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Design of Motorized Roll Bending Machine: Concept

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 IJSRD - International Journal for Scientific Research & Development| Vol. 8, Issue 2, 2020 | ISSN (online): 2321-0613

Design of Motorized Roll Bending Machine: Concept

Mr. Shete Yogesh Shreekrushna
Abstract— Nowadays, need of variety of operations goes on
increasing due to increase in both demand and productivity. II. CONSTRUCTION
So to fulfill these kind of needs we have to develop more
productive machineries. The main purpose of the research
paper is to explain the design and developed hydraulic
powered roller bending machine. It is used for Construction,
Aerospace, and Automobiles & Industrial. It’s time
consumption process. It reduces human effort and also
required low less skill to operate this machine. We are
designing hydraulic powered roller bending machine with
use of roller, bearing, hydraulic jack, & support (frame). The
objective of the subject is to make new design of manually
and hydraulically operated roller bending machine and stress Fig. 1: Construction of bending machine
acting on Metal after bending of Metal. The Metal bending The model of this project consists of following components,
machine is use to bend Metal in different angle shape and Bending Rollers Induction Motor
curvature as requirement of work. The machine is useful to Bearing Hydraulic Bottle Jack
bend different thickness Metal as per the requirement of Base Frame Drive Mechanism
shop. The machine is fully portable type and less weight and Joints & Fasteners Supporting Frame
easy to assemble and disassemble. The can operate unskilled
operator. III. CONSTRUCTIONAL DETAILS
Keywords: Roll Bending Machine, Induction Motor,
A. Bending Roller
Hydraulic Bottle Jack
Bending is to be done on sheet metal or metal bars, thus we
I. INTRODUCTION are going to use solid steel bars as a roller. These rollers
must have to meet some specific requirements of physical
Due to increase in globalization it is very important to properties and mechanical properties like Strength,
produce goods with high precision and high accuracy or toughness, resilience etc. so the selection of the material for
reliability. Metal bending machine is mostly use in roller is one of the prime factors of design.
fabrication industry generally using bending machine
produce U-shape and V-shape. In the design of metal
bending machine we use only three rollers for the bending
of Metal in different angle due to the number of compost use
overall cost of machine low and machine portable type the
weight of the machine is less than is very full portable. Our
project is to design and construct a bending machine. This
machine used to bend Metal into curve or other curvature
shape. The size of the machine is very convenient for Fig. 2: Bending Rollers
portable work. In various fabrication works as well as in
architectural work Metal are use in different ways. To bend B. Induction Motor
these Metals into these artistic forms is not easy thing to be Here in this concept, we are going to use induction motor
done manually. Using a particular machine specially for improving productivity and to minimize human
developed for bending of Metal help. Choosing component interference which leads to the continuous operation with
material is very important, because it will affect the overall constant speed. If the speed for each rotation remains
cost of the machine and product quality. With this constant, it will help to distribute load uniformly and hence
consideration, we will design this machine with the reduce surface rupture or other phenomenon.
maximum quality and low cost, In Metal during bending
operation stress concentration is occur in bend area of Metal
the bend section may be damage during service in particular
case where significant validity and thickness version exist
which are introduce during menacing process and operation
time. Hence the acceptance of Metal depends on magnitude
and shape of Metal. In Metal bending process the thickness
of Metal is change. The acceptability of Metal bend is
depending on magnitude and shape imperfection. Then we
also study on failure analysis of Metal bend in these we
assume Metal bend is uniform thickness. Fig. 3: Induction motor

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 Design of Motorized Roll Bending Machine: Concept
(IJSRD/Vol. 8/Issue 2/2020/031)

C. Bearing: Hinge is used for mounting of guide frame, which is

mounted over the hydraulic jack and applicable for
producing reasonable bending forces.

