International Journal for Research in Engineering...

International Journal for Research in Engineering Application & Management (IJREAM)

ISSN : 2454-9150 Vol-04, Issue-04, July 2018

213 | IJREAMV04I0440073 DOI : 10.18231/2454-9150.2018.0483 © 2018, IJREAM All Rights Reserved.

Design & Fabrication of Light Duty Bending cum

Rolling Machine Mr. Akashdeep Goswami, Assistant Professor, GIMT, Guwahati, India, adg_me@gimt-

guwahati.ac.in

Mrinaljyoti Das, Student, GIMT, Guwahati, India, [email protected]

Partha Pratim Borah, Student, GIMT, Guwahati, India, [email protected]

Rajdeep Bordoloi, Student, GIMT, Guwahati, India, [email protected]

Udayangshu Misra Bhagabati, Student, GIMT, Guwahati, India,

[email protected]

Abstract: A multi-purpose machine, which combines the facilities of both bending and rolling, is expensive, extremely

bulky and are not potable. This work is intended to design & fabricate a light duty bending cum rolling machine which

will be used to bend metal plates, rods, square bars into curvature shapes. It will be a portable, light weight machine

and can be used in small workshop, fabrication shop, small scale industry etc. It is based on simple kinematic system

which works on roller to bend metal. The operation does not require any skilled labour. Screw Jack of 5 Ton capacity is

used over the much costlier Hydraulic Jack and thus the product cost comes down. The theoretical results obtained

from calculation are also compared with the analytical results obtained from ANSYS® Workbench 16.0. The

percentage error is found to be low proving the results obtained are accurate and the design is validated.

Keywords —Bending machine, Light weight machine, Metal bending, Portability, Rolling machine, Screw jack.

I. INTRODUCTION

Due to increasing globalization, it is very much essential for

the manufacturer to produce goods having highest

reliability. Metal Bending and Rolling is generally used in

fabrication as an alternative method for casting or forging

operations. Since it is related to human being, it is

necessary to design the joint with prior attention to safety of

its user. Generally, bending is a process that produces U-

shape, V-shape, or channel shapes in ductile materials; most

commonly in sheet metal as per requirement on different

types of bending machines. A beam is an element whose

thickness and width is smaller than the length. A shell is a

geometric structure in which width and length are of same

magnitude and the thickness of this geometric structure is

smaller. There are two different machines available in

market for bending of sheet and bending of pipe. Roller

bending process can be used to deform a sheet or plate.

Cylindrical shells are the basic components used for the

various engineering applications like boiler chambers,

cylindrical tanks, heat exchanger shells, pressure vessels,

etc. The process can be performed using many materials

such as carbon and alloy steels, aluminum alloys and

titanium alloys. Rolling machines with three rollers are

used to produce cylinders with various curvatures. The

rolling process is generally performed by a three roll

bending machine often called as pyramid type. The process

mainly consist 3 steps:

1. Positioning of the sheet or pipe.

2. Lowering of central roller.

3. Repeating feed of sheet or pipe.

In first step, a flat blank sheet is fed into the machine by

two rotating side rollers until the sheet is properly

positioned. In the second step, central roller is displaced

downward causes bending of the sheet. In the final step,

two side rollers rotate again, so that the sheet is bending

continuously. The rolling process always starts with the

crucial operation of pre-bending both ends of the sheet. The

success of 3 roller bending process is depends on the

experience and skill of the operator.

