECHANISM
PROJECT MEMBERS:

1. JAYAPRAKASH. P (411413114021)
2. JEROME. V (411413114020)
3. PRASANTH. D (411413114029)

PROJECT GUIDE:
Mrs.M.BHAVANI M.E
ASSISTANT PROFESSOR

PROJECT GUIDE
Mr.T.SURESH M.E
ASSISTANT PROFESSOR
 ABSTRACT
The design and fabrication of sheet metal cutting machine using Geneva
mechanism is very useful to cut sheet metals in equal and accurate dimensions.
Geneva drive is an indexing mechanism that converts the continuous motion
into intermittent motion. Due to the intermittent motion, the sheet metal is
moved between the time intervals of cutting periods. Then the sheet metal
cutting is achieved by the crank and lever mechanism. The cutter will be back to
its original position by the spring effect.
OBJECTIVES:
1. To cut the sheet metal in accurate and equal dimensions.
2. To reduce the time for marking the dimension in sheet metal.
3. To get the sheet metal cutting machine in low cost.
4. To design the machine in compact size.
 INTRODUCTION
1.The sheet metal cutting machine is designed, in order to reduce the time
for marking and cutting the sheet metals. Geneva mechanism is
commonly used indexing mechanism where an intermittent motion is
required.
2.The fabrication of conventional Geneva mechanism is generally simple
and inexpensive. Because there is no special curved profile on any of
the components except straight lines and circular arcs.
3.The sheet metal cutting is done by crank and lever mechanism. After
cutting, the spring connected to the cutter will bring the cutter back to
its original position.
4.The main purpose of this machine is to reduce time for marking the
sheet metals. Hence, this machine is working fully based on timing.
 MECHANISMS
1. Geneva wheel mechanism

The Geneva mechanism is used here to get the intermittent

motion. This Geneva mechanism is also called as indexing
mechanism.
2. CRANK AND LEVER MECHANISM

Here the sprocket (crank) is connected to the lever (cutter) by a connecting

link (string). When the crank rotates, this rotation is converted into
oscillating motion. Hence the cutter gets oscillating motion to cut the sheet
metal.
COMPONENTS:
1. Geneva wheel
2. Sprockets
3. Roller chain
4. sheet metal cutter
5. Coil spring
6. Sheet metal roller
GENEVA WHEEL:

In our Geneva, the driven wheel has four slots and thus advances by one step of
90 degrees for each rotation of the drive wheel. Hence the intermittent motion is
achieved for ¼ of the 360 degrees.
SPROCKETS:

A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs, or even

sprockets that mesh with a chain. The sprockets are used for the power
transmission between two shafts through the roller chain.
ROLLER CHAIN:

Roller chain is the type of chain drive most commonly used for transmission of
mechanical power between two sprockets. It consists of a series of short
cylindrical rollers held together by side links. It is driven by a toothed wheel called
a sprocket.
sheet metal CUTTER:

A sheet metal cutter is a tool, designed to cut the sheet metal with a straight edge.
sheet metal cutters vary in size. This sheet metal cutter is used as the oscillator in
the four bar crank and lever mechanism.
COIL SPRING:

A coil spring, also known as a helical spring, is a mechanical element, which is

typically used to store energy and subsequently release it. This coil spring is used to
bring the cutter to its original position.
SHEET METAL ROLLER:

