Manual shearing machine for 3mm plate
Project data
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Category: Shears URL (first publication): https://www.youtube.com/watch?v=Oz5MzN0Pc_M Keywords: cutting, shear, diy, metal, machine, workshop, open source, spring steel, hardening License: CC BY-NC-SA 4.0 Organization: OHO Project status: Active Certification status: In process
Maturity of the project: prototype
Contains PDF-drawings: Yes CAD files are editable: Yes Assembly instructions are published: Yes Bill of materials is published: Yes
yes yes
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Project details
Description
The cutting shears boast a robust design made possible through thorough research of online videos and incorporation of repurposed car leaf springs that underwent a heat treatment. The end result is a durable yet environmentally conscious tool capable of handling challenging metal cutting tasks with ease.
Technical data
Below are some features of the manufactured shears:
- Maximum sheet thickness: 3mm
- Maximum round bar diameter: 13mm
- Maximum plate or angle thickness: 5mm
- Cutting length: 180mm
- Dimensions: Length: 0.6m x Width: 0.6m x Height: 1m
- Weight: Approximately 23 kg
- Blade Type: Hardened 9260 steel
- Drive: Manual lever
Technical documentation
Assembly instructions
Here are some plans with the assembly sets and pieces, which can be detailed at this link
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Project development
Based on the DIN 2221 standard, among others, OHO has established a series of stages in which the satisfactory completion of this project was carried out
Feasibility study
- Materials, components
- Manufacturing processes
- Specific training
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Sustainability
Do all materials and processes meet the sustainability criteria?
✓ Yes
It is observed that both the materials used and the manufacturing processes are sustainable from an economic, social and environmental point of view
Market analisis and requirements
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Market analysis
Analysis of the current products on the market:
* Price [USD]: 237
* Source: ebay
* Country: USA
* Machine condition: New
* Maximum sheet thickness [mm]: 6
* Maximum round bar diameter [mm]: 13
* Cutting length [mm]: 180
* High hardness steel blade: Yes
* To screw on a metal bench: Yes
* Price [USD]: 243
* Source: ebay
* Country: USA
* Machine condition: New
* Maximum sheet thickness [mm]: 4.08
* Maximum round bar diameter [mm]: 11.11
* Maximum thickness of plate or angle [mm]: 4.08
* Cutting length [mm]: 127
* High hardness steel blade: Yes
* To screw on a metal bench: Yes
* Price [USD]: 100
* Source: mercadolibre
* Country: Venezuela
* Machine condition: New
* Maximum sheet thickness [mm]: 4
* Cutting length [mm]: 240
* High hardness steel blade: Yes
* To screw on a metal bench: Yes
* Price [USD]: 363
* Source: mercadolibre
* Country: Venezuela
* Machine condition: New
* Cutting length [mm]: 160
* High hardness steel blade: Yes
* To screw on a metal bench: Yes -
Requirements definition
Definition of the main technical data (size, capacity, power...):- Maximum sheet thickness [mm]: 3
- Maximum round bar diameter [mm]: 13
- Maximum plate or angle thickness [mm]: 5
- Cutting length [mm]: 150-180
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Optimal functions and features:
Definition of necessary/optional functions and features- High hardness steel blade: Shear is required to have hardened steel blades
- To screw on a metal bench: It is preferred that the machine includes its own support structure
Search & analisis DIY technologies
- OHO Search engine
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Manual search
Searches were also performed within Google, Youtube, special websites etc., getting, among others, the following results:
* Title: Homemade shears for sheet cutting
* Views: 280000
* Likes: 4900
* Comments: 285
* Maximum sheet thickness [mm]: 3
* Maximum thickness of plate [mm]: 3
* Cutting length [mm]: 205
* High hardness steel blade: Yes
* To screw on a metal bench: Yes
This example will be used as the main reference machine* Title: Leaf Spring HACK - Metal Cutter
* Views: 486000
* Likes: 5800
* Comments: 162
* Maximum sheet thickness [mm]: 2.5
* Maximum thickness of plate [mm]: 2.5
* Cutting length [mm]: 200
* High hardness steel blade: Yes
* To screw on a metal bench: Yes* Title: Homemade metal shear
* Views: 331000
* Likes: 3200
* Comments: 123
* Maximum sheet thickness [mm]: 3
* Maximum thickness of plate [mm]: 3
* Cutting length [mm]: 130
* High hardness steel blade: Yes
* To screw on a metal bench: Yes -
Networking
This section refers to contacting partners, associated organizations and experts
Since the cases found on the internet provide enough information, it was not necessary to search for reference equipment in this way, it can be useful when working with unusual equipments
Development & documentation
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Analisis of functions & structures
From analyzing the operation and parts of the main reference machine and the rest of the examples obtained, a first list of components for the shear is generated
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Technical solutions
The OHO development team also proceeds to design and determine the engineering problems that arise, in order to obtain a quality product that can be manufactured with Appropriate Technologies
- Repo for Technical documentation
- Peer-Reviews
Manufacturing, tests and improvements
- Workshop
Determination of the workshop for manufacturing:
Among the most important aspects to be fulfilled by the manufacturing workshop, we have:- It does not require industrial or specialized processes such as plastic processing, CNC machining, complex chemical processes, among others
- It has basic tools for working with metal and wood at a non-industrial level
- It has measuring instruments appropriate to the processes, such as: vernier, tape measure, thread counter, gauges, etc.
