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AUTOMATIC ARTIFICIAL FLOWER STEM CUTTER

A thesis submitted to the

Faculty of the Mechanical Engineering Technology Program

of the University of Cincinnati

in partial fulfillment of the

requirements for the degree of

Bachelor of Science

in Mechanical Engineering Technology

at the College of Engineering & Applied Science

By

ALAN VERHOFF

Bachelor of Science University of Cincinnati

May 2012

Faculty Advisor: Laura Caldwell

Automatic Artificial Flower Stem Cutter

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ACKNOWLEDGEMENTS

I would like to take this time to thank my parents. Without their constant support and

encouragement I would not be graduating from college, or be the person that I am today. I

would also like to thank my advisor, Professor Laura Caldwell, for helping and guiding me

through the process of completing this project; also the rest of the MET department for

sharing with me some of their knowledge, and for making these last five years worth my

time. My friends, Adam Dehne, Craig Davis, Nick Plataniotis, Frank Ricciardi, Shawn

Westerfield, and Jeremy Jacobs, it is safe to say that without these guys I would have lost my

mind long ago.

TABLE OF CONTENTS

AUTOMATIC ARTIFICIAL FLOWER STEM CUTTER ....................................................1

ACKNOWLEDGEMENTS .................................................................................................. II

TABLE OF CONTENTS ..................................................................................................... II

LIST OF FIGURES ............................................................................................................. III

LIST OF TABLES ............................................................................................................. IV

ABSTRACT ......................................................................................................................... V

PROBLEM DEFINTION AND RESEARCH ........................................................................1

PROBLEM DEFINITION AND BACKGROUND .................................................................................................... 1 RESEARCH—EXISTING PRODUCTS ............................................................................................................... 1 CUSTOMER NEEDS ....................................................................................................................................... 5 PRODUCT / ENGINEERING FEATURES ............................................................................................................ 6 PRODUCT OBJECTIVES ................................................................................................................................. 9

DESIGN .............................................................................................................................. 10

CONCEPT SKETCHES .................................................................................................................................. 10 3D MODELING—CUTTER ........................................................................................................................... 12 3D MODELING—FRAME ............................................................................................................................ 13 3D MODELING—CLAMPS .......................................................................................................................... 14 3D MODELING—GUARDS .......................................................................................................................... 15

FORCE CALCULATIONS ................................................................................................. 17

CALCULATIONS &ASSUMPTIONS ................................................................................................................ 17 FREE BODY DIAGRAMS .............................................................................................................................. 18 FINITE ELEMENT ANALYSIS ....................................................................................................................... 21

COMPONENT SELECTION .............................................................................................. 25

FABRICATION .................................................................................................................. 26

CUTTING STOCK TO NOMINAL LENGTH ...................................................................................................... 26 CLAMP MACHINING ................................................................................................................................... 28 WELDING .................................................................................................................................................. 29 ASSEMBLY, WIRING, PAINTING .................................................................................................................. 30 FINAL PRODUCT ........................................................................................................................................ 32

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PROJECT TESTING AND RESULTS................................................................................ 34

PROJECT MANAGMENT ................................................................................................. 35

SCHEDULE—PROPOSED VS. ACTUAL .......................................................................................................... 35 BUDGET—PROPOSED VS. ACTUAL .............................................................................................................. 36

RECCOMENDATIONS ..................................................................................................... 37

WORKS CITED.................................................................................................................. 38

APPENDIX A—RESEARCH ............................................................................................ A1

APPENDIX B—SURVEY ................................................................................................. B1

APPENDIX C—QFD ......................................................................................................... C1

APPENDIX D—SCHEDULE ............................................................................................ D1

APPENDIX E—BUDGET ................................................................................................. E1

APPENDIX F—FORCE CALCULATIONS ...................................................................... F1

SHEAR STRESS CALCULATION: ................................................................................................................... F1 BLADE FBD: ............................................................................................................................................. F1 ARM FBD: ................................................................................................................................................ F2

APPENDIX G—BILL OF MATERIALS ........................................................................... G1

APPENDIX H—PART DRAWINGS ................................................................................. H1

LIST OF FIGURES Figure 1--Live Flower Stem Cutter (3) ..................................................................................1

Figure 2--Live Flower Stem Cutter, Underwater (4) ..............................................................2

Figure 3-Hand Operated Single Stem Cutter (5) ....................................................................2

Figure 4—Side Cutters, Single Stem Cutter (6) .....................................................................3

Figure 5—Modified Bolt Cutter, Single Stem Cutter (7) ........................................................3

Figure 6—Automatic Copper Tube Cutter (8)........................................................................3

Figure 7—Hand Operated Sheet Metal Shears (9) .................................................................4

Figure 8—4 Bar Pull Concept Sketch .................................................................................. 11

Figure 9—4 Bar Push Concept Sketch ................................................................................. 11

Figure 10—Selected Cutter (5” blade) ................................................................................. 13

Figure 11—Modeled Cutter ................................................................................................. 13

Figure 12—Anchoring Frame .............................................................................................. 14

Figure 13—Stem Clamps .................................................................................................... 14

Figure 14—Clamps and Braces ........................................................................................... 15

Figure 15—Guards and Guard Framing ............................................................................... 16

Figure 16—Cutter Assembly ............................................................................................... 16

Figure 17—Location Call Outs ............................................................................................ 18

Figure 18—Blade Free Body Diagram................................................................................. 18

Figure 19—Blade Dimensions ............................................................................................. 19

Figure 20—Arm Free Body Diagram .................................................................................. 19

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Figure 21—Arm Dimensions ............................................................................................... 20

Figure 22—Loading Conditions for Frame Flexure ............................................................. 21

Figure 23—How the Frame Was Fixed................................................................................ 22

Figure 24—Frame Flexure FEA Results .............................................................................. 22

Figure 25—Close Up of Stressed Frame Region .................................................................. 23

Figure 26—Loading Conditions of the Arm......................................................................... 23

Figure 27—How the Arm was Fixed ................................................................................... 24

Figure 28—Arm FEA Results ............................................................................................. 24

Figure 29—Close Up of Stressed Arm Region..................................................................... 25

Figure 30—Metal Cutter ..................................................................................................... 25

Figure 31—Clamp Cylinders ............................................................................................... 26

Figure 32—Main Cylinder .................................................................................................. 26

Figure 33—Stock Cut to Length (Anchoring Frame) ........................................................... 27

Figure 34—Stock Cut to Length (Clamp Actuator Brackets) ............................................... 27

Figure 35—Sine Vise for Milling Clamp Pieces .................................................................. 28

Figure 36—2” Clamp Pieces with Milled Angles ................................................................ 28

Figure 37—3” Clamp Pieces with Milled Angles ................................................................ 28

Figure 38—Welded Clamps ................................................................................................ 29

Figure 39—Welded Anchoring Frame ................................................................................. 29

Figure 40—Machining Upper Clevis ................................................................................... 29

Figure 41—Welded Assembly ............................................................................................. 30

Figure 42—Sand-Blasted Assembly .................................................................................... 31

Figure 43—Electrical Switch ............................................................................................... 31

Figure 44—Final Assembly (Side View) ............................................................................. 32

Figure 45—Final Assembly (Front View) ............................................................................ 33

Figure 46—Final Assembly (Close-Up) .............................................................................. 33

Figure 47—Automatic vs Manual Cutting of Small Stems ................................................... 34

Figure 48—Automatic vs Manual Cutting of Large Stems ................................................... 35

LIST OF TABLES Table 1—Importance Survey Results 5

Table 2—Satisfaction Survey Results 6

Table 3—Engineering Characteristics with Relative Importance 7

Table 4—Designer Multiplier 7

Table 5—Planned Satisfaction 8

Table 6—Relative Weight % 8

Table 7—Weight Rates 12

Table 8—Schedule 36

Table 9—Budget 37

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ABSTRACT

This report is the process taken to create a device that solves a real world problem. In

this case, the problem is fatigue in the hands after repeatedly cutting artificial flowers by

manual means; the solution to this problem is to develop a prototype that will shear these

artificial flower stems automatically. The entire process from surveying potential customers

to designing and manufacturing the product is covered in detail throughout this report. The

completion of this report is partial fulfillment of the curriculum for a bachelor’s degree in

MET at The University of Cincinnati.

