HYDRAULIC BENDING MACHINE

ACKNOWLEDGEMENT

It gives us immense pleasure to represent the report on HYDRAULIC BENDING MACHINE. We like to express our heart full thanks, gratitude and appreciation to our guide Prof. A.A. PATIL sir for this timel , careful and valua!le guidance "ith constant inspiration. We take this opportunit to offer our sincere thanks to #. $. %. of &echanical %epartment Prof. PATIL P.'. and principal of our college Prof. %($ ).). for providing us help in course of our pro*ect report. We "ould also like to thank him for sharing his kno"ledge on this su!*ect ,"ithout him the completion of this pro*ect seemed impossi!le. Last !ut not the least ,"e "ould like to thank the almight god "ho made us capa!le of "ithstanding all the difficulties that occurred during the completion of this pro*ect.

HYDRAULIC BENDING MACHINE

CONTENTS
CHAPTER NO:+. 1. 0. 9. :. 5. ;. =. >. +8. ++. TOPIC PAGE

NO:I,T-$%./TI$, 0 /$,)T-./TI$, 2 W$-3I,4 5 W$-3I,4 $6 #7%-A.LI/ 'A/3 +8 %()I4, +0 P-$/()) )#((T) 18 APPLI/ATI$, 15 A%<A,TA4() 2 %I)A%<A,TA4() 1= /$,/L.)I$, 08 6.-T#(- &$%I6I/ATI$, 01 /$)T ()TI&ATI$, 09 ?I?LI$4-AP#7 0;

HYDRAULIC BENDING MACHINE

INTRODUCTION

HYDRAULIC BENDING MACHINE &an device of mechanical are !ased on h draulic po"er. # draulic device uses principles of fluid static and fluid kinematics are used for either storing the h draulic energ and then transmitting "hen needed or maintaining the h draulic energ several times and transmitting the same. In all such machines, po"er is transmitted "ith the help of a fluid, "hich ma !e "ater or oil. $ur mechanism is used in industrial fitting and maintaining department, in automo!ile garage or in industrial "orkshop. $ur pro*ect is used for reducing manufacturing cost and saving time and also to reduce maintaining cost or a manufacturing cost. #ere "e manufacture a light "eight 2 eas to handle machine so that ou can carr an "here into the shop. It is also simple for assem!ling and disassem!ling.

HYDRAULIC JACKING SYSTEM:# draulic *acking s stem is ver eas "orking and gets result ver fast. In h draulic *acking 1 tons, 0 tons, : tons,+8 tons, +1 tons, is standard part and availa!le in market.

HYDRAULIC BENDING MACHINE We have used 0 tons *acking s stem. This s stem lifts 0 tons of load .In our pro*ect re@uiring !ending load of :88, "hich "ill !e more than sufficient for fine "ork. # draulic energ is mainl used for "orking a h draulic *acking s stem. ?ut in our mechanism this energ is used for !ending pipe. $ur machine is used in industrial fitting and as plum!ing instrument. $ur pro*ect is used for reducing manufacturing cost and also to save time thus reducing manufacturing and fitting time.

(Fig. 1) HYDRAULIC BENDING M/C

HYDRAULIC BENDING MACHINE

HYDRAULIC BENDING MACHINE

CONSTRUCTION

WORKING.

In our machine there are mainl four parts. This parts are stated !elo"AB

+. 1. 0. 9.

?ase Plate )upporter Plate .pper Plate Locking Plate

1. BASE PLATE :The Plate is used for mounting purpose. We drill 9 holeCs to cutter side and also 9 holeCs in center for mounting *acking s stem as "ell as "e "eld the *acking s stem to the !ase plate.

(Fig. !) BASE PLATE

HYDRAULIC BENDING MACHINE

!. SUPPORTER PLATE :-

)upporter plate is mounted on !ase plate "ith help of !oltCs. These plate is standing on ?ase plate. This plates forms a support for the plates. it also holds the pipe "hich is to !e !end.

(Fig. ") SUPPORTER PLATE

". UPPER PLATE :.pper Plate is mounted on supported plate. These plate is mounted on upper side. .pper plate !alances the pro*ect and get po"er for !ending.

HYDRAULIC BENDING MACHINE

#. MIDDLE PLATE :Locking plate is mounted !et"een supporter plates ! using !olt. Locking plate is used for holding the pipe or shaft these plate gets eas "orking.

