Upload
others
View
3
Download
0
Embed Size (px)
Citation preview
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,
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
International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-04, Issue-04, July 2018
214 | IJREAMV04I0440073 DOI : 10.18231/2454-9150.2018.0483 © 2018, IJREAM All Rights Reserved.
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
International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-04, Issue-04, July 2018
215 | IJREAMV04I0440073 DOI : 10.18231/2454-9150.2018.0483 © 2018, IJREAM All Rights Reserved.
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
International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-04, Issue-04, July 2018
216 | IJREAMV04I0440073 DOI : 10.18231/2454-9150.2018.0483 © 2018, IJREAM All Rights Reserved.
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,
International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-04, Issue-04, July 2018
217 | IJREAMV04I0440073 DOI : 10.18231/2454-9150.2018.0483 © 2018, IJREAM All Rights Reserved.
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
International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-04, Issue-04, July 2018
218 | IJREAMV04I0440073 DOI : 10.18231/2454-9150.2018.0483 © 2018, IJREAM All Rights Reserved.
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
International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-04, Issue-04, July 2018
219 | IJREAMV04I0440073 DOI : 10.18231/2454-9150.2018.0483 © 2018, IJREAM All Rights Reserved.
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
International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-04, Issue-04, July 2018
220 | IJREAMV04I0440073 DOI : 10.18231/2454-9150.2018.0483 © 2018, IJREAM All Rights Reserved.
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