SHEET METAL ENGRAVING AND FORMING MACHINE - EISRJC

E – International Scientific Research Journal, VOLUME – V, ISSUE – 1, 2013, ISSN 2094 - 1749
SHEET METAL ENGRAVING AND FORMING MACHINE
DR. Victorio C. Palabay
CP: 09192727472; FAX: (072) 242-5906
vcpalabay@yahoo.com041257
AFFILIATIONS:
Don Mariano Marcos Memorial State University
Filipino Inventors Society
IDEA TEAM (Inter-Agency Design and Engineering Assessment) DOST-R1
Accrediting Agency of Chartered Colleges and Universities in the Philippines (AACCUP)
IAMURE Multidisciplinary Research
ABSTRACT
This study sought to determine the feasibility of designing and developing a prototype
sheet metal engraving and forming machine (SMEFM) through the application of the project
development research design for machine inventions and evaluate the developed machine’s
performance, functionality and acceptability through the descriptive-evaluative research
design. The construction of the SMEF underwent three stages of development: the initial
design, second design and the final design, with each design being tested, assed and refined.
The fabricated machine using the final design was then evaluated for performance,
functionality and acceptability. As evaluated by the respondents composed of Industrial
Technology Faculty, Students and metal craft shop owners, the SMEFM is highly satisfactory in
terms of performance with regards to precision of the design, ease of operation, variation of
product, and speed and accuracy; highly functional as to simplicity of mechanism, variation of
performed operation, types of materials, and material gauges; and highly acceptable in terms of
production cost, design, and operation.
INTRODUCTION
Technology plays a vital role in national development as it serves as tool in
understanding man’s environment and in providing solutions to his many problems. The
importance of technology therefore, is greatly emphasized in the school curricula particularly
among technical vocational schools in the Philippines.
It is however, a challenge to most of these schools to cope with the demands of
technological courses. Problems such as insufficient and inadequate shop facilities as well as
obsolete equipment beset technological education. Given the teaching-learning scenario, this
condition cripples qualified instructors from providing sufficient and intensive training to their
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students. Learning certain principles and mechanisms pertinent to their major fields of
specialization in technological studies become a dilemma without the actual hands-on
experience due to lack of equipment that serves as instructional device.
As emphasized by Dales’s Cone of Experience, when it comes to learning, learners retain
more information by what they observed or read. The performance of a task therefore,
provides the learner experience that stimulates sensory perceptions enabling him to make
meaning out of such experience ( Estipular et.al., 2012).
The Industrial Technology Department of the College of Technology, DMMMSU Mid La
Union Campus recognizes the need for dynamic learning experiences but is not spared from the
lack of instructional technological tools.
With the institution’s objective of contributing to regional development by educating
the youth in high quality technological education, along with the rapid increase of enrolment
that equally increased the demand for shop facilities and equipment, the researcher conceived
of a feasible solution for the lack of instructional tools particularly , in the sheet metal
fabrication activities.
The main purpose of this study therefore, is to design, develop, fabricate and then
evaluate the performance, functionality and acceptability of a prototype sheet metal engraving
and forming machine (SMEFM). This study is conducted in two phases: Phase 1 Design,
Development and Fabrication Stage; Phase 2 Validation stage. The specific objectives of each
phase are as follows:
Phase 1. Design, Development and Fabrication Stage
1. Conceptualize and design the SMEFM;
2. Determine the availability of tools and materials for the design; and
3. Develop and fabricate a proposed SMEFM.
Phase 2 . Validation Stage
1. Determine the level of performance of the SMEFM in terms of::
a. Precision of the design
b. Ease of operation
c. Variation of product
d. Speed of accuracy
2. Determine the level of functionality of the SMEFM as to:
a. Simplicity of the mechanism
b. Variation of performed operation
c. Variation of types of materials
d. Variation of material gauges
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3. Determine the level of acceptability of the SMEFM as to:
a. Cost in terms of:
i. Maintenance
ii. Comparability
iii. Affordability
b. Design and operations in terms of:
i. Originality of the design
ii. Variation of the design
iii. Competitive appearance of the design
iv. Uniformity in the depth of the contours
v. Overall appearance of the design
vi. Safety in operation
vii. Environmental friendliness
c. User friendliness
4. Determine whether significant differences exist among the perceptions of the
respondents as to the validity in the performance of the SMEFM.
To accomplish these objectives, the prototype SMEFM undergoes three try-outs in the
development stage where the machine is tried, tested, and revised until satisfying the
requirements and qualities expected of this machine and then subjected to the validation stage.