HYDRAULIC BENDING MACHINE

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HYDRAULIC BENDING MACHINE

WORKING OF HYDRAULIC JACK

1$% &'(i)*+, -.,/i)g !)* &'(i)*+, -.,/i)g 1) 1ST CYLINDER WORKING:
The h draulic *ack is a device for lifting heav load ! the application of much smaller effort. It is !ased on pascalCs la", "hich states that intensit of pressure is transmitted e@uall in all directions through a mass of fluid at rest. It consists of c linder DfixedE in "hich the piston slides. The lo"er end of the piston carries a mova!le plate "hich moves up 2 do"n "ith the piston the upper 2 lo"er stationar plate are *oined ! column. When li@uid under high pressure is supplied to the c linder, the piston moves up"ard 2 applies tremendous pressure De@ual to the product intensit of pressure supplied 2 area of the ramE on an material placed on it.

!)

!ND CYLINDER WORKING :-

When the piston approaches the end of itCs stroke in the direction of force, itCs force of fluid into the drilled passage. 6lo" of fluid past the needle value is restricted so that the piston velocit is reduced. This prevents the piston from striking the c linder end. The slo"ing of the piston motion is called deceleration. 6luid entering the connecting part of the rod end passes directl ! the lip of the cushion seal 2 applies energ at the face of the piston

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HYDRAULIC BENDING MACHINE

for !ringing the ram !ack in position, the fluid from c linder is taken out su!se@uentl the ram in over up ! the action at return "eights. To raise the main ram rapidl , fluid is pumped The smaller inner ram, called *ack ram, has a greater area than the lip of the main ram. / linders 2 rams are often !uilt as an integer part of a machine slide or press element. (@ual pressure through out the circuit provides a sta!iliFing influence in the main ram assists the reiteration of this ram. In all such machines po"er is transmitted "ith the help of a fluid "hich man !e a li@uid "e can use !ut mostl oil is po"erful means that "hen choosing a h draulic fluid, the follo"ing factors must !e consideredA spread of operation, surrounding atmospheric conditions, economic conditions, availa!ilit of replacement fluid, re@uired pressure level, temp. -ange, contamination possi!ilities, cost of mission lines in "hich the fluid is used safel to operates and expected service life. # draulic fluids have specific characteristic that can affect the associated components. i.e. seals, coaching, parking and diaphragms must !e made !e of a material that "ill not deteriorate in association "ith the "orking fluid.

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HYDRAULIC BENDING MACHINE

(Fig.#) WORKING OF HYDRAULIC 0ACK

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HYDRAULIC BENDING MACHINE

DESIGN
1. DESIGN OF MIDDLE PLATE :#ere "e have selected 58 mm x 088 mm and no" "e have to find out the thickness of the plate re@uiring to sustain the force :88,. ThereforeG &aximum !ending moment at center of plate isAB H 6 x +:8mm D6Hforce acted on plateG +:8mmH i.e. distance at "hich force is applied at centre of plateE H :88, x +:8mm H ;:888 ,.mm

middle plate is made up of 08 /= &.). material "hose 7ield strength of tension D) tE H 988 ,ImmJ

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HYDRAULIC BENDING MACHINE ,o" ,"orking stress DK!E H &IL Where MMMM. De@ no.+E & H ?ending moment L H )ectional modulus

also ,DK!E H ) tI 6.). H 988I1 H 188 ,ImmJ Where AB 6.). N 6actor of )afet . L H D58tJEI5Hsectional modulus

Putting all these values in e@uation + "e getG

DK !E H &IL 188 H;:888ID58tJEI5 t H >.9= mm.

)o that the thickness should !e +8 mm.

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HYDRAULIC BENDING MACHINE

O PO O O

(Fig.1) MIDDLE PLATE

!. DESIGN OF BOTTOM PLATE.

&aximum !ending moment at center of plate H :88, x +1:mm D6Hforce acted on plateG +1:mmH force is applied at centre of plateE H 51:88 ,.mm Plate %imensions are 988 mm length x +:8 mm "idth i.e. distance at "hich

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HYDRAULIC BENDING MACHINE ?ottom Plate made up of 08 /= &.).material "hose 7ield strength of tension D) tE H 988 ,ImmJ ,o" ,"orking stress DK!E H &IL Where MMMM. De@ no.1E

& H ?ending moment L H )ectional modulus

We kno" also ,DK!E H ) tI 6.). H 988I1 H 188 ,ImmJ Where AB 6.). N 6actor of )afet . L H D58tJEI5Hsectional modulus

Putting all these values in e@uation 1 "e getG DK!E H &IL 188 H51:88ID+:8tJEI5 t H >.=9 mm. )o that the thickness should !e +8 mm.

