Learn about the GrabCAD Platform
Get to know GrabCAD as an open software platform for Additive Manufacturing
Visit our new homepage
Show off your skills and solve real design problems
This challenge is for designing the flat shear element for Open Source Ecology's Ironworker Prototype II. The rest of the prototype will be designed elsewhere. See our blog entry for more info on what we need to know.
Wiki: http://opensourceecology.org/wiki/Ironworker_Prototype_II_Proposal
Blog: http://blog.opensourceecology.org/2011/12/ironworker-blade-design-help/
This prototype will be the second version of the OSE's Ironworker. It will similar to Scotchman 120T. As well as having the 120T punch. This prototype will be able to shear 1”x12” flat and 6”x6”x1/2” angle steel. There will be a “tool cavity,” a space below the punching arm to which many accessory tools can attach. This will enable the machine to not only have the features above, but also attachments like brakes, notchers, and rod shears.
The shearing element must be designed first, as it will attach directly to the cylinder, and the rest of the machine will be designed around it. See above for a basic idea of the structure of it.
Basic Structure of Prototype:
1. It will have an upper and lower arm, both attached to the cylinder. The lower arm will be attached to the cylinder directly or via a linkage. The upper arm will be attached to the lower arm via a linkage.
2. The upper arm will have the punch permanently attached, and will have a table below it onto which you can put various accessories, including an angle shear.
3. The lower arm will only have a shear blade attached.
4. Accessory tools can be made as necessary. Possible tools include: brakes, tubing shear, notcher, rod shear and more.
The shear design should be as simple as possible.
The winning design will be the simplest design that uses the least material.
An angularly moving blade is preferred, as they seem much simpler to build, but vertically moving designs are welcome as well.
If you have good ideas for the rest of the prototype, please post them. These designs will also be eligible for winning.
Assembly must be able to shear 1"x10" steel
Assembly must use an ironworker blade that already exists. See American Punch Catalog for ideas: http://www.americanpunchco.com/AP_Catalog.pdf
The blade needs to cut a minimum of 12" wide material. Up to a 24" cutting surface is allowed
The force must be generated with a 5" bore hydraulic cylinder
There must be space to mount a linkage to the upper arm on the lower arm
There must be easy access to remove the blade if it dulls
The shear element should be designed for simplicity of fabrication
Winning design will be chosen based on the design and functionality
The competition is open to everyone
Team entries are welcome
You can submit several designs
Only models uploaded to GrabCAD library will participate in the competition
Tag your model with “Ironworker” to make it easier to find
Privately uploaded models will be made public after the competition deadline
Models can be done in any CAD software as long as a STEP or IGES files are also uploaded
Competition winner will be announced in GrabCAD’s blog
Only models uploaded through this challenge page will participate in the competition
The entire project is based on open source principles, encouraging people to participate for the good cause.
But there are some nice things we are giving away:
Limited Edition GrabCAD and Global Village Construction Set T-Shirt + Admission to a one-day Natural Building workshop at Factor e Farm. Includes hands-on experience: brick laying with CEBs and square bale insulation; assisting with lumber production with the Dimensional Sawmill, and square bale making with the Baler. See our Kickstarter campaign for more information on this package.
Most creative design will be chosen by Open Source Technology with a little help from GrabCAD.
Open Source Ecology is a network of farmers, engineers, and supporters that has been imagining and creating the Global Village Construction Set, an open source, low-cost, high performance technological platform. These DIY-fabricated industrial machines can be used to build a sustainable civilization with modern comforts. The GVCS lowers the barriers to entry into farming, building, and manufacturing. It is a life-size lego-like set of modular tools that can create entire economies.
Have an awesome idea for this competition? Want to win cool prizes? Sign-up now to upload your entries.
If you don't receive the email within an hour (and you've checked your Spam folder), email us as confirmation@grabcad.com.
19 comments
Cemal Uslu over 12 years ago
I wish i had enough time for those challanges from OSE. Those are great to improve skills and expand the angle of view.
dam school stops my education. :)
Kaspar Kiis over 12 years ago
We extended the deadline and also added the SketchUp file.
Dave Engle over 12 years ago
"This prototype will be able to shear 1”x12” flat and 6”x6”x1/2” angle steel."
I don't think there is anything on the supplier sheet that will cut 1" thick plate. I ran a 12' shear a few years back and 1" plate was not an option. Even with the larger "Buffalo Ironworker" machines, either punching, shearing rod/angle, etc., we never sheared anything in the 1/2" angle thickness that you are requesting. In regards to developing a Scotchman style machine to accomplish the task, the machine design as a whole and blade components will not successfully shear 1" plate.
Brianna Kufa over 12 years ago
There are machines which will cut that. It is a standard feature for most 120T Ironworkers. Please this page:
http://opensourceecology.org/wiki/Ironworker_Prototype_II_Proposal#Analysis_of_Industry_Standards
Allen over 12 years ago
Can we have some more details on what materials are readily available to for you guys to fabricate it with?... Should my design be made from 1/2" thick steel sheets welded together, or can it be 1" thick? Bearings or bushings?... Mainly I don't want to model something that is nice and would work well, but there is no means for you guys to cheaply create.
Brianna Kufa over 12 years ago
Hello Allen,
Anything that could be obtained at a local metals shop would be fine.
It can be 1" thick or more of solid sheets. I suspect the arm for it will need to be 2+ inches, and probably made of 1018 or another stronger steel than A36.
Please use bushings.
Feel free to email me personally if you have any more questions,
Brianna at kufadesigns dot com.
Brianna
Adam Pohl (POHL3D) over 12 years ago
Can someone with Skethup pro convert to STEP please? Marcus i'm looking at you!
Adolfo Cota over 12 years ago
This is the video of the machine in action. I understand now!
http://www.youtube.com/watch?v=wgXT620Y5ak
Like Nicolas, I say: Deadline is too short...
Marcus over 12 years ago
Hi,http://grabcad.com/adam.pohl I have not see you question, I will not participate in this challenge so I have not read this comment´s until today. Here is it : http://grabcad.com/library/ironworker-shear-assembly-for-grabcad-challenge
Kaspar Kiis over 12 years ago
Thank you Marcus for the CAD files. We have extended the deadline by 10 days. That makes two weeks from today. Your contribution to Open Source Ecology would be very much appreciated. Also please ask any questions you have and we will make sure they will be answered. Looking forward seeing your entries.
Philippe Carrier over 12 years ago
I just want to be sure; Are we talking about 120 Tons Metric, Long, Short or Uk? I hate this measure! lol!
Brianna Kufa over 12 years ago
Hi, Sorry for the confusion. It is a short ton (2000 lbs)
Thanks!
Brianna
Philippe Carrier over 12 years ago
Can the deadline be delayed a little bit? I'd like to make the scotchman similar design. I may have a few nice ideas!
Kaspar Kiis over 12 years ago
Philippe, I'm glad you have few good ideas. Is it ok for if we extend the deadline by the end of this week?
What about all the rest of you guys? Any entries soon?
Brianna Kufa over 12 years ago
That would work for me. Thank you Kaspar.
Philippe Carrier over 12 years ago
I'll do my best to get it done. I can't guaranteed that it will be 100% done by the end of the week, but there should be a good part done.
By the end of the week, do you mean Saturday January 21th?
Kaspar Kiis about 12 years ago
Philippe, I mean Sunday January 22th. That would be great.
Philippe Carrier about 12 years ago
Thank you very much Kaspar! I'll have a lot of fun working of this project. I'll spent the entire evening on it, after my classes. Thank you for the delay!
Please log in to add comments.
Log in