Abrasive Cut-Off

Machine
Report and the Detail Design of the Cut-Off Machine

MOW 217

Benade DJ
26317088

Kraamwinkel FH
26209382

Van Staden HJ
26059802
Table of Content

List of Tables......................................................................................................3
List of Figures.....................................................................................................4
List of Symbols...................................................................................................5
1. Introduction....................................................................................................6
2. User Requirements.........................................................................................7
3. Literature Study..............................................................................................7
4. Functional Analysis.........................................................................................8
4.1 System Level.............................................................................................8
4.2 Mission Level.............................................................................................8
4.3 System Level Functional Diagram.............................................................9
4.4 First Level Functional Diagram..................................................................9
4.5 Design Parameters per Function.............................................................10
5. Design Specifications...................................................................................11
6. Concepts & Concept Evaluation...................................................................12
7. Design calculations.......................................................................................15
7.1 Power Transmission and Torque..............................................................15
7.2 Forces on Pulley......................................................................................16
7.3 Shear Force and Bending Moment..........................................................16
7.4 Safety Factor of Shaft (Dynamic)............................................................18
7.5 Safety Factor of Shaft (Fatigue)...............................................................19
7.6 Bearing Calculations................................................................................20
7.7 Pulley Design...........................................................................................22
8. Detail Design................................................................................................22
8. Detail Design
List of Tables
List of Figures

Figure 5.1 Schematic Drawing for the cut-off machine layout.............................12

Figure 5.2 Forces on cutting disc and pulley.......................................................12
Figure 5.2 Forces on the cutting disc and pulley.
List of Symbols

Symbol Unit

Angular Velocity ω rad/s

Axial load Fa N

Basic life rating L10 106 cycles

Bending moment at Q MQ Nm

Bending moment at R MR Nm

Diameter d d mm

Diameter D D mm

Dynamic load P N

Dynamic load rating C KN

Endurance limit Se Mpa

Force in v-belt (slack side) FB1 N

Force in v-belt (Taut side) FB2 N

Force on cutting disc FC N

Load factor kc

Maximum normal stress σmax Mpa

Maximum shear stress τmax Mpa

Miscellaneous factor kf

Moment M Nm

Moment of inertia I m4

Normal stress σ Mpa

Power input to the arbor shaft Pin W

Power output from motor Pout W

Radial load Fr N

Radius r r mm

Reaction force on Q in the y-direction Qy N

Reaction force on Q in the z-direction Qz N

Reaction force on R in the y-direction Ry N

Reaction force on R in the z-direction Rz N

Reliability factor ke

Rotational speed n Rpm

Safety factor FS

Second moment of inertia J m4

Shear force between P and Q VPQ N

Shear force between Q and R VQR N

Shear force between R and S VRS N

Shear stress τ Mpa

Size factor kb

Static load Po N

Static load rating C0 KN

Surface factor ka

Temperature factor kd

Torque T Nm

Ultimate tensile strength Su Mpa

Yielding strength Sy Mpa

1. Introduction

A cut-off is one of the most commonly used machinery in the

manufacturing process, and almost every workshop has one. It is easy to
use, maintainable and cost effective.

The task was given to a group of engineers in training to design an

abrasive cut-off machine for cutting steel. After considering a few
concepts, along with a literature study, the final design and calculations
were done. Included in the final design are a modelled CAD drawing with
detail drawings.
2. User Requirements

An abrasive cut-off machine has to completely designed for cutting steel.

It must be able to cut 50mm solid steel and 75mm steel pipes. The cut-off
machine should be fitted with safety guards where required and also have
an adjustable down stop to the limit the depth of the cut. A mechanism is
required for pulling the machine down when someone is cutting.

3. Literature Study
4. Functional Analysis
4.1 System Level

Abrasive Cut -Off Machine

Adjustable down
Cutting Steel Ø304mm cutting Disc Electric Motor
stop

Up to 50mm Up to 75mm
solid steel 5 HP
steel pipe

4.2 Mission Level

• Long live expectancy

• Maintainable
• Reliable
• Functional
• Simplicity
• Safety
• Productivity
• Easy to use

4.3 System Level Functional Diagram

Start Motor
1.1

Pulling Down
Machine
1.2

Cut-off Machine
Cut Steel Cutting
1.3
Functional
1.0
2.0

Pulling Up the
Machine
1.4

Stop Motor
1.5

4.4 First Level Functional Diagram

Is cutting disc clear of
Start Motor Press Start Button Pull Down
work peace Yes
1.1 1.1.2 1.2
1.1.1