Automatic Silk Flower Stem Cutter Alan Verhoff

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PROBLEM DEFINTION AND RESEARCH

PROBLEM DEFINITION AND BACKGROUND

The purpose of this project is to design and build an automatic silk (artificial) flower

stem cutter for floral hobbyists and small town flower shops. This idea came about from

Dorothy Verhoff (1) who is a floral hobbyist. She was having pain in her hands and wrists

after hours of constantly cutting the stems of the silk flowers to fit the lengths needed for the

flower arrangements. After finding no such product on the internet or specialty stores, she

asked for something that would do the cutting for her, so that she would no longer have to

deal with the pain of cutting the stems, while still being able to do what she enjoys, making

flower arrangements.

In addition to helping Dorothy with her hobbyist flower stem cutting needs, this product

will also fit the needs of a small town flower shop. Mike Ellerbrock (2) is the part owner of

Town and County Flower of Ottawa Ohio. This company has three separate locations and

they deal with live and silk flowers every day. He, and his employees, were also tired of the

pain in their hands and wrists, and thought that a product of this nature would be very

beneficial.

In order to help Dorothy and Mike with their needs, research into some of the existing

products was conducted. This research was conducted in order to see how some of the

problems with cutting these stems by hand were solved.

RESEARCH—EXISTING PRODUCTS

Figures 1 and 2 are good examples of how many floral professionals and hobbyists

would cut live flowers. Since the stems of the live flowers are easy to cut, these mechanisms

do not have the need to be automatic.

Figure 1--Live Flower Stem Cutter (3)

Figure 1 shows multiple live flowers being cut at once. This is a very good idea,


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however silk flowers will be much more difficult to cut than their live counterparts, so the

mechanism that is to be designed will have to be much more robust, and be capable of cutting

multiple silk flowers stems. Because live flowers are much easier to cut, figure 1 is powered

only by the force being applied by its human operator, and there is little fatigue in the hands

and wrists after using this product. However, when cutting silk flower stems with a

mechanism like this, there will be significant fatigue in the hands and wrists, because of the

extensive force needed to cut multiple silk flowers stems with a single cut.

Figure 2--Live Flower Stem Cutter, Underwater (4)

Figure 2 is a much more refined version of figure 1. This mechanism has a similar way

of cutting the live flower stems, but adds the ability to cut the live stems underwater. This

underwater feature is added to keep the live flowers fresh for longer. When cut, the live

flowers will immediately absorb some of the water, allowing them to stay fresh for a longer

time than if they were cut with the mechanism in figure 1. This mechanism also lacks the

feature to cut the stems automatically, which is not an issue when cutting live flowers.

Figures 3, 4, and 5 are all examples of hand operated silk stem cutters. All of these

cutters are designed to cut a single silk flower stem, but they are not automatic.

Figure 3-Hand Operated Single Stem Cutter (5)


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Figure 4—Side Cutters, Single Stem Cutter (6)

Figures 3 and 4 show silk flower stem cutters that are capable of cutting only one stem at

a time. Because these designs are hand powered, and you can only cut one stem at a time,

these cutters will lead to fatigue in the hands and wrists, and require extended time to cut a

bush of stems to length. In

Figure 5 is a modified bolt cutter that is used to cut one silk flower stem at a time. This

design is hand powered, and cuts the stem with one cut.

Figure 5—Modified Bolt Cutter, Single Stem Cutter (7)

This design is good for very thick stems, because the operator is able to apply some of

his/her body weight to the lever, increasing the cutting force. This is a good design because;

the addition of the lever creates a mechanical advantage, therefore making it easier to cut

through the thick stems. However, even with this mechanism, the operator is likely to

experience fatigue in the hands and wrists from repeatedly pushing the lever down.

Figure 6 is a product by Milwaukee, which is a hand-held, automatic copper tubing

cutter. This product is designed to cut a single piece of copper tubing ranging from 3/8”—1”

in diameter.

Figure 6—Automatic Copper Tube Cutter (8)


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This product is very efficient at cutting round copper tubing, and is easily maneuvered to

different positions and orientations. However, the center of a silk flower stem in made of

copper, and this product may not be able to cut a harder material such as steel. Also, this

product has a minimum size of 3/8”, which will not work for flower stem because of the need

to cut the entire way through the stem.

Figure 7 is product made by JET. This product is used to cut sheet metal, and metal rods.

See Appendix—A for additional products that operate in a similar fashion, and are used for

similar purposes.

Figure 7—Hand Operated Sheet Metal Shears (9)

This product could be very affective at cutting silk flower stems. In the product

description it says that this mechanisms, and mechanisms like it, are capable of cutting up to

½” diameter steel rod. This would be ideal for a flower stem cutter, because the stem of the

flower are made of steel rod that is coated in plastic to give it a realistic look. Also, none of

the flower stems that Dorothy or Mike has ever encountered have had steel rods that were

larger than ½” in diameter.

On September 25, 2011, an interview was conducted with Dorothy Verhoff. Dorothy is a

floral hobbyist that makes arrangements for her own home and for her friends and families’

homes. During this interview, she discussed the fact that she enjoys working with flowers,

but the pain in her hands and wrists, from manually cutting the flower stems, make it very

difficult for her to make arrangements. She says, ‘Sometimes, after I have been cutting the

flower stems for long periods of time, my hands begin to hurt and it becomes very difficult

and painful for me to cut any more stems. When this happens I usually ask my husband or

my son to cut the flowers for me’. When asked if she would be interested in and automatic

flower stem cutter, Dorothy responded saying, ‘Yes, very much. That would just be the

greatest thing ever.’ (1)

On September 25, 2011, an interview was conducted with Mike Ellerbrock. Mike is the

owner of a small town flower shop called Town and Country Flowers. This business has


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three locations, and has built a reputation with the community of providing quality flowers.

Mike, and his employees, have similar problem to Dorothy when cutting the thick flower

stems. ‘At first you can just cut right through the stems, and then after awhile it just starts

wearing on you, and pretty soon you can barley squeeze the cutter enough to cut through the

stems. Especially some of my female employees, they are always asking if either I or one of

the other guys can cut through some of the really thick stems. Having an automatic flower

stem cutter would be a valuable piece of equipment to have. I can’t believe that someone

hasn’t thought of it already.’ (2)

After researching the existing products, and conducting the interviews, it was determined

that a product of this nature should be designed. It is clear that the main criterion of this

product is that it must reduce the fatigue in the hands and the wrist. The next section will

discuss how the main features of the product were developed, and which of these features

were the most important.

CUSTOMER NEEDS

In order to know what the customers of this product were looking for, a survey was sent

out to Dorothy, and to Town and Country Flowers. A total of 24 surveys were completed and

collected; these surveys were completed by business owners, employees that work with the

flowers on a daily basis, and an average floral hobbyist.