It is expected from this study that the prototype sheet metal engraving and forming machine be
used by the students in the different sheet metal fabrication activities.
Sheet metal is metal such as cold rolled steel, mild steel, nickel, titanium, aluminum,
brass, tin, and copper which is flattened into sheets. It is utilized in construction for roofing,
wall covering, formation of columns and balustrades, for conductor pipes and gutters. It is also
used to provide the self-contained units for the refrigeration system in air conditioners as well
as for tubing, signs, airplane wings, automotive bodies, and myriad applications more (Sheet
Metal and Its Uses, n.d.).
Sheet metals are manufactured into different products via press work. Press working,
also called cold stamping, is a manufacturing process by which various components are made
from sheet metal either by cutting operations or by forming operations (Introduction to Press
Working, 2010. In cutting operations, the sheet metal is subjected to shear stress beyond its
ultimate strength such as in blanking, punching, perforating, notching, shaving, slitting, lancing,
and trimming. Forming operations, on the other hand, subjects the sheet metal to stress but
below its ultimate strength where no cutting occurs but only contouring as in bending, drawing,
and squeezing (Press working Operations, 2010). The SMEFM adopts the forming processes in
press work operations.
Sheet metal forming is one of the widely used applications in the industrial fields.
Various sheet metal forming techniques are being studied and explored especially with the
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existing belief that the quality , profit and development capability of the product is dependent
on forming techniques ( Li et.al., 2010)
Among the studies conducted on sheet metal forming is the study of Guangyong et. al.
(2010). Recognizing that fracture and wrinkling in sheet metal forming can be eliminated
through appropriate drawbead design, they presented a multiobjectives robust optimization
methodology to reduce unnecessary stress and flaws on drawbead design. It has been found
that the presented method provides an effective solution to geometric design of drawbead and
thus results into a much improved quality of product.
In another vein, Bressan and Barlat (2010) presented a shear fracture criterion to
predict limit strains in sheet metal forming while Kyung Seok et.al. (2011) produced a design
and analysis of new test method for evaluation of sheet metal formability. Hu et.al. (2010)
experimented on Kringing-based models to be used to minimize the risk of failure in a sheet
metal forming process.
Meanwhile, the paper of Hariharan et.al. (2009), focused on material optimization by
reduction in raw material size for sheet metal components while Guangyong et.al. (2011)
proposed a two-stage multi-fidelity method to better compromise the uses of low- and highfidelity
solutions that resulted into a significantly improved computational efficiency and
accuracy of optimizing sheet-metal formability without wrinkle and fracture.
Other studies focus on resolving concerns with springback in sheet metal forming.
Sulaiman et.al. ( 2012 ) in sheet metal forming for automotive doors, investigated springback
behavior during the sheet metal forming process on different parameters by using numerical
method; Liu et.al (2009) proposed a method in springback control of sheet metal forming based
on the response-surface method and multi-objective genetic algorithm; while , Damoulis et.al.
(2010) presented new trends in sheet metal forming analysis and optimization through the use
of optimal measurement technology to control springback.
While Liu et. al. and Damoulis et.al. focused on springback control, Panthia e..al. (2010)
experimented on finite analysis of sheet metal bending process to predict springback of sheet
metals during sheet metal forming process.
In the business of sheet metal forming operations, environmental sustainability in
manufacturing has become a growing concern. Some studies have been conducted to explore
on this issue. Among these studies, Ingarao et.al. (2011) presented a holistic vision and
provided guidelines concerning sheet metal forming problems related to energy and resource
efficiency ; while Ingaraoa et.al. (2012) investigated both the efficient use of materials and
process energy saving during sheet metal forming process using sensitivity analysis which is
based on experimental and numerical data.
Aside from metal forming, the other function of the product of this study is metal
engraving. Metal engraving or metal etching has been used to create templates for book
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printing and relief sculptures for centuries. Today, engraving is typically used to personalize
tools or create a custom image on a piece of metal (Getty, n.d.)
There already exists a body of studies on the field of metal engraving. Among them are
the studies of Yang (2010) on the design and implementation of an engraving machine
controller and that of Benedetto (2010) on the development of a numeric control engraving
machine.
In another vein, Xin and Wei (2012) explored on the application of accuracy engraving
technique in the complex curved surface mould processing while Shu Kun Cao et.al. (2011) and
Yasuhiko (2012) dwelt on developing a dual function machine where engraving is one of its
function. Shu Kun Cao developed an engraving and milling machine design based on open CNC
system while Yasuhiko, a sewing machine with engraving function.