II. LITERATURE SURVEY

The manufacturing of pipes which use power operated sheet

bending machine and manually operated sheet bending

machine. It also includes limitations of manually operated

bending machine. From the results of the paper the

productivity of power operated bending machine is higher

[1].Author told in recent year’s pipe bending machine is

used in both industry and domestic purpose for bending the

pipe under the required angles and dimensions. In the




hydraulic pipe bending machine having a good advantage

compared to heat treatment methods [2].In this work, a

bicycle integrated pipe bending mechanism has been

designed and developed. The applications of bent pipes are

in frames, barricades, handle of bicycle. Most of industries

uses bent pipes as air conditioning, boiler, power

generation, ship building, furniture, railroad, automotive,

off-road and farm equipment, aircraft etc. Due to adequate

human power in countries like India, the human powered

machine will result in improvement of the economy and

employment of nation. In Asian countries people are facing

electricity cut-off during most of the days so such system

plays an important role in rural areas. [3]. Hydraulic

equipment has wide use in various automobile fields. These

hydraulic instruments are used for lowering and raising

chair in Barber shops and in dental clinics. Hydraulic

bending machine is the suitable equipment to bend pipes,

rods and bars. The pipe or rod to be bending is kept

between the rollers. With use of hydraulic jack we

implement force on the pipe and bend it to the required

angle depending on the dies used. Hydraulic bending

machine is less expensive, flexible and portable compared

to those which are discussed earlier. Hence it is better to

replace current standard machines by hydraulic pipe

bending machine [4]. Attempt is made to develop a pipe

bending machine which is useful to bend a pipe in

workshop. This project is to design and construct a portable

pipe bending machine. The size of machine is very

convenient for portable work. It is fully made by steel.

Moreover it is easy to be carry and use at any time and any

place. In this paper they designed manually operated pipe

bending machine with use of gears, motors, pulley, and

frame. This bending machine is both manually and power

operated [5]. Hydraulic press machine is implemented for

the pipe bending and sheet bending operation. The power

and productivity is more but the cost of production becomes

higher and hence the machine becomes costly [8].

III. OBJECTIVE OF THE WORK

The aim of our work is to design and fabricate a Light Duty

Bending cum Rolling Machine. The effort is to combine the

better of the two machines into a single multi-purpose

machine that is easy to operate and performs the

aforementioned operations efficiently.

Briefly, the following are the objectives of the work:-

To make a machine capable of bending as well as

rolling metal sheets, pipes and rods of various

dimensions.

To make it on a simple working principle.

To reduce the time of operation.

To make it in the least possible cost.

To make the machine easy to operate.

To make it portable.

Keeping these in view, the entire work was carried forward

and an effort was made to adhere to the objectives as firmly

as possible.

IV. CALCULATIONS

From general bending equation:

(Where,

)

…………….…………....…… (Eq. 1)

…..………………..……..…… (Eq. 2)

………………..…..……..…… (Eq. 3)

Following are the values of for our test specimens

TMT Bar = 690 MPa

Mild Steel = 841 MPa

Considering Distance = 99mm …………..………..…… (a)

For circular rod specimen of diameter, d = 8 mm…….... (b)

Substituting value of (a) & (b) in Eq.1 we get

For circular rod specimen of diameter,

d = 10 mm …………………………………………...(c)

Substituting value of (a) & (c) in Eq.1 we get




For rectangular plate,

breadth, b = 20 mm and height, h = 3mm ..............(d)

Substituting value of (a) & (d) in Eq.2 we get

For rectangular plate,

breadth, b = 20 mm and height, h = 5 mm …….. (e)

Substituting value of (a) & (e) in Eq.2 we get

For square bar of edge,

length, a = 10 mm………………………….….... (f)

Substituting value of (a) & (f) in Eq.3 we get

The Screw jack and the frame should be robust and fail

proof. To account for this safety aspect, a higher Factor of

Safety is used. For design safety we will consider Force,

F = 3000 N.

Calculation of Beam Deflection and Various Stresses:

Let us consider a rectangular plate of following parameters

b = 20 mm

l = 198 mm

h = 3 mm

y = ⁄ = 1.5 mm

F = 3000 N

E = 210000 MPa

Therefore, for a rectangular plate

Figure 1: Shear Force Diagram (SFD)

Figure 2: Bending Moment Diagram (BMD)

Figure 3: Beam Deflection Diagram

Design of Top Pedestal Bearing:

Following are the assumptions:

The expected life of bearing is 50 million revolution.

The Axial Load is 70% of the Radial Load

Selection of Bearing:

Let the bearing be single row deep groove bearing

Let Radial load, = 3000N

Axial load, = 2100 N

= 50 million

Average Life = = 5 x

Calculation of Equivalent Dynamic Load:

From Table below,

0, 0

0, 1.5

99, 1.5

99, -1.5 198, -1.5

198, 0

-2

-1.5

-1

-0.5

0

0.5

1

1.5

2

0 50 100 150 200 250

Forc

e, F

in k

N

Distance, d in mm

0, 0

99, 148.5

198, 0

0

20

40

60

80

100

120

140

160

0 50 100 150 200 250

Ben

din

g M

om

ent,

M in

N-m

Distance, d in mm

0, 0

99, -51.33

198, 0

-60

-50

-40

-30

-20

-10

0

0 50 100 150 200 250

Bea

m D

efle

ctio

n, 𝛿

in m

m

Distance, d in mm




Table 1: Value of Factors V, X and Y [7]