Table 1 is the results from the Importance section of the survey. In this section the

customers were asked to fill out how important each feature was in the design of an

automatic flower stem cutter. The frequencies of these results were then tallied and place into

this table, starting with the most important. (In this survey 5 is the maximum score)

Table 1—Importance Survey Results

From table 1 it is clear that there are many very important features that will drive the

design of this product. Safety, Reliability, Efficiency, Affordability, and No Fatigue in the

Hand all scored perfect fives, which means that the most emphasis will be placed on these

features when designing this product. This does not mean that the Speed of Operation,

Maneuverability, Size, and Noise level aren’t important; it simply means that more time and

Feature

Safety

Reliability

Efficiency

Affordability

No Fatigue in the Hand

Speed of Operation

Maneuverability

Size

Noise Level

5.0

5.0

4.6

4.5

4.3

4.3

Importance Results

Average Result

5.0

5.0

5.0


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consideration will be put into ensuring that the features that scored a five will be fully

incorporated in the design of the automatic flower stem cutter.

Table 2 is the results from the Satisfaction section of the survey. In this section the

customers were asked to fill out how stratified they were with their current method of cutting

silk flower stems. The frequencies of these results were then tallied and place into this table,

starting with the most important. (In this survey 5 is the maximum score)

Table 2—Satisfaction Survey Results

From table 2, it is easy to see that there is much room for improvement from the

customer’s current manual way of cutting silk flower stems. The Size, Efficiency, No fatigue

in the hand, and Speed of operations, are all categories that need improvement if this product

is to compete with their current way of cutting the flower stems.

Along with these two main parts, the survey also asks the customers how much they

would expect this device to cost. Roughly 70% of the customers expect this device to be in

the range of $300--$500. The materials used to make this product will then be purchased

using this cost range as a guide. A full version of this survey appears in Appendix—B. Now

that the customer needs are known, a way to meet these needs must be thought of in order to

ensure that the customer is satisfied with the product.

After the surveys were collected and the results were tallied, a QFD was constructed

analyzing the same criteria that were on the survey. These criteria were evaluated using some

engineering characteristics that would satisfy these criteria.

PRODUCT / ENGINEERING FEATURES

Table 3 is a table of the engineering characteristics used to evaluate the customer

criteria. Each criterion is satisfied by at least one engineering characteristic.

Feature

Noise Level

Maneuverability

Safety

Reliability

Affordability

Size

Efficiency

No Fatigue in the Hand

Speed of Operation

4.0

3.8

3.5

3.3

3.0

Satisfaction Results

Average Result

4.6

4.5

4.2

4.0


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Table 3—Engineering Characteristics with Relative Importance

Table 3 lists the engineering characteristics, with their relative importance, used to

satisfy the customer’s criteria for this product. These characteristics are features that can be

desigend into the product to satisfy the customer features. An example of how this works is

as follows: Guards can be designed into the product to satisfy some of the Safety criterion

requirement, however guards will aslo have an impact on the Affordability criterion as well.

These weights will be used when selecting components, and deciding which of the

characteristics are the most important.

Tables 4 and 5 are the first time that the designer of the product has a say in what the

product will do, and how it is expected to preform. Table 4 is the desingner mulitplier section

of the QFD, and table 5 is the planned satisfaction section of the QFD.

Table 4—Designer Multiplier

Table 4 is the results from the designer multiplier section of the QFD. In this section, the

customer importance weights, results of the survey, are listed. Next to these values, the

designer decides if the value will increase, decrease, unchange the values. From table 4, the

designer has only increased three of the weights by 10%, and has not decreased any of the

Engineering Characteristics Relative Importance %

Cutter spec sheet 22%

Motor/actuator spec sheet 18%

COSMOS used for factor of safety 10%

Cuts one bush at a time 10%

Footprint 8%

Lightweight 7%

Casters 5%

Clamps to hold the stems 5%

Separate switches for operators safety 4%

Guards 4%

Handles 4%

Noise of motor/actuator 3%

Customer Importance Designer's Multiplier

Safety 5.0 1.0

Reliability 5.0 1.0

Size 4.3 1.1

Efficiency 5.0 1.0

Speed of Operation 4.6 1.0

Affordability 5.0 1.0

No Fatigue in the Hand 5.0 1.0

Noise Level 4.3 1.1

Maneuverability 4.5 1.1


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weights. The designer increased these three criteria importance values to ensure that the

customer would be very satisifed with how the device prefomred and operated. Conversly,

the designer didn’t decrease any of the values because the customers wouldn’t be as satisfied

as what they were expecting.

Table 5—Planned Satisfaction

Table 5 if the results for the planned satisfaction section of the QFD. In this section, the

customers current satisfaction weights were either increased, decreased, or unchanged by the

designer. This process is done to set benchmarks for the designer to reach. All of the

satisfactions were increased by the designer, which means that if successful, the product will

exceed the customers current method of cutting silk flower stems.

Table 6 is the relative weights, which the QFD generated. These weights will be used to

rank the criteria in relative importance.

Table 6—Relative Weight %

The results of the QFD are listed in table 6. These results show which if the customer’s

criteria are the most important relative to each other. These weights will be used when

deciding how to design the product. All of these criteria are close to each other in terms of

importance, but more time will be put into the design of the heavier weights, such as No

Current Satisfaction Planned Satisfaction

Safety 4.3 4.8

Reliability 4.0 4.5

Size 3.8 4.7

Efficiency 3.5 5.0

Speed of Operation 3.0 4.5

Affordability 4.0 4.0

No Fatigue in the Hand 3.3 4.8

Noise Level 4.7 4.7

Maneuverability 4.5 4.5

Relative Weight %

No Fatigue in the Hand 14%

Speed of Operation 13%

Efficiency 13%

Safety 11%

Reliability 11%

Size 11%

Affordability 9%

Noise Level 9%

Maneuverability 9%


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fatigue in the hand, Speed of operation, and Efficiency.

When the QFD was completed, these relative weights were produced. These weights

will make it easier when selecting components because the ones with the greater importance

will have the biggest individual impact on how the product will ultimately perform. From the

table, the Motor/actuator, and Cutter spec sheets will have the greatest impact on whether the

product will perform as desired, or whether it will fail.

PRODUCT OBJECTIVES

The following is a list of product objectives and how they will be obtained or measured

to ensure that the goal of the project was met. The product objectives will focus on cutting

one bush at a time. This number of stems was chosen because this will primarily be used to

cut the stems to length, and this is usually done one bush at a time.

No fatigue in the hand (14%)

1.) The cutter will reduce the number of manual cuts by at least 80%, therefore, reducing

the fatigue in the hands.

Speed of Operation (13%)

1.) From the time the cutter is started to the time the stem/bush is cut will be 3 seconds or

less.

Efficiency (13%)

1.) The cutter will be able to cut the stems with one attempt

Safety (11%)

1.) Safety guards covering pinch points and moving parts.

2.) Separate switches to ensure that the user’s fingers will not be cut.

3.) Clamps to hold the stems while being cut, to prevent the stem from jumping.

Reliability (11%)

1.) Reliability of the cutter measured by component life and proper design criteria

specified in the following spec sheets:

-Motor spec sheet

-Cutter spec sheet

2.) A factor of safety of will be provided by COSMOS to show that structural

components of the cutter will not fail.

3.) Mechanical assembly will follow allowable torques of mechanical fasteners and the

use of Loctite.

4.) All electrical connections will be soldered and then covered in heat wrap to ensure a

quality connection.

Size (11%)

1.) The cutter will have a footprint similar to that of a standard printer.

Affordability (9%)

1.) The cutter will be priced for not only a flower shop, but also a flower hobbyist.