Pull machine up using

Press Start Button
handle
1.1.4
1.1.3

Pull Down Pull down on handle Cutting Finished cutting Pull Up

Yes
1.2 1.2.1 1.3 1.2.2 1.4

No

Pull machine down

Cutting using handle
1.3 1.3.1

Pull Up Pull down on handle Press Stop Button Motor Stop Remove Work peace
1.4 1.4.1 1.4.2 1.5 1.5.1

4.5 Design Parameters per Function

1.1.Start Motor
1.1.1.Is cutting disc clear of work peace

1.1.2.Press button Start button visible

Start button reachable
1.1.3.Pull up Use handle

1.1.4.Press button Start button visible

Start button reachable

1.2.Pull Down
1.2.1.Pull handle Handle long enough
Hand grip (ergonomics)
Enough momentum
1.2.2.Finished cutting Desired cut achieved

1.3.Cutting
1.3.1.Hold handle down Handle long enough
Sparks directed backwards
Pulley and disc safety guard
Cutting machine staionary
1.4.Pull Up
1.4.1.Press stop button Button visible
Red
1.4.2.Remove work piece Release clamp
1.5.Motor Stop

5. Design Specifications
Basic specifications for abrasive cut-off machine

Symbol Value Unit

Cutting wheel capacity Ø 304 mm

Cutting wheel speed nshaft 4000 rpm

Motor (Single Phase) Pout 3.75 kW

Motor Speed nmotor 2950 rpm

Hole in Cutting Disc d Ø25 mm

Use EN3 steel for shaft Sy 325 MPa

Su 450 MPa

Tabel 5.1 Basic specifications for abrasive cut-off machine

Assumptions

Symbol Value Unit

No power losses in pulley drive η 1 -

Operating temperature T 60 °C

Mass of shafts and pulley are neglable m 0 kg

Tabel 5.2 Assumptions

Figure 5.1 Schematic drawing for the cut-off machine layout

Figure 5.2 Forces on the cutting disc and pulley.

6. Concepts & Concept Evaluation

Concept 1

Figure 6.1 Concept 1

In the concept the hinge point is situated at the rear of the machine. Pulleys with
V-belts will be used to transmit power from the motor to the arbor shaft.

Concept 2

Figure 6.2 Concept 2

In this concept the hinge is located slightly in front of the motor (if the cutting
disc is said to be the front), this will act like a “see-saw”. When the machine is
not busy cutting steel, the cutting disc will be kept in the air due to the weight of
the motor at the back. Pulleys and a V-belt will be used for power transmission.

Concept 3

Figure 6.3 Concept 3

Fixing the cutting disc to the motor shaft directly.

Concept 4

Figure 6.4 Concept 4

The motor will be mounted on a steel plate and the cutting disc mounted on the
motor shaft. The plate with the motor will be able to slide between two slots to
keep it steady while the motor is pulled up with a chain and pulley or moving
down because of the motors weight (and gravity).

Concept Evaluation
Concept 1 Concept 2 Concept 3 Concept 4

Simplicity 4 4 4 2

Practicability 3 5 2 2

Manufacturability 4 4 5 3

Maintainability 4 4 5 3

Yielding Possibility 4 4 2 2

Safety 3 4 1 1

Cost 3 3 5 2
Able to comply with 5 5 1 1
specs
Total 30 33 25 16

Table 6.1 Concept Evaluation

Thus from the evaluation, Concept 2 will be the best option.

7. Design calculations

7.1 Power Transmission and Torque.

Pout = Assume η
Power on shaft ηPin P 3750 W =1
Toque on shaft T = (60P)/(2πn) T 8.95 Nm

7.2 Forces on Pulley

FB1 221 N
FB2 400 N
Ød 100 mm
T 8.95 Nm ØD 300 mm
C 59.67 N
T 8.95 Nm
7.3 Shear Force and Bending Moment

Qy 322.38 N
Ry 883.68 N
Qz 450 N
Rz 150 N
Moment at Q MQ 30.588 Nm
Moment at R MR 46.575 Nm

Shear Force between P &

Q VPQ 305.877 N
Shear Force between Q &
R VQR 302.517 N
Shear Force between R &
S VRS 621 N