We use the formula of column 4,

Now assuming rotating shaft, V=1 (Table 1)

Calculating X, (from Table 1)

Here,

0.7

From column 14, e = 0.28

So we select X= 0.56 (From Table 1)

Corresponding Y = 1.55 (Column 11)

Now,

= XV +

= (0.56 1 3000) + (1.55 )

Again,

(

)

From Table below, we standardize the value

Table 2: Deep groove ball bearings (Series 62) [7]

and

Hence the design is Safe.

Bearing Specification:

ISI No. 30BC03

Bearing of basic design (SKF) = 6306

Bore Diameter, d = 30 mm

Outer Diameter, D = 72 mm

Width, B = 19 mm

Radius, r = 2.0 mm

Maximum Permissible Speed = 10000 RPM

Design of Bottom Pedestal Bearing:

Following are the assumptions:

The expected life of bearing is 50 million revolution.

The Axial Load is 70% of the Radial Load

The load acting is half of the Top Pedestal Bearing

Load

Selection of Bearing:

Let the bearing be single row deep groove bearing

Let Radial load, = 1500 N

Axial load, = 1050 N

= 50 million

Average Life = = 5 x

Calculation of Equivalent Dynamic Load:

From Table 1: Value of Factors V, X and Y

We use the formula of column 4,




Now assuming rotating shaft, V=1 (Table 1)

Calculating X, (from Table 1)

Here,

0.7

From column 14, e = 0.28

So we select X= 0.56 (From Table 1)

Corresponding Y = 1.55 (Column 11)

Now,

= XV +

= (0.56 1 1500) + (1.55 )

Again,

(

)

From Table 2: Deep groove ball bearings (Series 62) [7],

we select 20 mm bore diameter bearing due to non-

availability of pedestal bearing of 17 mm bore diameter in

the market.

and

Hence the design is safe.

Bearing Specification:

ISI No. 20BC03

Bearing of basic design (SKF) = 6304

Bore Diameter, d = 20 mm

Outer Diameter, D = 52 mm

Width, B = 15 mm

Radius, r = 2.0 mm

Maximum Permissible Speed = 13000 RPM

V. RESULT & ANALYSIS

Design of the Bending Machine:

The final design of the machine is done in SolidWorks

Premium 2014 x64 Edition. Following are some of the

views of the machine:

Figure 4: Isometric View

Figure 5: Front View

Figure 6: Right Side View

Figure 7: Back View

Analysis of Test Specimen:

Following are the details of the analysis:

Product version: ANSYS® Workbench 16.0

Specimen geometry: 198mm × 20mm × 3mm

Material: Structural Steel

Coordinate system: Cartesian

Mesh element size: 6mm

Analysis type: Static Structural




Solver target: Mechanical APDL

Environment temperature: 22°C

Solutions obtained:

Y Axis - Directional Deformation

Equivalent (von-Misses) Stress

Following are the figures obtained from the analysis of the

test specimen:

Figure 8: Mesh with 6mm Element Size

Figure 9: Static Structural showing various supports and force

Figure 10: Y Axis - Directional Deformation

Figure 11: Equivalent (von-Misses) Stress

For comparing the results obtained from analytical and

theoretical calculation, we have considered a rectangular

cross section metal bar of dimension 20mm 3mm.

Following are the theoretical results obtained from

calculation:

Following are the analytical results obtained from

Workbench 16.0:

These results shows that the percentage error of is

0.179% and that of is 0.255%. Thus the results

obtained are accurate and the design is validated by these

results.

Following are the pictures of the real working model:

Figure 12: Isometric View

Figure 13: Front View




Figure 14: Back View

Following are some of the specimen tested on the model:

Figure 15: Various Test Specimens

Figure 16: Final Products Obtained

VI. CONCLUSION

One of the primary aims was also to fabricate the machine

in least possible cost. In our design we chose to use Screw

Jack over the much costlier hydraulic jack and the rolling

feed and bending pressure too are given manually, which

brings down the cost further.

