IJSRD - International Journal for Scientific Research & Development| Vol.

5, Issue 07, 2017 | ISSN (online): 2321-0613

Three Roller Rolling Machine

Suhel Khan Pathan1 Ahasan Habib2
1
M.Tech Student 2Head of Department
1
Department of Production & Industrial Engineering 2Department of Mechanical Engineering
1,2
Pacific University (PAHER) Udaipur (Raj.)
Abstract— My project is to design and fabrication of three  Storage Tanks, Silos
roller rolling machine. This machine is converted the
straight sheetmetal convert into curvature just like III. LITERATURE REVIEW
cylindrical and conical shape. The size of three roller rolling
machine is more convenient. Rolling machine is fully A. Himanshu:
fabricated by steel. For designing a three roller bending Himanshu has done bendability analysis for bending of steel
machine, it is required to calculate the exact force for plates on heavy duty 3-roller bending-chine. In this
bending. Based on this force, the machine parameters and experiment they found out the equivalent thickness,
motor power are decided. Various factors that should be equivalent width and maximum width analytically &based
considered while calculating this force are material on power law material model.
properties, width, and thickness, number of passes, bending B. Ahmed Ktari:
radius, force developing mechanism and link.
Key words: Bending Machine, Working Principle and Have done Modeling and computation of the three-roller
Process, Stress, Force bending process of steel sheets. This experiment consists of
two-dimensional finite element model of this process was
I. INTRODUCTION built under the Abaqus /Explicit environment based on the
solution of several key techniques, such as contact boundary
Roller rolling process can be used to deform a sheet or plate condition treatment, material property definition, meshing
to hollow shapes of constant (i.e. cylindrical, elliptical) or technique, and so on.
varying cross sections like cone frustum. Cylindrical and
conical shells are the basic components used for the various C. Jong GyeShin:
engineering applications like cylindrical tanks, boiler Has done the experiment on Mechanics-Based
chambers, heat exchanger shells, pressure vessels, tunnels, Determination of the Center Roller Displacement in Three-
etc. Roll Bending for Smoothly Curved Rectangular Plates. The
objective of this paper is to develop a logical procedure to
II. GENERAL DESIGN PRINCIPAL determine the center roller displacement, in the three-roll
Following basic shearing operation on a sheet metal, bending process, which is required in the fabrication of
components can be rolled to give it a definite shape. curved rectangular plates with a desired curvature.
Bending of parts depends upon material properties at the D. M K Chudasama:
location of the bend. To achieve bending, the work material
Have done the experiment on Analytical Model for
must be subjected to two major forces; frictional force
Prediction of Force during 3-Roller Multi-pass Conical
which causes a no- slip action when metal and roller came in
Bending. In this paper, the total deflection of the top roller
contact and a bending force acting against the forward speed
required is divided in steps to get the multi pass bending.
and the torque applied to move the material.
M. B. Bassett and W. Johnson: The bending of
A. Features: plate using a three roll pyramid type plate bending machine,
 Low initial cost J. strain Analysis Process manual, maintenance manual,
machine capacity chart and technical specification of
 Low tooling cost
rolling-machine.
 Easy & Quick setting
 repetition & bending
 User friendly
 Easy maintenance
B. Objectives of the work:
The following are the objectives of the work:
 To make a bending machine to bend metal sheets up to
10-12 mm.
 To make on simple working principle.
 To reduce the time for operation.
 To make in minimum cost.
 Easily operating
C. Applications:
 Fabricating/Rolling
 Boilers, Pressure Vessels

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 Three Roller Rolling Machine
(IJSRD/Vol. 5/Issue 07/2017/270)

IV. METHODOLOGY
A. Machine specification:-

Fig. 3.19: Movement of sheet into the rolling

4) Increase tension as you complete each roll.
5) Continually check that:
 the rolls remain parallel
 the plate is (and remains) square in the rolls
 The curvature and circularity are constant.
Repeat sequence until desired curvature is reached.
Using a standard pyramid roll

1) Total Machine Length – 6000 mm. V. CALCULATION & RESULTS DISCUSSIONS

2) Roller Length – 3750 mm. Calculations of Gear Drive Power Transmission System for
3) Sheet Bending capacity – 2 mm to 10 mm. rolling machine
4) Machine Structure Height – 382mm. FOR DRIVE 1 :-
5) Machine Width Top & Bottom – 1030 & 1670 mm.
6) Pedestal Size – S 517. A. Pd1 = Pr x K1
7) Gear Motor rating – 5 HP, 50 Hz, 230 VAC. Power supply P=746 w
8) Gear Size -40/1 there are 5% power losses
HP(Horse Power)= 5HP
B. Parts of Bending / Rolling Machine:-
N(RPM of electric motor)= 960RPM
1) Available item: - Pd = Design power
Different size Gear(Fabricated gear), Speed Reduction Gear (Pd)Power input=746x5x0.95=3543.5w
Box, Electric Motor, Coupling, power pack, Hydraulic Where,
cylinder Pr = Rated power
2) Fabricated item: - [load factor K1 = 1.25for medium shocks ]
Mild Steel I Beam, Pedestal Bearing, Roller =3543.5x1.25
C. Rolling Sequence Process:- Pd1 = 4429.3 W
A rolling sequence involves rolling material backwards and B. Torque of moter
forwards to achieve a desired shape. P= 2x3.14xNT /60
D. Steps = (4429.3x60)/(2x3.14x960)
= 44.059KNM
Note: The pressure is increased in the top roll.
= 44059.9 NM
1) Pre-set the ends to the desired radius. This can be done
by pressing, shaping, crimping or using initial pinch C. Power transmitted from electric motor pully to
rolls. reduction gear box pully
D1/D2 = N2/N1
D1= Dia. of electric motor pully =150mm
D2 = Dia. of reduction gear box pulley=225mm
N1= RPM of electric motor pulley =960RPM
Fig. 3.17: pre-set of sheet N2= RPM of reduction gear box pulley =
2) Apply slight pressure so that the rollers grip the plate. (150/225)= (N2/960)
Align the plate square to the rolls at 90 degrees using a N2= 640RPM
plate square. Inlet rpm into reduction gear box(U400) or gear
ratio are 40:1
So inlet rpm is 640rpm and outlet rpm with (40:1)
gear ratio
40:1= 640:N3
N3= 16RPM
T3/T4 = N4/N3
Where T3= 20 (No. of teeth)
T4 =57 (No. of teeth)
Fig.3.18 Arrangement of sheet into the rolling N4 = ?
3) Apply slightly more pressure by adjusting the rolls. N3 = 16 RPM
Roll the plate through to the preset end.

