Result

The results of the first test were inconclusive due to the misalignment in the punch, friction with the punch support, and the lack of a shear angle. The misalignment in the punch caused the punch rotate in its supports and not cause the proper shear. The friction caused a drastic increase in force required to actuate the punch, and prevented the punch from returning to its initial position. The lack of a shear angle increased the force by not having a cutting force but a punching force. 

       The second test resulted in finding the friction force between the punch and punch support. The force was found to be 28 lbs on average to move the punch. By polishing the outer surface of the punch and the inner surface of the support the friction could be reduced. 

       At this point the punch broke during testing and had to be rebuild. After the rebuild the punch only required 6 lbs on average to opperate.

       The third test was preformed in an arbor press, and the input force required the shear the plastic was between 4 and 8 lbs of force. The initial force was between 6 and 7 lbs to start shearing around the radii of the first curve. The force then drops to being between 4 to 5 lbs as it cuts the straight part of the profile. The force increases to being 8 to 9 lbs around the second curve.