IV. DESIGN DATA

A. Selection of V Belt:
We have,
1) Type of driving unit – Motor (1 hp)
Fig. 4: Bearing 2) Operational hours per day – less than 10 hrs
Bearing is necessary to support the rollers in this concept. 3) Power transmitted – 1hp / 0.75kW
Bearing is a mechanical element provides support and also 4) Input Speed – 1440 rpm
helps to reduce friction during rotations. There is variety of 5) Output Speed – 200 rpm
bearings available for every mechanism. The selection of B. Calculations:
bearing should be done on the basis of load applied and area
1) Correction Factor = 1 ( from PSG design data book )
of application.
2) Design power
D. Hydraulic Bottle Jack Design Power = Fa × Transmittedd Power
Hydraulic bottle jack is used to provide pressure over ∴ Design Power = 0.75kW
material undergoes bending during operations. This can be 3) According to chart in V. B. Bhandari, cross section for
done manually but there will be some limitations arise for above details is “A”
applying forces. We have selected this kind of hydraulic unit 4) For the same, Minimum pitch diameter is
because of its ease in handling and availability with least d = 75mm … … … … … (Standard)
price. 5) For large pulley,
Input Speed
D=d×
Output Speed
1440
D = 75 × = 540 mm
200
But, as per the preferred data, nearer diameter is D =
560 mm
6) Pitch Length of Belt, consider centre distance to be
300mm
Fig. 5: Hydraulic Bottle jack π(D + d) (D − d)2
L = 2C + +
2 4C
E. Drive Mechanism ∴ L = 1793.47 mm
Drive mechanism for this project is nothing but the unit As per the reference data, L = 1750 mm
which helps to transfer power or torque from motor to 7) Corrected centre distance, C = 265.65 mm
driving roller. 8) Correction Factor = Fc = 1
9) Arc of contact,
D−d
αs = 180 − sin−1 ( ) = 114.0978
2C
10) Correction factor, Fd = 0.81
11) Number of Belt,
P × Fa
N= = 0.91 ≈ 1
Pr × Fc × Fd
Fig. 6: Drive Mechanism
This is necessary for obtaining better rolling C. Determination of Bending Stress
option. We are going to use Belt & Pulleys for the same. In This is important to determine the bending stresses for the
this type we are using V Belt and grooved pulley of the selection of roller material and also to determine the
dimensions given in next chapter. capability of the machine. This is also useful to selection
F. Fasteners & Hinge other particulars such as Bearing, Motor, torque transmitted
to roller, Roller Diameter, Material of roller etc.
Fasteners are used for mounting of bearings on base frame Bending Stress can be calculated as follows,
and guide frame.

Fig. 8: Bending Stress

Fig. 7: Fasteners and Hinge

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 Design of Motorized Roll Bending Machine: Concept
(IJSRD/Vol. 8/Issue 2/2020/031)

When a member is being loaded similar as shown 6) Find the value of x and y i.e. Radial and thrustF afactor
in the figure, bending stress or flexural stress will occurs. from the catalogue. These value depends upon VF r and
Bending stress is more specific type of Normal stress. The Fa
stress at the horizontal plane of the neutral is Zero. If the Co
.
force acting like shown in figure, force from upper side is
generally forms Compressive stress, and the stress occurs at
7) Find the value of load factor or application factor ‘ka’
the bottom is normal tensile stress.
from the catalogue.
This stress will be calculated by using,
My 8) Calculate equivalent dynamic load by using relation.
σ=
Ix Pe  ( XVF a  YF a ) K a
Where, σ – Bending Stress in N/m2 9) Calculate the approximate life of bearing in hours from
M – Moment of Neutral Axis Nm the type of bearing; operation and type of machinery
y – Perpendicular distance to neutral axis in m that is depend upon application.
Ix – Moment of inertia around Neutral axis in m4 10) Calculate the required basic dynamic capacity for the
Maximum Bending Stress can be given by, bearing by using relation. C a
L ( )
10
Mc Pe
σbmax = .
I
With reference to above details, we have
determined required strengths of roller material for avoid 3) Life of Bearing
failure and these values as, The life of an individual bearing is defined as the total
Tensile Strength = 580 N/mm2 number of revolutions (or the number of hours at the given
Yield Strength = 400 N/mm2 constant speed) which the bearing can complete before the
Minimum Elongation = 21 % first evidence of fatigue failure develops on the balls or
Yield Stress = 295 N/mm2 races.
Hardness = 179 BHN The bearing life can be defined by rating life. It is
Izod Impact value = 55 N-m also known as l10 life of the bearing.
4) Life - Load Relationship
D. Selection of Bearing Extensive laboratory testing and subsequent statistical
A bearing is a machine element which supports another analysis have shown the relationship between the dynamic
moving machine element. It permits the relative motion load c, equivalent load p and the rated bearing life l 10 can be
a
between the contact surfaces of the members, while carrying expressed by the equation, C 
the load. Due to relative motion between the contact L10   
P
surfaces, some power is wasted in overcoming frictional
resistance and if there is direct contact between the rubbing
surface rapid where occur for reduce this same lubrication Where a = constant
must be provided such as vegetable oil, greases etc. = 310for ball bearing
1) Function of bearings = 3 for roller bearing.
1) The bearing supports the shaft as the axle and holds it in
correct position with respect to frame or casing. If the rating life of the baring is given in hour at
2) The bearing ensures free rotation of the shaft or axle some constant speed, then the rating life of the bearing in
with minimum friction. million revolutions is givenLby,  n  60
L1 0  h1 0
6
3) The bearing takes up the forces acting on the shaft or 10
the axle and transmits them to the frame or casing.
2) Selection of the Bearing from the Manufacturer’s Where, n = bearing speed in rpm
Catalogue Lh10 = rating life of bearing in hour at some constant speed
The following steps must be adopted in selecting the bearing L10 = rating life of bearing in million revolutions.
from manufacturer’s catalogue. From above considerations and calculation we have selected
1) Calculate the radial and axial load reaction (Fa and Fr) Bearing designated as, UPC205-16 with following details,
acting on the bearing. d = 25 mm D = 52 mm
2) Decide the diameter of the shaft on which bearing is B = 18 mm E = 32 mm
mounted. r = 1.5 mm Max. Speed = 8000 rpm
3) Select the proper size of the bearing suitable for given Static Capacity = 2200 Kgf Dynamic Capacity = 3000
application, specified with speed and available space. Kgf
4) Find the basic static rating (co) of the selected bearing
E. Selection of Motor:
from the catalogue.
Fa Fa A selection of motor has been done on the basis of
availability, modes of operation, rated power, speed
VF r Co
5) Calculate the ratio and . required, cost, and rated voltage.
Our selected motor have following details,
 Power = 1 HP / 0.75 kW
 Electric Supply = 230 V / Single Phase