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 Three Roller Rolling Machine
(IJSRD/Vol. 5/Issue 07/2017/270)

N4= 5.6 RPM =6 RPM L=6300mm

And so on N5= 16 RPM T5 = 20 (No. of teeth) 1) W2 = 4EI / RL
N6 = 6 RPM T6 = 57 (No. of teeth) E=196x103 MPa or Nmm2
N7 = 16 RPM T7 = 20 (No. of teeth) I= BH3/12
R = Radius of curvature =120mm
D. Force calculation:-
L = Length of sheet.n
Pitch circle dia.= 168mm or 478mm pitch circle 4X196X1000X1000X10x10x10
radius= 84mm or 239mm = .084m or .239m W2 =
Motor force= torque / pitch circle radius (Distance) 120X6300X12
so torque on teeth no. 57 then rev. 6 RPM =70123.5N W2 = 86419.75 N
Torque on teeth no. 20 then rev. 16 RPM
Fm1 = 44059.9 / .084 2) Bending shress.
Fm1 = 524522.6 N MY
Fm2 = 44059.9 / .239 b2 =
I
Fm2 = 184351N
86419.75X500X5X12
1) Compressive force b2 =
Fm1 = 524522.6 N Fm2 =184351N 1000X10x10x10
Pressure angle= 20’ Pressure angle= 20’ b2 = 2592.59 N/mm2
Fc1 = Fm1xsin20’ Fc2 = Fm2xsin20’ Thickness of sheet used practically varies from
Fc1 = 524522.6xsin20’ Fc2 = 184351xsin20’ 5mm or 10 mm. The experimental performed on sheet
= 179397.2N = 63051.7N having dimensions (1000 x 6300) mm. The power gained by
2) Tangential force upper roller through different gear drive system and this
Fm1 = 524522.6 N Fm2 =184351N load is applied on the sheet. A sheet passes through between
Pressure angle= 20’ Pressure angle= 20’ the upper and lower roller the sheet goes bend. This process
Ft1 = Fm1xcos20’ Ft2 = Fm2xcos20’ is continuing till the required result is obtained. The stress
Ft1 = 524522.6xcos20’ Ft2 = 184351xcos20’ induced on the sheet is calculated by the analytically as well
= 492890.0N = 173233.2N. as virtually using analysis software.

VI. DESIGN FOR 3 ROLLER SHEET BENDING MACHINE VII. CONCLUSION

Calculation of load & stress acting on the sheet As compare to the manually operated sheet bending
W = 4EI/ RL machine the power operated sheet bending machine is
Where, E = Modulus of elasticity of compression better. The productivity of power operated sheet bending
I = Moment of inertia of sheet. machine is higher. The part of machine is able to handle the
R = Radius of curvature heavy load on machine. The time required to complete
L = Length of sheet bending operation is less and the requirement of extra
FOR MILD STEEL worker’s reduced. Power operated sheet bending is less time
consuming process with high productivity.
A. t1=5mm After performing actual experiment force
b =1000 mm calculation and fem analysis on metal sheet at different
L =6300mm materials, we conclude that the force which required for
1) W1 = 4EI / RL bending the sheet is found by virtually it is tested in terms of
E= 196x103 MPa or N/mm2 factor of safety as well as material safety while bending
3
I = BH /12 operation. On the basis of the results and its analysis,
R = Radius of curvature =120mm following conclusion can be drawn. From the result’s
L = Length of sheet.n analysis for constant radius of curvature (R) ,constant
4x196x1000x1000x5x5x5 dimensions by changing the material, load(W) increases as
W1 = the value of modulus of elasticity(E) increases ie Load is
120x6300x12
directly proportional to the modulus of elasticity. From the
W1 = 10802.46N
result’s analysis and calculations we can conclude that for
2) Bending stress.
same material keeping dimensions constant change in radius
MY of curvature(R) changes the value of load(W) .As radius of
b1 =
I curvature(R) increases the load(W) value also increases.
M = Bending moment From the result’s analysis and calculations , for same radius
Y = Perpendicular distance of the neutral cassis of curvature (R) and material if thickness varies from 5 mm
10802.46X500X2.5X12 to 25 mm ,it directly affects the value of load(W) i.e. Load
b1 = increases as the thickness changes in increasing order.
1000X5X5X5 Required surface finish of cylinder or any circular product is
b1 = 1296.29 N/mm2 directly affected by skilled labour as they lowered the top
B. for t2 = 10mm roller with the help of power screw in some extent.
b =1000 mm

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 Three Roller Rolling Machine
(IJSRD/Vol. 5/Issue 07/2017/270)

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