(vacuum cleaner)

Maneuverability (9%)


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1.) The cutter will be able to be maneuvered by one person, of average strength, to the

position required.

2.) The cutter will have casters to improve maneuverability.

Noise level (9%)

1.) The noise level will around the level of a paper shredder.

The criteria from the survey and the QFD appear in the product objectives; however the

order in which they appear has changed. Their new order is based on the results of the survey

with the most important criteria appearing first, and the least important criteria appearing

last. Along with the criteria, the product objectives also include how the designer plans on

incorporating them into the design. For example, the Efficiency criterion says, ‘The cutter

will be able to cut the stems with one attempt’. In order to ensure this, the designer will have

to pay close attention to the cutter and the motor spec sheets, to ensure that the particular

cutter and motor will be able to handle the loads associated with cutting the flower stems.

The same process is repeated throughout the product objectives, for every criterion.

DESIGN

CONCEPT SKETCHES

The design of the automatic silk stem flower stem started with the concept sketches.

These are hand drawn sketches of conceptual ideas that will be used to ensure that the idea of

the cutter is not destined for failure from the start.

The idea of using one of the throat-less metal shears, found during the research, was

chosen as the basis of the design. Figure 7 is similar to the cutter that was chosen; the chosen

cutter has a 5” cutting blade, is capable of cutting up to 0.5” steel rod, and whose physical

dimensions fit the size requirements of this project.

Figures 8 and 9 are a sketches of how a throat-less metal shear could be modified to fit

the needs of this project. By fixing the shear to a custom frame, and attaching an electric

actuator to the handle, enough force could be generated to cut through the flower stems. Both

configurations would include similar frames, similar casters, and similar circuitry. (2 separate

switches for operation)


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Because these configurations are so close to each other in terms of design, a weighted

rates table (table 7) was constructed to determine which of the two configurations would

fulfill the customer needs the best.

Figure 8—4 Bar Pull Concept Sketch

Figure 9—4 Bar Push Concept Sketch


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By assigning a value (0-4) to each customer feature, based on how well each design

configuration would fulfill that feature, and comparing the two; the ‘better’ design was

chosen. For example; because of the geometry the cutter, the pull configuration would have a

bigger footprint, therefore receiving a lower value than the push configuration. The product

of the values and their relative weights was then summed, and the configuration with the

bigger total was the ‘best’ design.

3D MODELING—CUTTER

During the research for the automated cutter, a throat-less sheet metal cutter was found

that was capable of cutting up to 0.5” steel rod. Because the flower stems are made from steel

cores, and because these cores are not greater than 0.5” in diameter, this cutter fit the needs

of the design perfectly. Also, this model came in several blade sizes; because the size of the

blade affects the overall dimensions of the cutter, the cutter with the 5” blade was selected

instead of the cutters with the larger blades. Figure 10 is the cutter that was chosen.

0-4 Scale

4=Best 0=Worst

Act

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We

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ted

Rat

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Act

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Rat

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Product Objectivs Weights

Safety 0.11 4 0.44 4 0.44

Reliability 0.11 4 0.44 4 0.44

Size 0.11 2 0.22 4 0.44

Efficiency 0.13 4 0.52 4 0.52

Speed of Operation 0.13 4 0.52 3 0.39

Affordability 0.09 4 0.36 3 0.27

No Fatigue in the hand 0.14 4 0.56 4 0.56

Noise Level 0.09 4 0.36 4 0.36

Maneuverability 0.09 4 0.36 3 0.27

Total 3.78 3.69

PULL PUSH

Table 7—Weight Rates


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Since there were no 3d or detail drawings available for the cutter, the modeling of this

cutter was done by hand. The dimensions of the cutter were scaled off of the figure 10, and

were modeled in AutoCAD Inventor (figure 11).

Figure 11 is a screen shot of the modeled cutter; the rest of the automated device will be

built around this modeled cutter.

3D MODELING—FRAME

Figure 10—Selected Cutter (5” blade)

Figure 11—Modeled Cutter


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After the cutter was modeled, a frame was designed. This frame (figure 12) is to support

the cutter, and allow for the attachment of the clamps, actuators, casters, and other essential

items. This frame was made using standard sizes of square tubing and angle iron.

3D MODELING—CLAMPS

The design continued with the modeling of the stem clamps. These clamps were place on

both sides of the cutter to maximize the safety of the operation. The clamps have a ‘V’ shape

to them, in order to constrain the stems into a bundle. This bundling will ensure that the

stems are cut; as opposed to just sliding across the blade, as would occur if the clamps were

simply flat and not ‘V’ shaped. Figure 13 shows these clamps in their correct orientation with

the cutter.

Figure 12—Anchoring Frame

Figure 13—Stem Clamps


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The next step of the design process was the addition of the electric cylinders, and the

associated bracing needed (figure 14). Just as frame was made from standard material sizes,

the braces for the clamp cylinders were made from standard sizes.

3D MODELING—GUARDS

The guards, and guard-frame were then designed (figure 15). The guards are made from

plexi-glass, the two side guards have cutouts to allow the stems to easily pass into the cutter.

The guard-frame is made from standard size angle iron, and will be welded to the anchoring

frame; each frame piece, and its correlating plexi-glass guard has periodic holes drilled in

them to allow them to be bolted together.

Figure 14—Clamps and Braces


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The cutter assembly in shown in figure 16, this assembly is shown with casters to

improve the mobility of the device. The final assembly will include handles, also for

improved mobility, and wiring for all of the cylinders.

After the design was complete, force calculations needed to be solved for. These forces

will then later be applied to the design to verify that it will be robust enough to with stand the

Figure 15—Guards and Guard Framing

Figure 16—Cutter Assembly


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forces seen while cutting the flower stems.

FORCE CALCULATIONS

CALCULATIONS &ASSUMPTIONS

In order to calculate the force needed to shear the flower stems, a few assumptions were

made:

The stem of the flower is made of a steel core, .1” diameter, and a rubber/plastic

coating, .3” in diameter.

The steel core is assumed to be 1020 Cold-Drawn, with a Tensile Strength of

61,000psi. (Machine Elements in Mechanical Design, 4th Edition, Mott).

The Shear Strength of the steel is 2/3 of the Tensile Strength.

Assume also, that the maximum number of stems cut at one time to be two. This is

from knowing how rods behave when they are stacked on top of each other.

With these assumptions in mind, the following calculations were made:

Area

Shear Stress

Force Needed to Cut Stems


18

After the force needed to cut through the stems were calculated, free body diagrams

were used to calculate how much force was needed by the cylinder.

FREE BODY DIAGRAMS

Below, is a diagram of the location call outs used during the force calculations (figure

17). The called out points are the important points of the cutter, and the distances between

these points were used for the calculations as well.

Figure 17—Location Call Outs

Figure 18—Blade Free Body Diagram


19

Using figures 18 and 19, the following calculation was made:

The 175 lb force was solved for, and will be transmitted to the blade from the arm.

Figure 19—Blade Dimensions

Figure 20—Arm Free Body Diagram


20

Using figures 20 and 21, the following calculation was made:

The 175 lb force that was solved for in the blade free body diagram shows up in this one

as well. Using a similar method as before, a force of 48 lbs was calculated. This 48 lbs is the

force that the cylinder will need to pull in order to cut the stems.

The 48 lbs needed to cut the stems is when the cutter is at the end of its stroke. In order

to ensure that the 643 lb shearing force is maintained throughout the entire stroke, and Excel

sheet was set up; using simple trig formulas, the force at the beginning of the stroke, which

happens to be the maximum force, is 82 lbs. Because no electric cylinder was found that

could pull with this force and was still is dimensionally small enough to fit in the designed

space, an electric cylinder of 150 lbs pulling force was found, and had the dimensions that

would fit into the design. So the new pulling force of the cylinder is 150 lbs, this will be used

for all of the stress analysis.

