Design and Analysis of a Hand Lever Shear Machine

Project Overview: In this mechanical engineering project, I designed a Hand Lever Shear Machine from scratch, incorporating both analytical and CAD design aspects. The project involved full mechanical design calculations, kinematic analysis using the four-bar mechanism, and 3D modeling using SolidWorks. This project is suitable for industrial cutting of sheet metal and was developed as part of a university coursework and engineering portfolio. 🔧 Work Scope and Key Deliverables: 1. Mechanism Design (Theory of Machines): Developed a four-bar crank-rocker mechanism to control the motion of the shear blade. Verified mechanism configuration using Grashof’s Law. Conducted kinematic analysis for smooth, continuous input rotation and efficient shearing action. 2. Machine Design Calculations: Calculated shear forces required to cut mild steel sheets (up to 2.5 mm thick). Designed critical parts (blade and handle) using bending moment analysis. Selected materials based on mechanical properties and real-world application (e.g., D2 Tool Steel, AISI 1045 Q&T Steel). Applied Factor of Safety (FoS) and Tresca Failure Theory for structural integrity. Performed Fatigue Analysis for both blade and handle using Goodman criteria to ensure long-term reliability. 3. CAD Modeling (SolidWorks): Created full 3D models of all components: blade, handle, frame, and pins. Assembled parts to simulate real motion and fit. Produced detailed engineering drawings including dimensions, tolerances, and exploded views. 📊 Tools & Skills Used: SolidWorks (3D modeling, assembly, drawing generation) Engineering Mechanics & Design (bending, shear, stress analysis) Theory of Machines (four-bar linkages, motion design) Fatigue Analysis (Goodman Diagram, endurance limit, size and surface factors)