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HYDRAULIC BENDING MACHINE

(Fig.2) BASE PLATE

".

DESIGN OF SUPPORTER PLATE :)upporter plate has direct tension on it K Where, H 6IA BBBBBBBDe@ no. 0E

6 H 6orce H :88 , A H /I) area of supporter plate

Therefore percentage ield strength of plate is Q ) t I6.). H 988I0

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HYDRAULIC BENDING MACHINE H +00.00 ,ImmJ and /I) area of supporter plate is A H tJ B+8 t Putting all these values in e@uation 0 K H 6IA +00.00 H :88 ItJ B +8 t tJ B +8 tR :88 I+00.00 tJ H +8t N 0.;: H 8 t H +8.1: t H +8 mm therefore "e have selected thickness of +8 mm

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HYDRAULIC BENDING MACHINE

(Fig.3) SUPPORTER PLATE

Top plate doesnCt carries an force. It is *ust for holding support.

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HYDRAULIC BENDING MACHINE

PROCESS SHEET

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HYDRAULIC BENDING MACHINE

Part ,ame AB ).PP$-T(- PLAT( Part St AB 1 Part Wt AB 5 3g Part )iFe AB :88 x +88 x +8mm )r. ,o +. $peration
/utting the material as our re@uired siFe At one side tap &= siFe t"o hole %rilling 0: mm at length 088 mm %rilling +8 mm at +8mm length at another end

&achine
4as /utting mIc

Tool
4as ,oFFle

Time
+:min

1.

%rilling mIc R tapping manuall Lathe mIc

%rilling ?it ;.: mm manual operated tap &= 0: mm %rilling ?it

+: min

0.

+: min

9.

%rilling mIc

%rilling ?it +8mm

: min.

Part name AB TOP PLATE Part St AB + Part Wt AB 0 3g.

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HYDRAULIC BENDING MACHINE

Part )iFe AB 088 x +88 x +8 mm

)r. ,o +.

$peration
/utting the material as our re@uired siFe Tapping & = siFe at ?oth end in length of +:mm

&achine
4as /utting mIc

Tool
4as ,oFFle

Time
+:min

1.

%rilling ;.: mm 2 manuall operated tap &= siFe

%rilling ?it ;.: mm 2 & = tap

+: min

Part name AB FI4ING PLATE Part St AB 1 Part Wt AB 9 3g.

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HYDRAULIC BENDING MACHINE

Part )iFe AB 58 x 088 x +8 mm

)r. ,o +. 1.

$peration
/utting the material as our re@uired siFe & = siFe tapping at length of +8mm as ?oth side.

&achine
4as /utting mIc %rilling ?it ;.: mm 2 manuall operated tap &= siFe

Tool
4as ,oFFle %rilling ?it ;.: mm 2 & = tap %rilling ?it ;.: mm 2 & = tap

Time
+:min 08 min 08 min 08 min

0.

At ?ottom side t"o &= tap at length =8 mm

%rilling ?it ;.: mm 2 manuall operated tap &= siFe

Part name :- MIDDLE PLATE Part siFe AB +18 x : x 18mm Part Wt AB 8.1: 3g. Part St AB 1

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HYDRAULIC BENDING MACHINE

)r. ,o +.

$peration
/utting the material as our re@uired siFe %rilling t"o hole at same length

&achine
Po"er #acksa" mIc

Tool
#acksa" ?lade

Time
+8 min

1.

%rilling mIc

%rilling tap +8 mm

: min

Part name AB BOTTOM PLATE Part Wt AB 0 3g. Part St AB Part siFe AB 988 x +:8 x +8mm

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HYDRAULIC BENDING MACHINE

)r. ,o
+. 1.