The results obtained through theoretical calculation and the

one obtained from simulation are almost matching with

each other and this result in a valid design. This is a purely

mechanical device. Hence the considered specimen and its

dimensions are adequate and the fabricated machine can

perform efficiently with the aforementioned specifications.

APPENDIX

Following are the list of symbols used in calculation:

1. d = Diameter of circular cross-section (mm)

2. b = Breadth of rectangular cross-section (mm)

3. h = Height of rectangular cross-section (mm)

4. a = Edge length of square cross-section (mm)

5. l = Length of specimen (mm)

6. M = Bending Moment ( N-m)

7. I = Moment of Inertia

8. = Axial deflection (mm)

9. y = Distance from neutral axis to the extreme fibre

(mm)

10. = Stress ( MN / )

11. = Shear stress ( MN / )

12. z = Section Modulus (

13. = pie = 3.1417

14. F = Force (N)

15. = Radial load (N)

16. = Axial load (N)

17. = Life of Bearing in millions of revolution

18. = Static Load (N)

19. = Dynamic Load (N)

20. X = Radial factor

21. Y = Axial factor

22. V = Rotation factor

23. e = eccentric load

24. P = Equivalent load (N)

25. E = Young’s Modulus ( ⁄ )

ACKNOWLEDGMENT

The completion of any work depends upon cooperation, co-

ordination and combined efforts of several sources of

knowledge. We acknowledge the help provided by

Mechanical Engineering Department, IITG in terms of

software sections. We would like to express our special

gratitude and thanks to all the instructors of Central

Workshop, GIMT who have helped us in fabrication of the

model.

REFERENCES

[1] P. S. Thakare, P. G. Mehar, Dr. A. V. Vanalkar and Dr.

C. C. Handa, “Productivity Analysis of Manually

Operated And Power Operated Sheet Bending

Machine: A Comparative Study” in International

Journal of Engineering Research and Applications

(IJERA), ISSN: 2248-9622, Vol. 2, Issue 2, Mar-Apr

2012, PP.111-114.

[2] V. Senthil Raja, R.Maguteeswaran, C. Karthik,

S.Rajarajan and D. Shanmuga Vadivel, “A New Model

in Design and Manufacturing of Mobile Hydraulic Pipe

Bending Machine in Industry” in International Journal




of Engineering Research & Technology (IJERT), ISSN:

2278-0181, Vol. 3 Issue 1, January – 2014, PP 2706-

2713.

[3] H. A. Hussain, M. Sohail Pervez, Md. Naushad Alam

and Atul. P. Ganorkar, “Design and Development of

Bicycle Integrated Pipe Bending Machine” in IOSR

Journal of Mechanical and Civil Engineering (IOSR-

JMCE), e-ISSN: 2278-1684, p-ISSN: 2320-334X,

2014, PP 24-28.

[4] S. A. Mohan Krishna, “Experimental Design and

Fabrication of a Portable Hydraulic Pipe Bending

Machine” in International Journal of Development

Research, ISSN: 2230-9926, Vol. 4, Issue 12, pp.

2681-2684, December, 2014, PP 2681-2684.

[5] Prashant P. Khandare, Dhiral N. Patel, Mayur K. Aher,

Ravi S. Parbat and Prof. Swapnil S. Patil, “Study of

Portable 3 Roller Pipe Bending Machine” in

International Conference on Emerging Trends in

Engineering and Management Research, ISBN 978-

81- 932074-7-5, 23 March 2016, PP 624-630.

[6] Mahesh Gadekar and Mr. Amol, “Design &

Development of Three Roller Sheet Bending Machine”

in International Journal on Recent and Innovation

Trends in Computing and Communication, ISSN:

2321-8169, Volume: 3, Issue: 8, August 2015, PP 5132

– 5135.

[7] K. Mahadevan and K. Balaveera Reddy, “Design Data

Handbook for Mechanical Engineers in S.I. and Metric

Units”, CBS Publishers & Distributors Pvt. Ltd, ISBN:

978-81-239-2315-4, Fourth Edition: 2013.

[8] C. Vinod, P.C. Kumar and CH. S. Reddy, “Design and

Dynamic Analysis of Hydraulic Press Machine for

Sheet not Pipe bending Operations” in International

Journal of Engineering Technology Science and

Research, ISSN:2394-3386, Vol 4, Issue 12, December

2017

International Journal for Research in Engineering...

Documents

Transcript of International Journal for Research in Engineering...