Design, Modelling & Fabrication of Circle Cutting Machine

Abstract

This paper details the design, modelling& fabrication a of a circle cutting machine engineered for efficient, precise, and cost-effective production of circular shapes. The machine employs a shearing operation to cut circles of varying diameters from metal sheets. Addressing the need for improved circular sheet cutting in industries, this solution offers a motorized, low-cost, and space-saving alternative. The integration of a servo motor enhances cutting accuracy and consistency. Its robust design and user-friendly interface contribute to the machine\'s durability and reliability, presenting an effective substitute for traditional cutting methods[3]. This research demonstrates the benefits of a locally manufactured circle cutting machine, providing small and medium-scale enterprises with an affordable and efficient cutting solution.

Introduction

The circular cutting of sheet metal is vital across many industries such as automotive, aerospace, medical, and packaging. In India, traditional manual and semi-automated methods (e.g., gas cutting) are common but limited by accuracy, efficiency, and reliance on skilled labor. In contrast, countries like China, Japan, and Korea use advanced CNC machines offering higher precision and productivity, though India depends on costly imports for such technology.

To enhance competitiveness, especially for small and medium enterprises, there is a need for a locally manufactured, fully automated, cost-effective circular sheet metal cutting machine. The paper presents the design and development of such a machine aimed at delivering precise, consistent cuts while improving operational efficiency and reducing costs.

Objectives:

• Achieve high precision and repeatability

• Optimize efficiency by reducing waste and errors

• Enhance throughput and reduce labor costs

Research & Design Methodology:

• Focus on accurate circular cuts with tight tolerances

• Streamline production and minimize defects like burrs and irregular edges

• Enable complex designs not possible with manual methods

• Reduce costs through material optimization and automation

Technical Design:

• Calculations for shafts, gears, blade, and grabhand components ensure safe and efficient operation with appropriate torque, stress, and safety factors.

• Blades are made of high-carbon high chromium steel to withstand high bending and torsional stresses.

• The overall design ensures mechanical safety and durability, though some deflection analyses require completion.

Results and Discussion:

• Shaft designs are safe with adequate safety factors against mechanical failure.

• Gear design shows acceptable bending stress with a 1:1 gear ratio.

• Blade design requires strong materials to handle significant stresses.

• Grabhand experiences low stresses but further analysis is needed on deflection.

• The design is generally safe and suitable for practical implementation, pending final material choices and complete structural evaluations.

Conclusion

Ultimately, the development and evaluation of this circular cutting apparatus confirm its practicality and utility within industrial settings. By drawing upon a comprehensive review of existing methodologies and a comparative study of current technologies, the device has been refined to maximize operational output while minimizing expenditures. The investigation underscores significant advancements, such as improved accuracy, decreased reliance on manual intervention, and reduced material consumption. By presenting a budget-friendly substitute for high-cost automated systems, this powered circular cutting machine empowers small and medium-sized businesses with a competitive edge. Subsequent enhancements could prioritize automation, expanded material processing capabilities, and further gains in operational efficiency to broaden its applicability across diverse industrial fields.

References

[1] Mihir Patel, Hardik Prajapati, Shivansh Patel, Prof. Darshan K. Bhatt, “Design and Development of Circular Sheet Cutting Machine”, 2014. [2] R. K. Singh, A. K. Sharma, R. Kumar, “Design and Development of a Precise Circle Cutting Machine for Industrial Application” International Journal of Advance Manufacturing Techniques, 2019. [3] Ranjan, SS Solanki, Vivek Keshri , “Automatic metal sheet cutting machine” International Journal of Advanced Engineering Applications, Vol.1, Iss.4, pp.1-2, 2013 [4] V. Uday Kiran, B. Hemanth Kumar, S.R. Ravishankar, A. Sai Kalyan ,T. Samuel Paul, “ Stress Analysis On Spur Gear In Marine Applicatoins By Fem Technique”, International Journal of Advanced Research in Mechanical Engineering & Technology, 2020 [5] Avinash Jathar, Avinash Kushwaha, Utkarash Singh, Prof. Shubhash Kumar, “Fabrication and Review of Hydraulic Heavy Sheet Metal Cutting Machine.” Gournal of Emerging Technologies and Innovative Research, Vol 3, 2016. [6] Prof. Mestry M. Pa.,Mr.Gopal Aravandekar, Mr.Bhushan Bambulkar, Mr.Pranav Gawas, Mr.Tejas Kadam, Review of Pneumatic Sheet Metal Cutting Machine. International Journal of Research Publication and Reviews Vol 2 2021 [7] Prof. Mrs. Jyoti Katre, Pankaj Badhiyel, Palash Balpande2, Kaustubh Ghotkar3, \"Design And Fabrication of Sheet metal cutting machine by pneumatic power\", International Journal of Engineering and Technology, Vol. 8, Issue 5, Mar 2021 [8] Yogita Bagul, Arif Mansuri, “A Review On Sheet Metal Cutting/Shearing Machine”, International Research Journal of Modernization in Engineering Technology and Science, Vol 4, 2022 [9] \"Development of a Precision Circle Cutting Machine using Servo Motor\" (IEEE International Conference on Industrial Automation and Robotics, 2019) [10] \"Circle Cutting Machine Design with Improved Safety Features\" (International Conference on Mechanical and Electrical Engineering, 2020) [11] Karthikumar K, K.V.S.S. Saikiran, Jakobus Satish, “Pneumatic Sheet Metal Cutting Machine”, International Journal and Magazine of Engineering and Technology, Management, Research”, Vol. 3, March 2016.

Copyright

Copyright © 2025 Dr. A. P. Ninawe, Ayushi Kalambe, Bhavik Borkar, Kaustubh Dhoble, Kunal Yeole, Vaibhav Golait, Dr. P. G. Mehar, Dr. S. R. Ikhar. 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.