$peration
/utting the material as our re@uired siFe %rilling 6our hole at +8mm

&achine
4as cutting mIc %rilling mIc

Tool
4as noFel %rilling ?it +8 mm

Time
+8 min +8 min

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HYDRAULIC BENDING MACHINE

APPLICATION

(1) INDUSTRIAL APPLICATION :In Industrial application, !ending pipe or

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HYDRAULIC BENDING MACHINE shaft to for re@uired condition. thus saving time and get the process fast.

(!) HOME APPLIED USE :In home applied get plum!ing pipe !end. )o get save plum!ing cost and these leakage pro!lem is minimum.

(") AUTOMOBILE INDUSTRIES :In automo!ile industries remove the shaft !ending or !ending a shaft.

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HYDRAULIC BENDING MACHINE

AD5ANTAGES

DISAD5ANTAGE

AD5ANTAGES :-

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HYDRAULIC BENDING MACHINE +E (as handling 1E Lo" maintenance 9E :E 5E ;E (as /onstruction )mall space mounting ,o damage (as maintenance

DISAD5ANTAGE :-

+E 1E 3)

,ot used in an D?ig pipeE siFe pipe or shaft. ,ot used in on construction moment. )iFe "ill !e selected.

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HYDRAULIC BENDING MACHINE

CONCLUSION

.nder the !ending condition considered in the experimental "ork studied a!ove, the follo"ing conclusions can !e dra"n , +E ?ending process is chip less process "hich produces fine product. 1E The !ending process starts "ith increase in force to a certain limit then it starts to !reak "ith each increment in force.

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HYDRAULIC BENDING MACHINE 0E Also the cross section differs "ith increase in plunger height to a certain limit then it starts to !reaks "ith more increase in height of plunger. The maximum !end "hich can !e occurred is ;: to >8 degrees.

9E

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HYDRAULIC BENDING MACHINE

FURTHER MODIFICATION

In further modification "e can provide sliding s stem to locking plate. %ue to "e can o!tain height as per re@uirement. Also "e can provide "heel !elo" the !ase plate due to handling !ecome eas .

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HYDRAULIC BENDING MACHINE

# draulic !ending machine "e can also used for another application like !earing press fitting in sheet metal.

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HYDRAULIC BENDING MACHINE

COST ESTIMATION

COST OF MATERIAL &aterial Top Plate

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Wt
0 3g

-ate I3g
-s 98

Total
-s +18

HYDRAULIC BENDING MACHINE

?ottom Plate )upporter Plate Locking Wt 6ixing Plate Total Wt

0 3g 5 3g 8.1: 3g 9 3g +5.1: 3g

-s 98 -s 98 -s 98 -s 98 B

-s +18 -s 198 -s +8 -s +58 -s 5:8

COST FOR MACHINING &achine used 4as cutting mIc Lathe mIc %rilling machine Po"er #acksa" machine Tapping mIc Total .sing time
+ hr +: &in 1 hrs. +: min + hr

-ate Ihr
++8 +18 +18 +:8 188

Total
-s ++8.88 -s 08.88 -s 198.88 -s 98.88 -s 188.88 -s 518.88

COST FOR STANDARD PART

-ateAB ,A&( $6 )TA,%A-% PA-T) ,ut 2 ?olt D8.: 3gE # draulic !ottle *ack Welding Painting Transport Total T$TAL
-sAAB 98.88 -sAAB +:88.88 -sAAB 988.88 -sAAB 088.88 -sAAB 188.88 -sAAB 1998.88

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HYDRAULIC BENDING MACHINE

TOTAL PRO0ECT COST AB

/ost of material R /ost for machine R /ost for std. part H 5:8.88R 518.88 R1998.88 H 0;+8.88 T$TAL P-$'(/T /$)T H -) 0;+8.88

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HYDRAULIC BENDING MACHINE

BIBLIOGRAPY
+. &A/#I,( %()I4, D a E -.). 3hurmi gupta D ! E ?handri '.%. 1. W$-3)#$P T(/#,$L$47 D a E ).3. #a*ra choudhar D ! E -aghuvanshi -.<. 0. P.).4. %()I4, %AT( ?$$3. D a E 6acult of &echanical (ngineering,

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HYDRAULIC BENDING MACHINE 3olkata. 9. &AT(-IAL T(/#,$L$47 D a E &aha*an &.). :. &AT(-IAL #A,%?$$3 D a E Tata &c 4ra" hill pu!. 5. &A/#I,( T$$L %()I4, #A,%?$$3. D a E Tata &c 4ra" hill pu!.

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