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.