These cited studies are related in the observance of the mechanisms of sheet metal
forming and engraving. However, the current study does not pose any technological and
scientifically nor mathematically advanced systems and mechanisms rather, the fabrication of a
simple sheet metal forming and engraving machine that shows the basics of press working and
be utilized as a tool for instruction for Industrial Technology students of the DMMMSU Mid la
Union Campus.
MATERIALS and METHODS
Specifications and Description of the Different Components of the SMEFM
The specific parts and description of the different components of the SMEFM are as
follows:
Main body frame : The main body frame is fabricated using 6mm thick steel plate with
25 mm length, 37.5 mm width, and 137 mm height. This serves as the foundation on which all
the mechanism parts are attached.
Upper fixed arm attachment: This guides the engraver arm assembly for stability when it
is adjusted to the desired feed, depending on the thickness of the work piece. It is made of a
channel bar 8mm thick, 12 mm width, and 15mm length.
Movable engraver arm assembly: This is the part where the upper engraver blade is
mounted and which allows flexibility when it is adjusted to the desired depth of the feed. This
is fabricated using 3 mm thick, 50 mm width angle bar.
Fixed engraver arm assembly: This holds and supports the lower engraver blade in a
steady position when it is pressed. This is made out of 3 mm thick, 50 mm width angle bar.
Lower and upper engraver blade: This is the die component of the machine. This is
fabricated out of tool steel, 12 mm by 70 mm.
Chain tensioner : This part controls the appropriate tightness of the chain when it is
moved in any given direction or rotation.
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Mechanical feed adjuster: This will control the desired pressure that is needed
depending on the kind of work piece. This is made out of 22 by 250 Φ tool steel.
Coil return spring: This part provides flexibility for the movable arm assembly to be
adjusted and return to its position when it is manipulated. It is fabricated making use of a
10mm by 200 mm coil spring.
Chain A sprocket assembly: This will transmit the torque or power needed when the
engraver blades are engaged. This could be cranked in a clockwise or counter clockwise
direction. This is made out of 14 by 36 sprocket combination assembly.
FIGURE 1
THE SHEET METAL ENGRAVING AND FORMING MACHINE
FINAL DESIGN
Development of the SMEFM
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The SMEFM is developed by subjecting it to revisions in three stages of development.
The Initial stage
The initial stage is composed of rudimentary parts based on the design concept of the
researcher. Thereafter, the proponent tested the device and requested the presence of the
accredited metal-craft fabricators of the Department of Science and Technology in the City of
San Fernando, La Union for its evaluation. Based on the experts’ standards, the product turnout
was within acceptable limits and the appearance of large designs and shapes that were
being processed were clearly visible. However, the accuracy of small circular and irregular
shapes was not clearly visible. The device was also found deficient in terms of operational
efficiency and quality of output.
Modifications were then incorporated such as the diameter of the upper engraver blade
was reduced from 3” Φ to 2” Φ in order to penetrate small designs and irregularly shaped work
pieces.
The Second Stage
The second design was equipped with an adjustable lower engraver attachment that will
allow flexibility in order to suit the design, width and depth of groove that will be pressed
depending upon the thickness and the kind of sheet that will be pressed. At this stage, a variety
of sheet metals from gauge #31 to #16 could be engraved with a design. Although the
accredited experts had evaluated the second design to be more superior to the initial product,
the researcher was concerned with the wear and tear of the movable parts of the machine
which tended to degrade easily. The product again underwent modifications.
The Final Stage
The final design is an improved version of the second design where a chain tension rod
or chain tensioner has been installed to control the desired tension of the chain to provide ease
of operation especially when it is moved in the forward and backward directions. Another
significant modification of the final design was the control of vibration that would result to
chain mis-alignment and removal. Miscellaneous improvements were done also on the upper
and lower engraver blades. A double bearing has been installed at the center of the part being
pressed, allowing the workpiece to move freely, especially when working with heavy gauge
materials. A flat form clamping flange was also added to facilitate permanent anchoring of the
machine for safer operation.
Description of the Mechanism
The prototype SMEFM consists of various parts with specific functions for the smooth
and safe operation of the machine. The following paradigm, Figure ___ details the
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interrelationships of the different parts. The figure shows that when the lever feed adjuster is
loosened the movable engraver arm assembly moves up, allowing the work piece to be set
between the upper and lower engraver blades.
It should be noted that the sheet metal workpiece should be provided with a pattern
design (pre-design) directly etched on the work piece surface.
After inserting the workpiece, the lever feed adjuster is tightened by turning it in a
clockwise direction. This allows the upper engraver blade to press in the sheet metal surface to
form a groove. The correct depth of the groove could be checked by observing the depth of the
pressed portion ( approximately 3 mm).
Engraving the design is begun by moving the lever arm in a clockwise direction.
At this stage, the lever arm transmits power to the driver pulley, to the chain, and to the driven
pulley. The tension rod provides control to the vibration, allowing the upper engraver blade to
rotate and press the sheet metal surface thereby making the pre-design appear clearly visible.
As the upper engraver blade rotates and with the pressure applied to the lower engraver blade,
the rotation eases the maneuvering over the entire pre-designed sheet metal surface. The
operation is repeated until the over-all design is completed. The workpiece is then released by
loosening the mechanical feed adjuster. The completed workpiece is finally checked for
accuracy of the design.
FIGURE 2
Interrelationship of Parts of the SMEFM
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RESULTS and DISCUSSION
The assessment of the three (3) groups of respondents : Bachelor of Science in Industrial
Technology students, BSIT faculty, and metal craft shop owners on the SMEFM’s level of
performance, functionality and acceptability are as follows:
Level of Performance
As to the level of performance, the overall assessment of the three groups of
respondents indicates a highly satisfactory rate. (Table 1). The highest rating was rendered by
the faculty, followed by the metal craft shop owners, and the lowest rate was given by the
students. These differences could be ascribed to the extent of technical knowledge of the
faculty and of the additional practical exposures of the metal craft shop owners providing them
of an understanding of the mechanisms of the machine. The students’ reservations, on the
other hand, can be ascribed to their lack of technical expertise on the technicalities involving
the performance of the machine.
By indicator, variation of product was given the highest assessment, indicating that the
respondents were impressed by the product output of the machine as to the variation of
designs produced, whether these were simple or intricate. The same was observed for
precision of the design, which indicated that there was high conformance and faithful rendering
of the conceived design to the workpiece. However, the lowest rated indicator was in ease of
operation, since familiarity with the mechanisms of the machine has yet to be established.
Various comments from the respondents suggest that it would require some amount of
training, familiarity and practice in order to hone the manipulative skill of the operator of the
machine and thus improve on the speed and accuracy of operation that will redound to a better
performance, both of the machine and the operator.
The test for significant difference of the perceptions of the respondent groups using
Analysis of Variance yielded to a probability value of 0.7061, which indicates that there was no
significant difference in the assessments of the three groups of respondents as to the level of
performance of the SMEFM.
Level of Functionality
As to functionality, the faculty rated all the indicators as very highly functional, with the
exception of variation of types of materials. Their average mean of 4.24, however, indicated
that they considered the machine to be very highly functional. The metal craft shop owners, on
the other hand, gave an average assessment of 4.09 or highly functional, while the students
again gave the lowest assessment of 3.98, but which is still within the descriptive range of
highly functional.. The overall assessment was highly functional at 4.05. These results are
shown in Table 2.
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Again, the faculty gave the most optimistic ratings followed by the metal craft shop
owners, while the students were more conservative, which could be ascribed to the level of
expertise of the instructors and the metal craft shop owners who understand better the
mechanical operations of the machine in contrast to the limited knowledge and expertise of the
students.
The test for significant difference of the perceptions of the respondent groups using
Analysis of Variance yielded a probability value of 0.0185, which indicates that there was a
significant difference in the assessments of the three groups as to the level of functionality. In
addition, post hoc analysis using the Scheffe method indicated that there were significant
differences between the perceptions of faculty and students, faculty and metal craft shop
owners, and students and metal craft shop owners. However, there was greater variability
between perceptions of the faculty and metal craft shop owners suggesting that the faculty And
metal craft shop owners could perceive a wider range of use for the machine than the students.
Level of Acceptability
The three groups of respondents gave a highly acceptable assessment of 4.14 in terms
of cost which implies that that the cost of maintenance and production of the machine is
manageable compared to commercially produced types of machine. As observed by the faculty
and the metal craft shop owners, the expected commercial availability of the machine, cost for
importing similar machines could be avoided. In addition, because of the conformity of the
machine to local conditions, i.e. small –scale operations and use of locally available materials,
cost of acquisition could be further downgraded, rendering the machine highly affordable and
accessible. This comparability and ease of maintenance also enhances the savings expectations
of the prospective users of the machine.
Based on the Analysis of Variance, there is a significant difference in the perceptions of
the three groups of respondents and along with the post hoc analysis using the Scheffe method
showed the same results and conditions as to the perceptions of respondents in terms of
functionality.