sheet metal roller is an element which is used to roll the sheet metal while the
intermittent motion. The sheet metal roller is used to feed the sheet metal without
any damage.
 WORKING PRINCIPLE
The handle is fixed to the crank (sprocket). If the handle is rotated,
1. When the cam pin is in extreme right position i.e. engage position, the crank
shaft will be at extreme bottom position. Hence the cutter is in full open
position and the spring will be in rest position.
2. When the cam pin is in extreme bottom position i.e. disengage position, the
crank shaft will be at extreme left position. Hence the cutter is in partial
cutting position and the spring will be in partial tension.
3. When the cam pin is in extreme left position i.e. disengage position, the
crank shaft will be at extreme top position. Hence the cutter is in full
cutting position and spring will be in full tension.
4. When the cam pin is in extreme top position i.e. disengage position, the
crank shaft will be at extreme right position. Hence the cutter is in
partial cutting position and the spring will be in partial tension.
Thus the sheet metal cutting is achieved by the above four process of the
Geneva and cutter.
 DESIGN CALCULATION FOR sheet metal FEEDING
Length of the sheet metal to be feed can be adjusted by..
The sheet metal feed length = (circumference of the roller)/no.
of slots in Geneva wheel
L = (2 * * R) / n
Where n is the number of slots in the Geneva wheel.
R is the radius of the roller,
L is the length of the sheet metal to be feed.
DESIGN CALCULATION FOR CAM DRIVE

1. Angle of locking section, γ= π/2 (Z+2) =270˚

2. Semi-indexing angle(driven) α= π/Z = 45˚

3. Semi-indexing angle (driver) β= π(Z-2)/(2Z) =45˚

4. Gear ratio є=1 for Z=4

5. Radius ratio, µ= R/r =1.000

6. Indexing time ratio, ν= β/π =0.2500

 COMPONENTS SPECIFICATION
MATERIAL SELECTION AND NO. OF MATERIALS
S.NO
. PART MATERIAL NO. OF
1 Geneva wheel Mild steel 1
2 Sprockets Cast iron 2
3 Roller chain Stainless steel 1
4 sheet metal cutter Steel 1
5 sheet metal roller Mild steel 1
6 Coil spring Steel alloy 2
7 Shaft Mild steel 3
8 Frame and base Mild steel 1
 COST ESTIMATION

S.NO PART AND DESCRIPTION COST

 
1 Geneva wheel 1300
2 Sprockets  550

3 Roller chain  250

4 sheet metal cutter 500

5 sheet metal roller 500
6 Coil spring  100
7 Shaft  350

8 Frame, base and other materials  1500

9 TOTAL  5050
MERITS:
1.No need for marking the sheet metal.
2.It will reduce the time for marking the sheet metal.
3.The dimension of the sheet metal will be accurate.
4.Manufacturing cost is less.
5.No noise pollution.
6.Compact in size.
7.Can be used for small scale industries.
8.Can able to change the machine elements easily
LIMITATIONS:
1. Can’t able to cut the sheet metals above 15 cm width.
2. Can’t able to cut bunch of sheet metals i.e. more than 5 sheet metals.
3. Can’t be used for large scale industries.
APPLICATIONS:
1. It can able to use in sheet metal cutting industries.
2. It can able to use in sheet metal crafting.
3. It can be used in many small scale sheet metal industries.
 Conclusion
The design and fabrication of sheet metal cutting machine using the Geneva
mechanism is will be very useful in small scale industries. There are many
machines based on sheet metal cutting but it has some demerits like large in size,
costly, need skilled people to operate and it needs electrical input. But our machine
will overcome this demerits by compact in size, less cost, no need for skilled
people and there is no need for electrical input. The design procedure is done for
fabricating the Geneva wheel and other elements of this machine. The main aim
for this machine is to reduce timing for sheet metal cutting and neglect the time for
marking the sheet metal, this aim is achieved in our sheet metal cutting machine
using Geneva mechanism.
 REFERENCE:
1. C.Y. Cheng, Y. Lin, Improving dynamic performance of the Geneva mechanism
using non-linear spring elements, Mechanism and Machine Theory 30(1995)
119–129.
2. E.A. Dijksman, Jerk-free Geneva wheel driving, Journal of Mechanisms 1
(1966) 235–283.
3. E.A. Fenton, Geneva mechanisms connected in series, ASME Journal of
Engineering for Industry 97 (1975) 603–608.
4. E.A. Sadek, J.L. Lloyd, M.R. Smith, A new design of Geneva drive to reduce
shock loading, Mechanism and Machine Theory 25 (1990) 589–595.
Thank you…