Figure 21—Arm Dimensions


21

FINITE ELEMENT ANALYSIS

After the calculations were completed, multiple stress analysis simulations were run on

the designed parts to ensure that they would be able to stand up to the loading conditions.

The first simulation was done on the anchoring frame. The goal of this simulation was to

measure the frame flexure; to verify that the frame would not bend is such a way as to cause

failure. Figure 22 shows the loading conditions of the frame; a force of 150 lbs was applied

to the frame. This 150 lb force was applied the exact same way as the cylinder would apply

it. Also included in this simulation is the force of gravity. Figure 23 shows how the frame

was fixed.

Figure 22—Loading Conditions for Frame Flexure


22

The results of the simulation are shown in figures 24, and 25. After the results of the first

simulation were verified to be within the acceptable range, a second simulation was run. This

second simulation had the exact same loading and constraining conditions, the only

difference was that the mesh size was reduced around the stressed regions. The results of the

second simulation were only a few percent different, so the simulations verified each other.

Figure 23—How the Frame Was Fixed

Figure 24—Frame Flexure FEA Results

Max Displacement: 0.008”


23

Because the cutter is commercially rated to cut up to 0.5” steel rod, no stress analysis

was done on it, except for the arm of the cutter. The arm will be modified, and a stress

analysis was done on this to ensure that the planned modifications would not jeopardize the

integrity of the arm. Figures 26 and 27 show how the arm was loaded, the same 150 lb load

in the exact direction that the cylinder would apply it, and how it was constrained

respectively.

Figure 25—Close Up of Stressed Frame Region

Figure 26—Loading Conditions

of the Arm

Max Stress: 6.9ksi

Safety Factor: 4.34


24

Figures 28 and 29 show the result of the simulation, and a close up of the stressed region

respectively. Just as before, the mesh size was reduced around the stressed region and the

simulation was re run; and just as before the second simulation yielded results that were just

a few percent different than the first. The results of the simulation are: Max Stress 6.6 ksi,

Max Displacement 0.0007”, and a Safety Factor of 4.58. All of these numbers are acceptable.

Figure 27—How the Arm was Fixed

Figure 28—Arm FEA

Results

Max Displacement: 0.0007”


25

Simulations were also run on the clamps for the stems. These forces were so low and the

material was size was so over designed that the forces and stresses were minimal. After the

FEA was completed, and the results analyzed, it was decided that the design would perform

as expected and the project moved from the design stage to the Component selection stage.

COMPONENT SELECTION

Only three components needed to be chosen for this project the metal cutter (figure 30),

the electric cylinders for the clamps (figure 31), and the main electric cylinder (figure 32).

Figure 29—Close Up of Stressed Arm Region

Figure 30—Metal Cutter

Max Stress: 6.6ksi

Safety Factor: 4.58


26

FABRICATION

CUTTING STOCK TO NOMINAL LENGTH

After all of the design work was completed, and all of the components were selected; the

fabrication of the flower cutter could begin. The fabrication started by contacting local metal

suppliers and purchasing the stock at standard lengths, to keep the price as low as possible.

Then, using the horizontal band saw, the standard lengths were cut to the nominal lengths per

the detail drawings located in Appendix H. Some examples of this are figures 33, and 34.

Figure 31—Clamp Cylinders

Figure 32—Main Cylinder


27

Figure 33—Stock Cut to Length

(Anchoring Frame)

Figure 34—Stock Cut to Length

(Clamp Actuator Brackets)


28

CLAMP MACHINING

The clamps were made by again using the horizontal band saw, and cutting 12-2”, and

12-3” pieces. These pieces then had the required angles milled into them using a sine vise

(figure 35). The completed clamp pieces can be seen in figures 36, and 37.

Figure 35—Sine Vise for Milling Clamp

Pieces

Figure 36—2” Clamp Pieces with

Milled Angles Figure 37—3” Clamp Pieces with

Milled Angles


29

WELDING

After the machining was completed on the cut pieces, they were then welded together.

The anchoring frame (figure 38) was welded using a MIG welder, while the clamps and

clamp actuator brackets (figure 39) were welded using a TIG welder.

Bothe clevises were machined out of solid pieces of steel (figure 40).

Figure 39—Welded Anchoring Frame Figure 38—Welded Clamps

Figure 40—Machining Upper Clevis


30

ASSEMBLY, WIRING, PAINTING

After all of the sub-assemblies were completed, everything was clamped onto the

anchoring frame. Then, the main actuator was then put into place, and electricity was applied

to the actuator to make it both extend and retract. This was done several times in order to

ensure that the alignment of the sub assemblies were in their correct orientation and position.

The clamps were tightened down, and the main actuator was removed from the assembly so

the sub-assemblies could be welded to the anchoring frame, without endangering the

electrically sensitive actuator. Figure 41 is a picture of the welded assembly.

The next steps were sand-blasting, painting, and wiring. The blades were removed from the

cutter, and the entire assembly was sand-blasted (figure 42). The assembly was then painted,

and while the paint was drying, the wiring was completed. The wires were soldered to the

switches, and heat shrink and electrical tape were wrapped around the switches and wires for

added protection (figure 43).

Figure 41—Welded Assembly


31

Figure 42—Sand-Blasted

Assembly

Figure 43—Electrical Switch

Solder

Heat-Shrink


32

FINAL PRODUCT

The blades were then bolted back onto the cutter, the actuators and wiring were then put

into place, and the Plexi-Glass guards were bolted onto the guard frame. Pictures of the

completed assembly are below (figures 44, 45, 46).

Figure 44—Final Assembly (Side View)


33

Figure 45—Final Assembly (Front View)

Figure 46—Final Assembly (Close-Up)


34

PROJECT TESTING AND RESULTS

In the project objectives it states that the cutter will reduce the number of manual cuts by

at least 80%. In order to test this at least 6 stems need to be cut at a time. In the demo for

Professor Caldwell the cutter cut through 7 stems. These 7 stems were comprised of an

assortment of different sized stems, and the cutter was able to cut shear all 7 of them in the

first attempt. The cutter was also tested by cutting through an average bush of flowers. This

bush was comprised of 18 stems of small diameter, and like the previous test, it cut right

through the stems.

Figures 47 and 48 are pictures of graphs that were made to demonstrate the increased

efficiency of the automated flower cutter. From figure 47 it is clear that after 11 small stems

it is more efficient to use the automated cutter, as opposed to the manual cutter. And the

efficiency increases even more, starting at 7 stems, when you are cutting larger stems as you

can see from figure 48.

Figure 47—Automatic vs Manual Cutting of Small Stems


35

PROJECT MANAGMENT

SCHEDULE—PROPOSED VS. ACTUAL

In order to ensure that the project would be completed by the required date, a schedule

was developed. The expected completion dates are in blue, and the actual completion dates

are in red if they were completed behind schedule and green if they were completed either

before or on schedule. Table 8 is a compressed version of the schedule.

Figure 48—Automatic vs Manual Cutting of Large Stems


36

For a copy of the Schedule, refer to Appendix—D Schedule.

BUDGET—PROPOSED VS. ACTUAL

Because this project will be funded the designer, it is important to have a proposed

budget. This budget is just a rough estimate, and will be refined after the parts have been

purchased and the project has been completed. Table 9 is a copy of this budget.