7.4 Safety Factor of Shaft (Dynamic)

M 46.575Nm
T 8.95Nm
d 0.025m

Steel Sy 325MPa
Su 450MPa

47.4271
Te=(M2+T2)1/2 Te 3Nm

154588
3
τ=16Te/πd τ 56Pa

10.5117
τmax= Sy/2FS FS 7
7.5 Safety Factor of Shaft (Fatigue)

From
SKF 6305
Ød 25mm
ØD 32mm
r 1mm

M 46.575Nm
T 8.95Nm

Steel Sy 325MPa
Su 450MPa

Endurance
Limit

Se’=
0.5Sut Se’ 225 Mpa Sut ≤ 1460 MPa

Surface Factor ka = 4.51 Sut-0.265 ka 0.893 Machined

2.79 ≤ d ≤ 51
Size Factor kb=1.24d-0.107 kb 0.879 mm
Combined
Load Factor kc 1 Loading
T<
kd
Temp Effects 1 300°C
Reliability ke 0.897 90% Reliability
Miscellaneous factor kf 1 No Corrosion

Se =
kakbkckdkekfS’e Se 158.45 Mpa
Stress Concentration

D/d 1.28

r/d 0.04

Bending
Table A-13-9 (Shigley) Kt 2.1
Fig 6.20
(Shigley) q 0.7
Kf = 1 + q(Kt – 1) Kf 1.77

Torsion
Table A-13-8 (Shigley) Kts 1.7
Fig 6.21
qs
(Shigley) 0.85
Kfs = 1 + qs(Kts –
Kfs
1) 1.595

Alternating and mean

stresses
σ a = 32M/πd3 σa 30.36 MPa
σm= 0 σm 0.00 MPa
τa = 0 τa 0.00 MPa
3
τm = 16T/πd τm 2.92 MPa

Combine Components:
Tresca
σ a’ = ((kf σa)2 + 3(kfsτa)2)1/2 σ a’ 53.74 MPa
σm’ = ((kf σm)2 +
σm’
3(kfsτm)2)1/2 9.31 MPa

Mean Stress: Asme

(nσ’a/Se)2 + (nσ’m/Sy)2 = 1 n 2.94 → FS

7.6 Bearing Calculations

y-component at
Q Qy 322.38 N
z-component at
Q Qz 450.00 N
Resultant force
at Q Q=(Qy2+QZ2)1/2 Q 553.56 N

y-component at
R Ry 883.68 N
z-component at
R Rz 150.00 N
Resultant force
at R R=(Ry2+RZ2)1/2 R 896.32 N

Radial force on
Fr
bearing 896.32 N
Axial force on
bearing Fa 0.00 N

Design Temp T 60 °C
Rotational Speed n 4000.00 rpm

25000.0
Design for L10h 0 hours
L10h = (C/P)p x
(106/60n) C 16.29 kN
Choose SKF 6305 Explorer Roller
→ Bearing
From SKF C 23.40 kN
C0 11.60 kN
d 25.00 mm
D 62.00 mm

Equivalent dynamic
bearing load

FA /FR 0.00 N
P = FR P 896.32 N

Equivalent static bearing

load

Po = 0.6Fr + 0.5Fa P0 537.79 N

P0 < FR → P0 = FR P0 896.32 N

Static Safety Factor

S0 = C0/P0 S0 12.94 is > 1

Basic Rating
Life

17793.3
L10 = (C/P)p
(p=3 for roller bearings) L10 5 Cycles
L10h = L10x 74138.9
(106/60n) L10h 5 hours

Adjusted Rating
Life

SKF table 1 p53 a1 1.00 90% Reliability

dm=0.5(d+D) dm 43.50 mm
SKF diagram 5 at dm and 4000
p60 v1 10.00 mm2/s rpm
SKF diagram 6 ISO VG
p61 22 at 60°C an d v1
v 24.00 mm2/s at 40°C
ĸ = v/v1 ĸ 2.40
SKF Diagram 1 at ĸ =
p54 a23 2.00 2.4
35586.7 Which is
Lna = a1a23L10 Lna 0 hours sufficient

7.7 Pulley Design

Speed Ratio

n 1d1 = n 2d2 d2 135.59mm

Round
d2 136.00mm
Power
Transmission

T = (FB2 –
FB1)xd/2 T 8.95Nm

Pre-tension

Fi = (FB2 – FB1)/2 -
Fc Fi 89.5N

8. Detail Design
9. Conclusion
10. References
11. Annexure

11.1 Appendix A