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org © 2018 IJCRT | Volume 6, Issue 2 April 2018 | ISSN: 2320-2882

DESIGN AND ANALYSIS OF PIPE BENDING

MACHINE
1
Kulkarni Priyanka V., 2Mukhekar Vishnu A., 3Kute Abhishek V., 4Asst Prof Joshi Aniket V.
1,2,3,4
Department of Mechanical
1,2,3,4
G.H.Raisoni COEM, Chas, Ahmednagar, India
Abstract :- This paperis aimed at manufacturing and analysis of pipe bending machine. It also describes the construction of the
machine and mechanism involved. It covers various drawbacks of manually operated pipe bending machine. As bent pipes have
various applications in industry it is important that the pipes should be bend at accurate angle with minimum errors. This design of
machine ensures minimum errors also less time consumptions. The large advantage of machine is that it can be operated by low
skilled workers.

Index Terms- arc of pipe bend, bending, Design Fixture, Pressure, Torque.

I. INTRODUCTION
As we know bent pipes have numerous applications in industry. They are mainly used for transportation of fluids. In some cases it
is also used for supporting purpose (frame). Previously bending operation was done manually which requires lots of human efforts
and accuracy was very low. The other drawbacks of manual bending machine include injuries to workers, low productivity, more time
consumption etc.
The main purpose of this invention is to cover the drawbacks of manual bending machine. In some applications very high
accuracy in bending angle is needed. This is not possible with the help of manual machine.
The machine works with the help of stepper motor. The main components of machine are stepper motor, reduction gearbox, PLC
(programmable logic controller) and fixture. Stepper 3 PH induction motor provides input energy for operation. Reduction gearbox is
usefull for the reduction of motor speed upto required speed. PLC ensures the cycle time of operation and also governs human
machine interaction. Fixture plays important role in bending operation. It provides path for bending pipe and also acts as a support
structure for pipe.

II. Literature Review

Aniruddha Kulkarni Et.al [1]

This paper involves information about development of power operated sheet metal bending machine. It shows the drawbacks of
manual bending machines and how they are clarified in this machine. It states that the manual operation is replaced by automatic
operating equipment. It
Also involves the analysis of bending machine by considering various aspects. It gives brief information about how tis machine is
capable of fulfilling today’s industry needs.

A. D.Zope [2]
The main objective of this paper is to design, development and analysis of metal bending machine. The machine is able to bend
the sheets into curve shape. It states that the size of machine is so convenient that it can be easily transported from one place to
another. The material used for production of machine is MS. Hence it is easy to carry from one place to other. It reduces human
efforts and also increases accuracy. The main advantage of this machine is that it requires less skilled operators. It uses shaft,
hydraulic jack, bearing and frame. It uses simple mechanism instead of complicated one. It is light weight in nature and easy to
transport. It can bend up to 8 mm thickness sheet.

Akbar H Khan [3]

The main purpose of paper is development of manual operated pipe bending machine. This machine is useful to bend pipe of
various thickness in workshops also use in industry. Paper provides brief information about design and construction of pipe bending
machine. It ensures safety of workers. It is made of steel. It can bend pipe of different thickness into different angles. It can also bend
pipe into curvature shape. It is basically manually operated bending machine. Machine requires less skilled operator. The machine
uses dies, gears and frame for its operation. Pipe with 0-10 mm thickness can be bend with this machine. It reduces cost of machine as
well as increases its efficiency.

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III. Working

Pipe bending is a complex process. This process starts with loading of pipe into a bending machine. Then the pipe is clamped
between two dies, one of the die exerts pressure and force and other die is the fix die.

When pipe is fed into the machine one die supports it and with help of mechanical force and pressure the pipe gets its shape
through fixture. Buckling is one of the most dangerous problem during operation. Folding can may occur due to excess pressure.
Before this invention pipe is bent with forcing it into pre-determined shape.
IV. Component of machine

1. fixture
Bending is a commonly forging operation. Simplicity process is the bending a piece of metal, is to support it on the punch and to
support its free end with automatically. If bending sample is thins out then the
Fixture is commonly used for work holding purpose. It holds, supports and locates the job or work piece. It also provides a
reference surface for particular operation.
In case of our pipe bending machine it supports the pipe while operation and also provides path for bending work. Bending is
forging operation. Hence it is necessary to use correct fixture for the process. In this case the fixture is securely attached to base plate.

fig 1:- fixture

2. 3 PH Induction motor

The main components of induction motor are stator and rotor. A stator is provided with AC supply. After supplying AC supply to
stator it creates magnetic field around it. Hence it starts rotating. Due to induction effect the rotor also starts rotating. This is how
induction motor works. In this machine motor act as actuator i.e. provides required rotation for the operation.