Table 8—Schedule

Expected Actual

5-May 11-May

17-May 17-May

1-Jun 21-May

4-Feb 4-Feb

28-Feb 28-Feb

28-Apr 4-May

Completion

24-Dec 28-Dec

28-Jan 1-Feb

May 6 - May 18

May 19 - June 1

3D Modeling of Entire Device

Calculations, Shop Drawings, Component Selection

Design Freeze

Begin Fab, Work on Winter Report/Oral

Electrical Research, Complete Fab

Test/ Fine Tuning

Demo to Advisor/Faculty

Spring Report/Oral

Nov 27 - Dec 24

Dec 25 - Jan 28

Jan 29 - Feb 4

Feb 5 - Mar 9

Mar 10 - Apr 28

Apr 29 - May 5


37

Proposed Budget Actual

Component Description Cost Cost

Frame

Links/Braces Steel $50 $45

Casters $20 $18

Clamps Steel $20 $20

Guards Plexi Glass $30 $50

Drivers/Cutter

Drivers/Cutter Actuators $200 $335

Cutter Metal Cutter $175 $100

Electrical

DC Power

Supply AC-DC $50 $60

Wiring/Switches $25 $20

Miscellaneous Bolts/Nuts/Paint $40 $20

Total $610 $668

From table 9, the projected budget is $610. After the project was completed the final cost

was $668. This is over budget, but because this was a prototype, the amount spent on the

project is an acceptable number. A full version of the proposed budget can be found in

Appendix—E Budget.

RECCOMENDATIONS

Although the project was finished on time and completes the task that it was designed to

do, there are a few things that should be modified in order to make the product better as a

whole.

Using only one actuator to move the clamps. This would reduce the cost by roughly

$100, which would keep the cost at a more reasonable level.

Using aluminum instead of steel for the anchoring frame the guard frame and the

clamps. This would make the cutter much lighter and easier to move.

Account for the power supply in the design of the cutter. As it works now, the power

supply sits next to the cutter, and must be moved independently of the cutter. The

best thing to do is raise the cutter up by using larger diameter casters, allowing the

power supply to fit under the cutter. Then securing the power supply to the cutter so

that they will move together.

Table 9—Budget


38

WORKS CITED 1. Verhoff, Dorothy. Floral Hobbyist. 17460 Road K Ottawa, Ohio, 45875, 9 25, 2011.

2. Ellerbrock, Mike. Owner of Flower shop. 15800 Road Z Columbus Grove, Ohio, 45830,

9 25, 2011.

3. Flower Stem Cutter. wholesalefloral.com. [Online] [Cited: 9 22, 2011.]

http://www.wholesalefloral.com/Flower_Stem_Cutter_p/stemcutter.htm?Click=3793&gclid=

CMLgxeuCsasCFUTBKgodMHihhg.

4. High-capacityFloor model Underwater Stem Cutter. floralsupply.com. [Online] [Cited: 9

22, 2011.] http://www.floralsupply.com/cooler-buckets-flower-prep-items/stemcutter/1211-

unifuse1-flower-stem-cutter.htm.

5. Floral Stem Cutter 12.6-Inch. amazon.com. [Online] [Cited: 9 23, 2011.]

http://www.amazon.com/Fiskars-01004726-Floral-Cutter-12-6-

Inch/dp/B002IPH602/ref=sr_1_1?ie=UTF8&qid=1316701477&sr=8-1.

6. 7 1/2" Heavy-Duty Floral Stem. tooltron.com. [Online] [Cited: 9 22, 2011.]

http://www.tooltron.com/products/7-1%7B47%7D2%22-Heavy%252dDuty-Floral-Stem-

Cutter.html.

7. How to cut silk flower stems for floral arrangments. wonderhowto.com. [Online] [Cited: 9

23, 2011.] http://www.wonderhowto.com/how-to-cut-silk-flower-stems-for-floral-

arrangements-273769/.

8. Milwaukee 2471-21 12-Volt Copper Tubing Cutter Kit. amazon.com. [Online] [Cited: 9

27, 2011.] http://www.amazon.com/Milwaukee-2471-21-12-Volt-Copper-

Tubing/dp/B001FB64N0/ref=sr_1_1?ie=UTF8&qid=1317140163&sr=8-1.

9. Vansantent.com. [Online] JET. [Cited: 10 27, 2011.]

http://vansantent.com/sheet_metal_machines/slitting_shear.htm.

Appendix A1

APPENDIX A—RESEARCH

Don't get stuck with a short flower stem

cutter that cut a full bunch try this 22.5" long

stainless steel fresh flower stem cutter. Can

be used underwater. Mounting brackets are

attached. Easy grip padded wooden handle.

Not for cutting silk flower wired stems.

Measure 22.5" long x 6". 13". Stainless steel

blade is 12.5" long.

Easily moved.

Good design for real flowers.

Would not be able to cut silk (fake) flower

stems.

Not automatic.

Hands may get fatigued after hours of use.

http://www.wholesalefloral.com/

Flower_Stem_Cutter_p/stemcutte

r.htm?Click=3793&gclid=CMLg

xeuCsasCFUTBKgodMHihhg

Flower Stem Cutter

wholesalefloral.com 9/22/2011

http://www.wholesalefloral.com/Flower_Stem_Cutter_p/stemcutter.htm?Click=3793&gclid=CMLgxeuCsasCFUTBKgodMHihhg




Appendix A2

This new product provides a complete

maintenance free underwater stem cutting system

for florists and floral departments.Allows

submerged trimming which prevents air bubbles

from choking the bloom.The 25-gallon tub

secures the cutter and is small enough for

portability and easy trim removal.The fitted

plastic spigot allows for quick draining. Easy to

clean polyethylene is USDA/FDA approved and

will not rust, chip or crack. The stainless

mechanism is maintenance free and allows safe

changing of the cutting blade.Uses the Same

blades as the Watercut II machine.The product

measures 20î x 29î x 14î h making it small

enough to be used on a table top or increase the

standing height to 29î with our elevated

dolly.This is THE finest underwater flower cutter

made!SHIPPING NOTE:Comes ion two cartons.

Freight on this item WEST of the Mississippi

River is high due to the cartons sizes.

Easily moved.

Good for real flowers.

Bad for silk flowers, (underwater not

needed).

Expensive ($899.95).

http://www.floralsupply.com/cool

er-buckets-flower-prep-

items/stemcutter/1211-unifuse1-

flower-stem-cutter.htm

High-capacity Floor model

Underwater Stem Cutter

floralsupply.com 9/22/2011

http://www.floralsupply.com/cooler-buckets-flower-prep-items/stemcutter/1211-unifuse1-flower-stem-cutter.htm




Appendix A3

Professional grade

Cuts stems up to 1/2-inch diameter

Tabletop design for more control

Cuts up to four times easier than standard

wire cutters

Good for both real and silk flowers.

1/2 –inch max. diameter.

Hand fatigue after much use.

Easy to use.

C-45 carbon steel. Foam grip handles. Ideal

For Stem Cutting Both Silk And Fresh

Flowers, PVC Dipped Handles Machine

Cutting Edges.

Good for both real and silk flowers.

Easy to use.

Not automatic.

Fatigue in the hands, after hours of use.

