Ironworker Shearing Test Plan

Test plan for 10/25/13:

Phase 1 - blade non-pass through (meaning blades do not cross one another yet) tests using hold-down. Goal: robust shearing of 1"x6" flat slabs of mild steel.

• Theoretical angle of blade upon touchdown of pivot end: 1/12
• Measured angle, to 1/16 height accuracy at both blade end separation distances

preliminary

Interestingly the blade is closer in the middle and a little farther on the edges on the edges we can get eight sheet of paper in between the two blades and then the middle we can get only two sheets

1. With this background info we can proceed to do the test plan
2. By comparison the ironworker prototype to can fit these sheets of paper as we test it:

1. 4 sheets, consistent

Cutting tests

Non-Pass Through

1. 1/4"x2" -ok
2. 1/2"x2" up to 1/2"x6" - did 1/2x2, warped at 1/2x4. Blades settled at 1/16" above:
3. 1" rebar
4. 1x2 to 1"x6" -

Pass through Cutting Tests

1. 1/2x7 - 1/2"x12"

Limit tests

1"x7" and up - feasibility of whih is determined during testing

We sheared up to 8 inch slabs:

1/2 Inch Steel Version

Blade Gap adjustment

• 4 sheet blade gap is about 12 +/- 4 thousandths of an inch thickand and two sheets at the year and closer to the pivot.
• initial gap was 2 paper widths on pivot side, and about 6 on the other side.
• paper. Sheets were inserted and eight were used on the one side under the blade and successively four and two and zero under the blade bolts to even out everything to two paper widths blade gap
• see Dozuki guide for directions on this procedure

Results

• resulting cuts were perfected without a sliver burp unevenness coming off on the wider side - see picture with edge sticking up in 2 places. The large piece in front has a straight cut, and metal does not bend. The sliver that came off the cut does bend (rest of metal is not holding it in shape).

After Correction

And after blade gap correction to about 7 thousandths of an inch throughout:

Straight to within 1/32 of an inch, no burps on the edge, shown here with a 9" wide cut of 1/2" steel sheet: