A

PROJECT PROGRESS REPORT

"ROLLER METAL BENDER"

Submitted

In partial fulfilment for the award of the degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

SUBMITTED TO:
SUBMITTEDBY:
DR. NEERAJ SAINi
Mr. RITESH KUMAR ASHISH
MAHOLIYA(17EEJME005)
HARSH KASHYAP(17EEJME011)

Faculty(Department of mechanical engineering)

DEPARTMENT OF MECHANICAL ENGINEERING

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TECHANICAL UNIVERSITY.KOTA

2020-2021

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Contents

1. INTRODUCTION

1.1 Objectives of the work

1.2 Design Process

2. OVERVIEW OF MANUAL ROLLER BENDING MACHINE

3. ADVANTAGES

4. DISADVANTAGES

5. APPLICATIONS

6. DESIGN

6.1 Component

6.2 Calculation

7. THREE DIMENSIONAL VIEWS

8. RESULT

9. CONCLUSION

10. REFERENCES

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1. INTRODUCTION

The main problem people who are occupied with doing various metallic project and
generally construction, faces the bending of metallic strips, the reason that this problem is
arisen during these project is because the metallic pieces need a lot of pressure, strength as
well as accuracy to be bent. There are many machines to be used to achieve this but the
cost is high. This construction is more user friendly to everyone, relatively affordable,
extremely useful amd it will fill with feeling of joy and satisfaction the people who want
to spend their time productively.

1.1 OBJECTIVES OF THE WORK:

The main objectives of the work are

a. To design the fabricate a bending machine for metal strips.

1.2 DESIGN PROCESS

The The process of design is essentially an exercise in applied creativity. Various design process
have been defined to help organize to attack upon un-constructed problem definition is vague for
which many solution exist .some of this design process as shown below.

1.Recognition of need: It involves identification by someone that a problem exists for which some
corrective action should be taken. The problem may be identification some defect in the existing
machinery or a need of new product in the market.

2. Definition of problem: It involves through specification of the item to be designed. This

3. Synthesis: In this phase we developing preliminary(basic) ideas regarding the topology and
geometry of the problem, i.e., regarding the shape and size and connectivity of various parts in the
product. In this phase a prototype model is created.

4. Analysis: In this phase a prototype model is analyzed by giving different boundary conditions and
constraints, subjecting the model to different temperatures and loads to perform feasibility study. If
the product fails at this stage, once again the design is reverted back to the synthesis phase.

5. Evolution: The end products of the analysis phase is compared with destination phase. If they
require any changes, then the design is once again reverted back to the synthesis phase.
6. Prese6ntation: This includes documentation of the design by means of drawings, material
specifications, bill of materials, views, tolerances etc.

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2. OVERVIEW OF MANUAL ROLLER BENDER MACHINE

The The design and fabrication of portable manual roller bending machine based roller

mechanism to bend pipes/rods. The mechanism is widely used in industry to for bending purposes. The

machine is made with a supporting frame that supports the roller mechanism between it. The work to be
bent can then be rolled across it to achieve desired bending. The rollers are fitted with bearings so as to
achieve the desired smooth motion. One of the rollers is integrated with a hand driven spindle wheel to
drive it manually. This wheel is also connected to the other roller using a chain sprocket mechanism to
drive it along with spindle at the same rate.The frame is made with a mechanism to fit a movable roller in
the centerthrough a screw mechanism. This is used to adjust the bending angle. The mechanism is fitted
through a slot made in the frame center. This screw based mechanism along with the spindle powered
rollers allows the user to achieve desired bending.

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3. ADVANTAGES

Very Useful in Fabrication

Easy To Make Curved Parts

Supports a Variety of Soft Metals

Portable

Low initial cost

Low maintenance cost

Simple Design

4. DISADVANTAGES

As it is a prototype model, here bending is limited up to the thickness of 6mm. For higher thickness of
specimen this machine size should be increased.

Chances of accident due to improper concentration on work.

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5. APPLICATIONS

Fabricating/Rolling

Boilers, Pressure Vessels

Storage Tanks, Silos

Tubes and Pipelines

Pumps, Burners and Filters

Heating and Ventilation

Wind Towers, Power Generation.

6. DESIGN

6.1 COMPONENTS

Sl No. Name of the parts Material Quantity Quantity

1 Bending rollers Mild steel 1

2 Spindle wheel Mild steel 1

3 Bearings Steel 4

4 Elevating Screw Stainless steel 1

5 Supporting frame Mild steel 2

6 Supporting Table Cast iron 1

7 Other

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6. CALCULATION
Following basic shearing operation on a sheet metal, components can be rolled to give it a definite shape.
Bending of parts depends upon material properties at the location of the bend. To achieve bending, the
work material must be subjected to two major forces; frictional force which causes a noslip action when
metal and roller came in contact and a bending force acting against the forward speed and the torque
applied to move the material.