Difficult for thick stem silk flowers.

http://www.tooltron.com/product

s/7-1%7B47%7D2%22-

Heavy%252dDuty-Floral-Stem-

Cutter.html

7 1/2" Heavy-Duty Floral Stem

Cutter

tooltron.com 9/22/2011

http://www.amazon.com/Fiskars-

01004726-Floral-Cutter-12-6-

Inch/dp/B002IPH602/ref=sr_1_1

?ie=UTF8&qid=1316701477&sr

=8-1

Floral Stem Cutter 12.6-Inch

amazon.com 9/23/2011

http://www.tooltron.com/products/7-1%7B47%7D2%22-Heavy%252dDuty-Floral-Stem-Cutter.html




http://www.amazon.com/Fiskars-01004726-Floral-Cutter-12-6-Inch/dp/B002IPH602/ref=sr_1_1?ie=UTF8&qid=1316701477&sr=8-1





Appendix A4

If you've worked with silks, you know that

sometimes stems are hard to cut. In this

video tutorial, Dana Plazyk of Flowers by

Design shows you some simple techniques

and special tools to get the job done! See

how to design and cut silk flower stems for

floral arrangements.

Easy to move.

Works good for silk flowers.

Not automatic.

http://www.wonderhowto.com/ho

w-to-cut-silk-flower-stems-for-

floral-arrangements-273769/

How to cut silk flower stems for

floral arrangements

wonderhowto.com

9/23/2011

Interview with Mom, September 25, 2011

Dorothy Verhoff, Floral Hobbyist, 17460 Road K, Ottawa, Ohio, 45875.

Assembles flower arrangements for family and friends

Fatigue in the hand after cutting thick silk flower stems

Interested in an automated stem cutter

Interview with Family friend, September 25, 2011

Mike Ellerbrock, Owner of a Flower shop, 15800 Road Z, Columbus

Grove, Ohio, 45830.

Owns a flower shop, with three different locations

Has a device that cuts the thick stems, but is interested in an automated

version

http://www.wonderhowto.com/how-to-cut-silk-flower-stems-for-floral-arrangements-273769/



Appendix A5

12V LITHIUM-ION battery for

longer run-time

Close quarter rotating cutting head

cuts pipe in confined spaces

Automatic adjustment from 3/8” – 1”

tubing with Auto locking mechanism

and Water resistant metal cutter head

Ergonomic, compact, and lightweight

design for operator comfort and Ultra-

efficient drive mechanism delivers

over 200 cuts per charge

Battery Fuel Gauge displays

remaining run-time and Built-in LED

light illuminates work surface

Looks like a very promising device for silk

flower stem cutting

Need to figure out how to incorporate into

table top form

Easy to use

Needs to be able to cut smaller stems

http://www.amazon.com/Milwau

kee-2471-21-12-Volt-Copper-

Tubing/dp/B001FB64N0/ref=sr_

1_1?ie=UTF8&qid=1317140163

&sr=8-1

Milwaukee 2471-21 12-Volt

Copper Tubing Cutter Kit

amazon.com

http://www.amazon.com/Milwaukee-2471-21-12-Volt-Copper-Tubing/dp/B001FB64N0/ref=sr_1_1?ie=UTF8&qid=1317140163&sr=8-1





Appendix A6

Capable of shearing sheet steel, steel

bars and rods plus many non-metallic

materials

Replaceable high quality stainless

steel blades are hardened and

tempered for maximum service life

An adjustable hold down clamp aids

in securing material

Compound leverage allows the

operator to easily perform work

within shears' rated capacity

Includes 35-1/2" handle

Round Capacity 1/2” (mild steel)

Good option for cutting the stems

Not sure if it’s able to cut multiple stems

Needs to be automatic

Modifications needed to fit my application

http://vansantent.com/sheet_meta

l_machines/slitting_shear.htm

Jet Hand Slitting Shears

Vansantent.com

10/27/2011

http://vansantent.com/sheet_metal_machines/slitting_shear.htm

http://vansantent.com/sheet_metal_machines/slitting_shear.htm

Appendix A7

Rack and pinion gearing, plus

extended handle, improve your

leverage

Tool steel blades slice thru 14-ga.

mild steel, 18-ga. Stainless

Throatless shear is crafted of rugged

cast iron

Good for cutting sheet metal

Modifications needed to the mechanism to fit

my needs


http://www.eastwood.com/throatl

ess-shear.html

Economy Throatless Shear

Eastwood.com

10/27/2011

http://www.eastwood.com/throatless-shear.html

http://www.eastwood.com/throatless-shear.html

Appendix A8

Cuts up to 3/16" mild steel

Will also cut up to 5/16" round bars

8" High speed steel blades

Adjustable material hold down

Spring return handle

Cuts thick round bar


Modifications needed to fit my application

http://www.ebay.com/itm/Throatl

ess-sheet-metal-hand-shear-3-16-

mild-steel-capacity-Woodward-

Fab-

/350499003126?pt=Motors_Auto

motive_Tools&vxp=mtr&hash=it

em519b5e5af6#ht_656wt_1185

Throatless sheet metal hand shear

3/16" mild steel capacity

Ebay.com

10/27/2011

http://www.ebay.com/itm/Throatless-sheet-metal-hand-shear-3-16-mild-steel-capacity-Woodward-Fab-/350499003126?pt=Motors_Automotive_Tools&vxp=mtr&hash=item519b5e5af6#ht_656wt_1185







Appendix A9

Super Heavy Duty steel frame and

hardened high carbon steel blade

Carbon steel blade is easily

replaceable. Replacement blades are

available from us

Blade length: 8"

Mild steel cut thickness: 3/16"

Stainless steel cut thickness: 1/8"

Steel rod cut thickness: 1/2"

Aluminum cut thickness: 1/4"

Copper cut thickness: 3/16”

We stock replacement blades for this

shear!

Able to cut the stems (1/2” steel round bar)

Needs modifications to make it automatic

Good price ($134)

http://www.ebay.com/itm/8-

Sheet-Metal-Shear-Steel-

Aluminum-Copper-Hand-Cutter-

/350502153852?pt=LH_DefaultD

omain_0&hash=item519b8e6e7c

#ht_1946wt_1185

8" Sheet Metal Shear Steel

Aluminum Copper Hand Cutter

Ebay.com 10/27/2011

http://www.ebay.com/itm/8-Sheet-Metal-Shear-Steel-Aluminum-Copper-Hand-Cutter-/350502153852?pt=LH_DefaultDomain_0&hash=item519b8e6e7c#ht_1946wt_1185






Appendix B1

APPENDIX B—SURVEY

AUTOMATIC SILK FLOWER STEM CUTTER

CUSTOMER SURVEY

Using a hand powered silk stem flower cutter, is known to cause fatigue in your hands

after extended use. As my senior design project I have chosen to create a solution to this

problem. If you could please fill out this survey, your opinions will be used to drive the

design process to ensure that the product is the best that it can be.

How important to you is each feature for the design of an automatic silk flower stem

cutter?

Please circle the appropriate answer. 1 = low importance 5 = high importance

Avg.

Safety 1 2 3 4 5 (24) N/A 5

Reliability 1 2 3 4 5 (24) N/A 5

Size 1 2 3 (4) 4 (8) 5 (12) N/A 4.3

Efficiency 1 2 3 4 5 (24) N/A 5

Speed of Operation 1 2 3 4 (8) 5 (16) N/A 4.6

Affordability 1 2 3 4 5 (24) N/A 5

No fatigue in the hand 1 2 3 4 5 (24) N/A 5

Noise level 1 2 3 4 (16) 5 (8) N/A 4.3

Maneuverability 1 2 3 4 (12) 5 (12) N/A 4.5

How satisfied are you with your current silk flower stem cutting device?

Please circle the appropriate answer. 1 = very UNsatisfied 5 = very satisfied Avg.