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 Design of Motorized Roll Bending Machine: Concept
(IJSRD/Vol. 8/Issue 2/2020/031)

 Type = Induction Motor selection of V belt leads to the minimum sleep and hence
 Rated Speed = 1440 rpm there is less chance of accidents will occur. As of motorized
Direction = Both CW & CCW operations, it will also raise the area of applications and can
bend square tubes, round tubes of both large or small
V. MATERIAL SELECTION diameters, metal bars of small diameter, metal pipes and
also can be useful for sheet metals. This will lead to the
Sr. Required Probable
Name of Entity greater accuracy and higher productivity of specific plant or
No. Properties Material industry.
C 30 The constant speed of motor also affects the quality
Tensile Strength
0.25-0.35 % of operations. As the speed of rotation remains constant for
01 Bending Roller Hardness
C each time it will helps to spread load uniformly results in
Resilience
0.6-0.9% Mn better work outcome.
Corrosion
Resistance White Metal, REFERENCES
02 Bearing Thermal Bearing
Conductivity Steel [1] PSG, “Design Data Book”.
Hardness [2] V. B. Bhandari (2012) “Design of Machine Elements”
Tensile Strength Mild Steel, Mc Graw Hill, ISBN.
Machinability Plain Carbon [3] Hiroyuki Goto, Ken Ichiru, Hidenobu Saitro, Yuu
Base Frame / Ishikura And Yutaka Tanaka "Applications with a new
03 Resilience Steel,
Support Frame 6-dof bending machine in tube forming processes".
Hardness Alloy Steel
Availability etc [4] Jose Vitor Souze, International Journal of Machine
Corrosion Tools &Manufacture, 2002.
Resistance [5] Z. Hu, R. Kovacevic, M. Labudovic, “Experimental and
Stainless numerical modeling of buckling instability of laser
04 Joints Strength
Reliable
Steel sheet forming”, International Journal of Machine Tools
Availability & Manufacture, 2002.
Table 1: Material Selection [6] Nayyar, P. E. Mohinder L. (2000). "A1". In Mohinder
L. Nayyar, P. E. Piping Handbook (7th Ed) New York:
McGraw-Hill. ISBN.
VI. OPERATION & WORKING
[7] Effect of internal pressure and shape imperfections on
The working of this machine is very simple to perform. The plastic loads of pipe bends under in-plane closing
basic principle of operation is to apply pressure over the moment, T. Christo Michael, A. R. Veerappan, S.
pipe or metal by using hydraulic system. We are going to Shanmugan, Engineering Fracture Mechanics
use hydraulic bottle jack for this purpose. 105(2013)1 – 15.
[8] Cherniy V. P. 2001. Effect of Curved Bar Properties on
Bending of Curved Pipes. Journal of Applied
Mechanics, Vol. 68, pp. 650 – 655.
[9] Cherniy. V. P. 2003. The Bending of Curved Pipes with
Variable Wall Thickness Journal of Applied Mechanics,
Vol. 70, pp. 253 – 259.
[10] YANG Hea, LI Henga, ZHANG Zhiyonga, ZHAN
Meia, LIU Jinga, LI Guangjunb, Advances and Trends
Fig. 9: Working Principle on Tube Bending Forming Technologies, 2012.
A pipe or metal undergoing bending operation [11] Hiroyuki GOTO, Ken ICHIRYU, Hidenobu SAITO,
should insert from one end of the machine through the Yuuishikura, Yutaka Tanaka, "applications with a new
rollers provided in particular manner as shown in figure 6-dof bending machine in tube Forming processes".
above. When this metal got inserted, the rotating operation [12] H. A. Hussain, M. Sohail Pervez, Md. Naushad Alam,
gets started. After specific rotations the pressure should Atul. P. Ganorkar, "Design and Development of
started to apply in upward direction, which helps to move Bicycle Integrated Pipe Bending Machine" 2014.
end side body in upward direction. This movement of end
side body results in the formation of deflection of pipe or
metal inserted.

VII. CONCLUSION
Addition of motor as a driving element is one of the most
positive things in case of this machine. this motor especially
selected for the heavy loads and can work effectively with
minimum rotations per minutes. So it will definitely helps to
improve the productivity with minimal human efforts. Also

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