Where,

a = distance from exit zone to the no-slip point (assume a =

L/2);

F = force applied to rollers;

T = torque applied to rollers;

L = roll gap;

r = radius of rollers;

μ = frictional force 0.4 Nm-1;

ho, hf = thickness of the sheet before and after time t.

At least two rollers are involved in flat rolling depending on the thickness and properties of material while
three or multiple roller system is required in shape rolling. A work material under bending load is
subjected to some form of residual stress and deformation as it bends. Materials at the outer bend radius
undergo tensile plastic deformation while the material at the inner bend radius undergoes compressive
plastic deformation.

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1. Design of power screw

Specifications

µ: co-efficient of friction=0.15

W: weight of the roller=2.5Kg=24.525N

: Helix angle

: Friction angle

dc: major diameter=7.4mm

do: minor diameter=6.04mm

P: pitch=6.35mm

Torque required lifting the load:

Lead= pitch (single trapezoidal thread)

Lead= 6.35mm

Helix angle

Torque required raising the load (for 1 revolution of one

screw)

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 It is the load acting on one screw As the lowering load is positive, the screw is self locking i.e., as
screw is self locking.

2. Force analysis

Maximum torque required for a cylinder rolling

Specifications

s: material yield limit=218 N/mm2 (from data hand book)

B: maximum width of rolled shield= 40mm

: Thickness of rolled sheet in mm

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When considering the deformation of the material, there is reinforcement and the reinforcement co-
efficient K is introduced to modify the equation.

4. Force condition

When rolling steel plate, the force condition is shown in above Figure. According to the force balance, the
supporting F2 on the roll plate can be obtained via the following formula.

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According to the force balance, the pressure force F1which is generated by the upper roller, acting on the
rolling plate i.e.,

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5. CALCULATION of driving Torque:

The lower roller of the plate of plate rolling machine is the driving roller and the driving torque on the
lower roller is used to overcome the deformation torque Tn1 and friction torque Tn2

The friction torque includes the rolling friction torque between the upper and lower roller and steel plate,
and sliding friction torque between the roller neck, and shaft sleeve which can be calculated as follows.

In the above formula,

f=co-efficient of rolling friction = 0.008*103 mm =co-efficient sliding friction

d1,d2= upper roller and lower roller diameter (mm)

D1, D2= upper roller and lower roller neck diameter (mm)

Di=0.5di (i=1,2)

D1=0.5d1

D1=0.5*62=31 mm

D1=D2 (same size)

Tn2=0.008*103[206.91+2(115-63)]

+0.04*103[206.91+115.63*31]
Tn2=3508.07 N-mm

Total torque T = Tn1 + Tn2

T=1601.13+3508.07

T=5109.206 N-mm

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7. THREE DIMENSIONAL VIEW

8. RESULT :

Bending comparison of MS and Al sheet:

The thickness v/s time graph for length 1220mm of both Aluminium and Mild steel test
specimenAccording to the above graph the bending process of mild steel takes more time than alluminium
in manual roller bending machine.

9. CONCLUSION :
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The mechanism is widely used in industry to for bending purposes. The machine is made with a
supporting frame that supports the roller mechanism between it. The work to be bent can then be rolled
across it to achieve desired bending. The rollers are fitted with bearings so as to achieve the desired
smooth motion.

10. REFERENCES

T[1] V. B. Bhandari,“Design of Machine Elements” Mc Graw Hill, ISBN, 2012.

[2] Hiroyuki goto, Kenichiru, Hidenobusaitro, Yuuishikura and Yutaka tanaka, "Applications with a new
6- dof bending machine in tube forming processes".

[3] Jose Vitor Souze, International Journal of Machine Tools &Manufacture, 2002.

[4] Z. Hu, R.Kovacevic, M.Labudovic, “Experimental and numerical modelling of buckling instability of
laser sheet forming”, International Journal of Machine Tools & Manufacture, 2002.

[5] Nayyar, P.E., Mohinder L. "A1". In Mohinder L. Nayyar, P.E...Piping Handbook (7th Ed.). New York:
McGraw-Hill. ISBN, 2000.

[6] Effect of internal pressure and shape imperfections on plastic loads of pipe bends under in-plane
closing moment. Christo Michael, A.R.Veerappan, S. Shanmugan, Engineering Fracture Mechanics
105(2013)1 – 15.

[7] Cherniy.V.P. Effect of Curved Bar Properties on Bending

[8] Cherniy. V. P. The Bending of Curved Pipes With Variable Wall Thickness. Journal of Applied
Mechanics, Vol. 70, pp. 253 – 259, 2003.

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