Design and Synthesis of Power Press Machine

Abstract

Power press machine is essential in metalworking and fabrication, enabling precise cutting, shearing, punching, and notching operations. However, traditional cutting machines often come with high costs and limited portability, making them less accessible for small-scale and flexible manufacturing setups. This study focuses on the design and development of a compact and versatile power press that addresses these limitations. The power press machine operates using a three-phase motor with an efficient power transmission system utilizing V-belt pulley. It incorporates an automated control mechanism, multiple worktables for diverse operations, and a lubrication system to enhance efficiency and longevity. The reciprocating motion of the slider block ensures precision in cutting and shearing tasks. Designed for ease of maintenance and high operational accuracy, this power press reduces material wastage and labour costs while improving productivity. Its compact form factor makes it suitable for various industrial applications without requiring major modifications. The developed system provides a cost-effective and reliable solution for precision metalworking, contributing to enhanced manufacturing efficiency and process automation.

Introduction

Manufacturing industries use metalworking processes like cutting, punching, and shearing to produce precise components, commonly employing power press machines for controlled mechanical force application. Traditional cutting machines, however, face challenges such as high costs, maintenance complexity, energy inefficiency, and limited accessibility for small and medium enterprises (SMEs).

This study proposes designing a compact, cost-effective, and versatile power press machine that integrates efficient power transmission, automated control, multiple worktables, and lubrication systems to enhance productivity, accuracy, and durability while reducing material waste.

Objectives:
The machine aims to perform versatile operations such as punching holes of varying sizes and cutting materials precisely.

Research Methodology:
Design calculations focus on shear force, energy requirements, and dimensions of key components like shafts, pulleys, and flywheels. Detailed engineering analysis ensures the machine’s performance, safety, and durability. Components were designed using CAD software.

Key Features:

• Uses a scotch yoke mechanism with V-belt pulley system for efficient power transmission.

• Handles a shear force of 77,000 N and requires 195.5 J energy for punching.

• Compact and portable with lightweight structural plates.

• Optimized component sizes, e.g., 50 mm shaft diameter, 80 mm cam diameter.

• Reduces setup time and material wastage.

• Minimizes reliance on hydraulic systems, lowering costs and maintenance.

• Ensures safety with robust construction.

Results and Discussion:
The design delivers a multifunctional power press that balances strength, efficiency, and portability, suitable for SMEs and industries needing precise metalworking without high operational costs or complex maintenance.

Conclusion

The development of a compact, efficient, and cost-effective power press machine successfully addresses the challenges of traditional metalworking systems. The designed machine demonstrates high shear force capability (77,000 N), precise power transmission using a scotch yoke mechanism and V-belt pulleys, and improved energy efficiency (195.5 J for punching operations). With a mean flywheel speed of 226.415 RPM and optimized component dimensions, the system ensures stable performance and durability. Its compact and portable design, along with multiple functionalities such as punching, cutting, and shearing, enhances versatility while reducing operational costs and material waste. Additionally, the incorporation of robust safety features, minimized setup time, and an efficient idle-to-punching cycle (11/12s idle, 1/12s punching) further improves productivity and operator safety. The machine’s reduced reliance on hydraulic mechanisms makes it an energy-efficient and cost-saving solution for modern industrial applications.

References

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Copyright

Copyright © 2025 Dr. S. R. Ikhar, Abhishek Pahune, Anuj Bramhankar, Kushal Kamble, Shubham Waghdhare, Pratik Chaware. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.