In terms of the design and operations of the SMEFM, the average weighted mean rating
of 4.12 showed that the SMEFM was highly acceptable. As for particular indicators, the highest
rating of 4.50 was attributed to the environmental friendliness of the machine which indicates
that the respondents do not see any adverse effect to the environment that may result from
the use of the SMEFM. Also considered very highly acceptable were the overall appearance of
the design of the machine and the variation of the design produced. All other indicators
garnered descriptive ratings of highly acceptable.
The lowest rating of 3.09 given was on user friendliness which makes the machine
moderately acceptable in this aspect. It was the observation of the respondents that the
machine was too unwieldy and heavy for operation by females. Also, the sheer size of the
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machine and its lack of portability would intimidate women users, although they conceded that
more brawny and athletic types of women may be able to operate the machine, hence the
moderately acceptable assessment, showing that for some of the male respondents, the
machine could also gain some acceptability to some women.
Based from these results, it can be concluded that it is feasible to design and develop a
Sheet Metal Engraving and Forming Machine which satisfies performance, is functional and
acceptable for instructional and commercial purposes.
Table 1. Level of Performance of the SMEFM
List of Tables
Level of Performance Faculty students Metal Craft
Owners
AWM
DER
Precision of the Design
Ease of Operation
Variation of Product
Speed and accuracy
Average Mean
4.29 VHS
4.17 HS
4.33 VHS
3.20 MS
3.99 HS
3.89 HS
3.99 MS
4.02 HS
2.89 MS
4.18 HS
4.00 HS
4.15 HS
3.25 HS
3.89 HS
4.03
4.02
4.10
3.04
3.78
HS
HS
HS
MS
HS
3.67 HS
Source Sum of squares DF Mean Square F Ratio Probability
Between .186 2 .093 .362* .7061
Within 2.314 9 .257
Total 2. 500 11
*Not significant
Legend: AWM – Average Weighted Mean
DER – Descriptive Rating
VHS – Very Highly Satisfactory
HS- Highly Satisfactory
MS – Moderately Satisfacotry
Table 2. Level of Performance of Functionality
Level of Performance Faculty students Metal Craft
Owners
AWM
DER
Simplicity of the mechanism
Variation of performed 4.42 VHF 4.05 HF 4.00 HF
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Operation
Variation of types of
materials
Variation of material gauges
Average Mean
4.21 VHF
4.08 HF
4.25 VHF
4.24 VHF
3.86 HF
3.98 HF
4.00 HF
4.15 HF
4.10 HF
4.05 HF
4.09 HF
4.06
4.04
4.09
4.05
HF
HF
HF
HF
4.08 HF
3.98 HF
Source Sum of squares DF Mean Square F Ratio Probability
Between .136 2 .068 6.426 * .0185
Within .095 9 .011
Total .231 11
*Significant
Legend: HF - Highly Functional
VHF - Very Highly Functional
Table 3. Level of Acceptability in terms of Cost
Level of Performance Faculty students Metal Craft
Owners
AWM
DER
Maintenance
Comparability
Affordability
Average Mean
4.33 VHA
4.25 VHA
4.38 VHA
4.32 VHA
4.05 HA
3.96 HA
4.09 HA
4.28 VHA
4.18 HA
4.30 VHA
4.25 VHA
4.15
4.07
4.19
4.14
HA
HA
HA
HA
4.03 HA
Source Sum of squares DF Mean Square F Ratio Probability
Between .135 2 .068 .362* .7061
Within .026 9 4.2889E-03
Total .161 11
*Significant
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Legend: HA- Highly Acceptable
MA – Moderately Acceptable
VHA – Very Highly Acceptable
Table 4. Level of Acceptability in terms of Cost
Level of Performance Faculty students Metal Craft
Owners
AWM
DER
Originality of the design
Variation of design
Competitive Appearance of
design
Uniformity in the depth of
contours
Overall appearance of the
design
Safety in operation
Environmental friendliness
User friendliness
Average Mean
4.29 VHA
4.17 HA
4.25 VHA
4.21 VHA
4.33 VHA
4.33 VHA
4.46 VHA
3.85 HA
4.24 VHA
4.18 HA
4.12 HA
4.22 VHA
4.11 HA
4.24 VHA
4.05 HA
4.20 VHA
4.18 HA
4.03 HA
4.18 HA
4.50 VHA
4.76 VHA
3. 00 MA
4.11 HA
4.16
4.15
4.21
4.11
4.23
4.44
4.50
3.09
4.12
HA
HA
VHA
HA
VHA
VHA
VHA
MA
HA
4.46 VHA
4.43 VHA
2.92 MA
4.09 HA
Source Sum of squares DF Mean Square F Ratio Probability
Between .104 2 .052 .292* .495
Within 3.730 9 .178
Total 3.833 11 *Significant
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