fig 2:- 3 ph induction motor

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3. Reduction gearbox
A reduction gearbox is a mechanical device which is used to shift or reduce speed. Reduction drives are used in engines to
increase the amount of torque per revolution of a shaft. The no of revolutions of induction motor are not suitable for operation as they
are very high in numbers. This will lead to cause damage to pipes. Hence reduction gearbox is necessary to reduce rotational speed of
motor.

fig 3:- reduction gearbox

4. Pulley
Pulley is mostly useful for this machine. Mainly use for the pressure and force on the tube or pipe and the die also. Pulley sizes
will be changes as per requirement of drawing. One pulley is fixed for using die and other is moving use to punch as.

fig 3:- pulley

5. Assembly of Machine

This build machine more equipment are used. the forming rolling punch of tube or pipe bending is suggested for all types of
bend.where the centerline radius is at the 2 to 3 times outside diameter of the tube or pipe. I had design these machine with the more
quality and low cost

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fig 4:- pipe bending machine

IV. Material list

Material used for pipe bending machine is listed below in the table. The material list is finalised by using research paper referred
and by discussion with organisation.

Table 1:- Material list

Name of Material No Hardness Tempering Density

part temp

Base plate Mild Steel 01 - - -

Die OHNS 01 48/50 Hrc 760ºc - 870º 8670
c kg/m3
Punch OHNS 01 48/50 Hrc 760ºc - 870º 8670
c kg/m3

V.Design calculations;-

[1] Force
Material – Mild Steel
Allowable bending stress (σb) =300 N/mm2
Flexural formula

𝑀 σ
=
𝐼 𝑌
Bending moment is given by,

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M=F×L

(𝜎 × I)
𝐹=
𝐿×𝑌
Where, I= Moment of inertia
Y= Distance between C.G. and base line
L= Length of pipe
𝜋
𝐼= (𝐷4 − 𝑑 4 )
64

D= Outer diameter =25.4 mm, t=thickness=1.4mm

d= inner diameter= 25.4-2.8= 22.6 mm

𝜋
𝐼= (𝐷4 − 𝑑 4 ) = 7626 mm4
64
𝐷
Y= = 12.7 mm
2

Assume length of pipe 500mm

Therefore force will be,
300×7626
F= = 360.28 N
12.7×500

[2] Torque:-
Power = 1.5 kw = 1500 w, N= 1440 rpm

𝑃 × 60 1500 ×60
T= = = 9.95 N m
2𝜋𝑁 2 𝜋 ×1440

𝜋
T= (D3- d3) τ
16

rTherefore τ = 10.46 N/mm2

[3] Pressure:-

𝐹 360.28
P= = 𝜋 = 3.41 N/mm
𝐴 (𝐷2 −𝑑 2 )
4

[4] Arc of the bending

R= 3.5d or 0.4d ( where- d- is outer Dia. Of pipe )

=88.9 mm or 101.6mm

VI. Result and analysis

1] The designed machine is tested and analyzed using Ansys software. The results after analysis are given below:-

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www.ijcrt.org © 2018 IJCRT | Volume 6, Issue 2 April 2018 | ISSN: 2320-2882

fig 1:- safety factor

fig 02:- equivalent elastic strain

fig 03:- total deformation

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2] Analysis report

Sr. Name Value Unit

No.
1 Compressive ultimate strength 0 Pa
2 Compressive yield strength 2.5e+008 Pa
3 Tensile yield strength 2.5e+008 Pa
4 Tensile ultimate strength 4.6e+008 Pa
4 Possion’s ratio 0.3 -
5 Bulk modulus 1.6667e+01 Pa
1
6 Young’s modulus 2.e+011 Pa
7 Shear modulus 7.6923e+01 Pa
0
8 Ductile coeffiecient 0.213
9 Strength coeffiecient 9.2e+008 Pa

VII. Conclusion

Tube or pipe bending process are used in automobile, power plant and industries etc. Our bending machine is automatic an based
on PLC. It can preferable for small workshop, industry holder because of the light weight and less expensive.

VIII. Acknowledgement

I would like to express my special thanks appreciation to my teacher Assi. Prof. Joshi A.V. as well as our principle Dr. Ghule C.V.
who gave me the golden opportunity to do this wonderfull project on this topic Pipe Bending Machine.

IX. Reference

[1] “Sheet metal bending machine”, international journal of innovations in engineering research and technology [ijiert] issn: 2394-
3696 volume 2, issue 3, march.-2015

[2] “Tube Bending by using Microcontroller with Stepper Motor”, International Conference on Current Research in Engineering
Science and Technology (ICCREST-2016)
[3] “Design Data Book”, Mr. P.s.Gill, 3rd Edition
[4] Mr. V.B.Bhandari, “Design of machine element”, MrMc-Graw Hill Publication, 4rd Edition.

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