- Includes painting equipment such as compressor and spray gun
- It is a space large enough and ordered for manufacturing, assembly and painting operations
- It has qualified personnel in basic and intermediate works with metal, wood, painting, among others
- Some parts or processes that are not available may be purchased or ordered from more specialized stores and workshops
- Purchase
Purchase of materials and components:
From the list of parts, the amounts of materials to be required from local suppliers were totaled- Structural profiles
- Fasteners
- Special profiles
- Metal plates
- Consumables
- Manufacturing of prototype
Fabrication according to specified quality standards:
The manufacturing process is oriented according to the order of the assemblies in the parts list and their assembly logic, this is shown in the various stages of the manufacturing video:
- Tests and improvement
Module tests, system tests, improvement of components:
Some tests were carried out on the equipment, to verify the correct adjustment of the parts and the efficiency in its operation.- Lateral slack: Apply moderate force on the lever, from left to right and vice versa, alternately. The plates do not tilt
- Example of real use: Making cuts of the samples of plate and sheet
- Visual detail of the cut: Straight shape of the cut, Straight edge, no burrs
- Updates of technical documentation
Updates of plans, parts lists, assembly instructions:- The main plates (2.1 to 2.3) were manufactured in a thickness of 12mm, which is sufficient, instead of the 16mm initially proposed
- Modification in the length of the bushings, according to the new plate thicknesses
- Pieces 2.5 and 2.6, manufactured in 1/2" square bar, available in the workshop
- Mobile blade (piece 2.7), with dimensions adjusted according to the leaf spring piece achieved, recovered material
- Plans are expected to be updated with these changes, in order to have accurate information regarding the equipment manufactured
Certification DIN Spec 3105
- Formal audit
Verification of the completeness of the documents:- Parts list
- Drawings of all parts and assemblies
- Assembly instructions
- Optional documents, technical notes
- In the image, it can be seen that this verification is complete, except for the previous corrections, which refer to the final update of the blueprints
- Assignment of reviewers
Search and assignment of peer-reviewers with sufficient expertise: - Peer-reviews
Realization of the peer reviews, technical clarification, improvements: In process - Certificate
Issue of the certificate: In process
+ General Reviews 
Reviews
| Pos. | Qty. | Part Name | Part code | Part Type | Specifications | Review Status | Show All Comments | |
|---|---|---|---|---|---|---|---|---|
| A1 | 1 | 3D views | |
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| A2 | 1 | Exloded 3D views | |
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| B | Parts list | |
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| 1.0 | 1 | Table structure | |
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| 1.1 | 2 | Table angle | Production | Angle 1 1/2*1 1/2"*4mm, A36 steel | |
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| 1.2 | 2 | Table side angle | Production | Angle 1 1/2*1 1/2"*4mm, A36 steel | |
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| 1.3 | 2 | Table front angle | Production | Angle 1 1/2*1 1/2"*4mm, steel A36 | |
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| 1.4 | 2 | Table back leg angle | Production | Angle 1 1/2*1 1/2"*4mm, steel A36 | |
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| 1.5 | 2 | Table reinforcement angle | Production | Angle 1 1/2*1 1/2"*4mm, steel A36 | |
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| 1.6 | 1 | Angle2 table reinforcement | Production | Angle 1 1/2*1 1/2"*4mm, steel A36 | |
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| 1.7 | 4 | Anchor plate | Production | Plate 1 1/2*3/16", A36 steel | |
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| 2.0 | 1 | Shear body | |
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| 2.1 | 1 | Lower base plate | Production | Plate 16mm, steel A36 | |
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| 2.2 | 1 | Support center b | Production | Plate 16mm, steel A36 | |
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| 2.3 | 1 | Upper base plate | Production | Plate 16mm, steel A36 | |
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| 2.4 | 2 | Support plate | Production | Flat bar 1 1/2*3/16", steel A36 | |
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| 2.5 | 1 | Blade support1 | Production | Square bar 1/2", steel A36 | |
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| 2.6 | 1 | Blade support2 | Production | Square bar 1/2", steel A36 | |
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| 2.7 | 1 | Mobile blade | Production | Leaf spring 10mm, steel 9260, optional 13mm | |
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| 2.8 | 1 | Fixed blade | Production | Leaf spring 10mm, steel 9260, optional 13mm | |
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| 2.9 | 2 | Screw for pivot | Standard | Hex bolt 1/2*2 1/4" NC | |
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| 2.10 | 6 | Fixed blade screw | Standard | Hexagonal screw 3/8*1 1/8" NC, optional l 1" hexagonal screw | |
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| 2.11 | 4 | Pivot nut | Standard | Hex nut 1/2" NC | |
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| 2.12 | 2 | Washer2 | Standard | Flat washer for 1/2" NC | |
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| 2.13 | 2 | Washer | Standard | Flat washer for 3/8" NC | |
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| 2.14 | 4 | Support nut | Standard | Hex nut 3/8" NC | |
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| 2.15 | 2 | Support bushing | Production | Round bar 3/4", A36 steel | |
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| 3.0 | 1 | Lever | |
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| 3.1 | 1 | Lever arm | Production | Plate 12mm, A36 steel | |
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| 3.2 | 1 | Lever bar | Production | Plate 3/16" or 3/4" round bar | |
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| 3.3 | 2 | Lever arm | Production | Plate 12mm, A36 steel | |
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| 3.4 | 2 | Lever bushing | Production | 3/4" round bar, A36 steel | |
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| 3.5 | 2 | Union screw | Standard | Hex bolt 1/2*2 1/2" NC | |
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| 3.6 | 4 | Rib nut | Standard | Hex nut 1/2" NC | |
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