Safety 1 2 3 (6) 4 (6) 5 (12) N/A 4.2

Reliability 1 2 3 (4) 4 (16) 5 (4) N/A 4

Size 1 2 (4) 3 (4) 4 (4) 5 (8) N/A 3.8

Efficiency 1 2 (4) 3 (4) 4 (16) 5 N/A 3.5

Speed of Operation 1 (4) 2 3 (12) 4 (8) 5 N/A 3

Affordability 1 2 3 (8) 4 (8) 5 (8) N/A 4

No fatigue in the hand 1 (4) 2 (4) 3 (4) 4(4) 5 (8) N/A 3.3

Noise level 1 2 3 4 (8) 5 (16) N/A 4.6

Maneuverability 1 2 3 (4) 4 (4) 5 (16) N/A 4.5

Is having an automatic silk flower stem cutter something that you would be interested in

having?

YES NO

How much would you be willing to pay for a device like this?

$50 $100, $100-$200 (4) $200-$500 (20) Other $ _______

Thank you for your time.

Appendix C1

APPENDIX C—QFD

G

uard

s

Separa

te s

witchs f

or

opera

tors

safe

ty

Cla

mps t

o h

old

the s

tem

s

Moto

r/actu

ato

r spec s

heet

Cutt

er

spec s

heet

CO

SM

OS

used f

or

facto

r of

safe

ty

Footp

rint

Handle

s

Nois

e o

f m

oto

r/actu

ato

r

Lig

htw

eig

ht

Caste

rs

Cuts

one b

ush a

t a t

ime

Custo

mer

import

ance

Desig

ner's M

ultip

lier

Curr

ent

Satisfa

ction

Pla

nned S

atisfa

ction

Impro

vem

ent

ratio

Modifie

d I

mport

ance

Rela

tive w

eig

ht

Rela

tive w

eig

ht

%

Safety 9 9 9 3 9 9 3 3 5.0 1.0 4.3 4.8 1.1 5.6 0.11 11%

Reliability 9 9 9 5.0 1.0 4.0 4.5 1.1 5.6 0.11 11%

Size 3 3 3 9 4.3 1.1 3.8 4.7 1.2 5.9 0.11 11%

Efficiency 1 9 9 9 5.0 1.0 3.5 5.0 1.4 7.1 0.13 13%

Speed of Operation 1 1 9 9 3 4.6 1.0 3.0 4.5 1.5 6.9 0.13 13%

Affordability 3 1 3 9 9 3 3 3 1 5.0 1.0 4.0 4.0 1.0 5.0 0.09 9%

No Fatigue in the Hand 3 1 3 1 9 5.0 1.0 3.3 4.8 1.5 7.3 0.14 14%

Noise Level 3 3 9 4.3 1.1 4.7 4.7 1.0 4.7 0.09 9%

Maneuverability 3 9 9 9 9 4.5 1.1 4.5 4.5 1.0 5.0 0.09 9%

Abs. importance 1.23 1.31 1.36 5.10 6.14 2.79 2.11 0.98 0.80 1.85 1.39 2.84 27.9 53.1 1.0

Rel. importance 0.04 0.05 0.05 0.18 0.22 0.10 0.08 0.04 0.03 0.07 0.05 0.10

Alan VerhoffAutomatic Silk Flower Stem Cutter

9 = Strong3 = Moderate1 = Weak

Appendix D1

APPENDIX D—SCHEDULE

TASKS No

v 2

0-2

6

No

v 2

7-

Dec

3

Dec

4 -

10

Dec

11

- 1

7

Dec

18

- 2

4D

ec 2

5 -

31

Jan

1 -

7

Jan

8 -

14

Jan

15

- 2

1

Jan

22

- 2

8

Jan

29

- F

eb 4

Feb

5 -

11

Feb

12

- 1

8

Feb

19

- 2

5

Feb

26

- M

ar 3

Mar

4 -

10

Mar

11

- 1

7

Mar

18

- 2

4

Mar

25

- 3

1A

pr

1 -

7

Ap

r 8

- 1

4

Ap

r 1

5 -

21

Ap

r 2

2 -

28

Ap

r 2

9 -

May

5

May

6 -

12

May

13

- 1

9

May

20

- 2

6

May

27

- J

un

2

Jun

3 -

9

Proof of Design to advisor 21

Concept sketches to advisor 23

3d modeling-frame 10

7

3d modeling-motor/actuator 17

7

3d modeling-electrical/assembly 24

7

Calculations based on simulations 7

14

Shop drawings, BOM, Purchase 14

14

Component selection 28

28

Design freeze 4

4

Fabrication-cut stock to length 18

7

Winter oral 17

17

Report 17

Research electrical circuitry 24

12

Fabrication-weld frame 31

14

Fabrication-Guards-casters 7

21

Finish Fab.-electrical-misc. 21

12

Demo to Adviser 14

14

Demo to Faculty 17

17

Spring Oral 21

21

Report 5

5

Alan VerhoffAutomatic Artificial Flower

Stem Cutter

Appendix E1

APPENDIX E—BUDGET

Actual

Component Description Cost Cost

Frame

Links/Braces Steel $50 $45

Casters $20 $18

Clamps Steel $20 $20

Guards Plexi Glass $30 $50

Drivers/Cutter

Drivers/Cutter Actuators $200 $335

Cutter Metal Cutter $175 $100

Electrical

DC Power Supply AC-DC $50 $60

Wiring/Switches $25 $20

Miscellaneous Bolts/Nuts/Paint $40 $20

Total $610 $668

Proposed Budget

Appendix F1

APPENDIX F—FORCE CALCULATIONS

SHEAR STRESS CALCULATION:

The stem of the flower is made of a steel core, .1” diameter, and a rubber/plastic

coating, .3” in diameter.

The steel core is assumed to be 1020 Cold-Drawn, with a Tensile Strength of

61,000psi. (Machine Elements in Mechanical Design, 4th Edition, Mott).

Assume also, that the maximum number of stems cut at one time to be two. This is

from knowing how rods behave when they are stacked on top of each other.

All distances were taken from the solid model.

BLADE FBD:

A

643 lbs

B

C

Appendix F2

ARM FBD:

Forces needed throughout the entire stroke of the cutter.

D

BC F req.

Degrees Force Needed (lbs)

59 54.95

60 54.39

61 53.85

62 53.34

63 52.86

64 52.40

65 51.97

66 51.56

67 51.17

68 50.80

69 50.45

70 50.12

71 49.81

72 49.52

73 49.25

74 49.00

75 48.76

76 48.54

77 48.34

78 48.15

79 47.98

80 47.83

81 47.69

82 47.56

Appendix G1

APPENDIX G—BILL OF MATERIALS

Description Specification Quantity

Frame Tube AISC 2"*2"*1/4" 30"

Frame Rails AISC L 2"*2"*5/16" 36"

Guard Frame AISC L 1"*1"*1/8" 72"

Flat Bar Steel AISC 1/2"*1/2" 145"

Clevis Mild Steel 2"*1" 8"

Plexi Glass Top 18"*9.5" 1

Plexi Glass Sides 15.5"*17.5" 2

Plexi Glass Backs 15.5"*9" 2

Metal Cutter 1/2" Steel Rod Cap. 1

Casters 2" Caters 4

Bolts 1/4-20 UNC * 0.75" 24

Nuts 1/4-20 Jam Nuts 24

Clevis Pins 1/4"-2" 2

Main Cylinder Electric Actuator 50lbs 1

Clamp Cylinders Electric Actuator 20lbs 2

Electrical Components Wires, Switches…. ???

Bill of Materials

Appendix H1

APPENDIX H—PART DRAWINGS

Appendix H2

Appendix H3

Appendix H4

Appendix H5

Appendix H6

Appendix H7

Appendix H8

Appendix H9

Appendix H10

Appendix H11

Appendix H12

automatic artificial flower stem cutter - uc drc home

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