Fabrication of Manual Roller Bending

Machine
Here we study the design and fabrication of a mini manual roller bending
machine that uses chain sprocket 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 center through 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.
 CHAPTER I

INTRODUCTION

Roller bending process can be used to deform a sheet or plate to hollow shapes
of constant (i.e. cylindrical, elliptical) or varying cross sections like cone frustum.
Cylindrical and conical shells are the basic components used for the various
engineering applications like cylindrical tanks, boiler chambers, heat exchanger
shells, pressure vessels, tunnels, etc. The process can be performed using many
materials such as carbon and alloy steels, aluminum alloys and titanium alloys.
Rolling machines with both three and four rolls are indispensable to the production
of cylinders with various curvatures. The rolling process is usually performed by a
three roll bending machine often called as pyramid type, because of the peculiar
arrangement of the three rollers. The entire process of the roll bending may be
divided into three steps: namely,

1. Positioning of blank sheet or plate.

2. Lowering of the center roller.

3. Feeding of the plate.

In the very 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, center roller is
displaced downward causes bending of the sheet. In the final step, two side rollers
rotate again, so that the sheet is bent continuously. The rolling process always began
with the crucial operation of pre bending both ends of the sheet. This operation
eliminated flat spots when rolling a fall cylindrical shape and ensured better closure
of the seam. The success of three roller bending process heavily depends on the
experience and skill of the operator.
PROBLEM IDENTIFICATION:
Manufacturing is a field of transferring raw material into finished goods. There are
many manufacturing firms that can be found such as automobile factories, bakery
factories, electrical factories, etc. Many of the factories produce their products in
mass production. So, these factories or companies are competing each other to get
their products in the market. Therefore, they must have good manufacturing facilities
to improve their productivity. Except this machine is power operated machine so that
it requires motor, gear bore, and gearing arrangement. Here motor supplies the power
to the gear box. Now this gear box transmits the power to the gears and at last it
transmits to the roller. In the process the sheet is insert in between the lower rollers
and upper roller than with the help of screw given at both of machine is lowering by
revolving with rod. Now this screw roller at the end, and when screw rotates in
downward direction then roller is also lowered their position. Now much distance
the upper roller should came or the setting of roller is depends upon the thickness &
diameter of sheet which is to be bend in the machine. Once the setting of screw is
over, operator start the machine, the sheet passes towards the other side of the
machine. After the one pass, again the setting of screw is to be done if requires and
next pass is again start; it is restricted up to the cylindrical pipe is made. After getting
a cylinder pipe, some positions of pipe is welded called tacking. After the welding,
the welded position of pipe is passing through the roller. Then this pipe is removed
from the machine by removing the base after removing the screw the side body is
tilled to the side. Before tilting the body, one rod is inserted in between the upper
roller and lower roller, and then the body is tilled and removes the pipes from the
machine.
 The manual process causes fatigue to labors, lowers the efficiency of labors
and there by lowers the working efficiency of sheet bending operation. So the main
causes get a desired curve on a 3 roller sheet bending machine, it is generally used
by apply force by using a screw jack which is approximate & depends on
experimentation and labor skill, so that it is a trial and error method carried out by
skilled labor because of this applied force may vary person to person and may get
different sizes of the cylinder shells.

1.1 Roller for bending pipe

To give the required shape and size, roller is used. Primary function of the
roller is to achieve angular shape to the pipe. This is done through screw which apply
pressure on roller and also this roller achieved rolling action by using an AC motor.

1.2 Functions of Bending Machine

1. To bend a pipe having thickness upto 5 mm in required angular shape.

2. To provide curvature shape to pipe.

3. Machine is convenient for portable work.

4. The machine is power operated to achive maximum accuracy in less time

1.3 Roller requirement

1. Roller should be very accurate and easy to handle.

2. The effort required to bend pipe should be minimal.

3. The rolling attachment should also provide directional stability. This implies that
the pipe should have a tendency to move to & fro.
1.4 Pipe Bending Machine

A roll bending machine uses roller to bend a metal. The roller of bending
machine can be two rollers, three rollers, or four rollers. The common product of roll
bending machine are tube bending, plate bending and a coil. All modern roll bending
machine is power driven and some of the bending machine equip with electronic
control for more. During the roll bending process the pipe extrusion, or solid is
passed through a series of roller( typically 3) that apply pressure to the pipe gradually
changing the bend radius in the pipe. The pyramided style roll benders have one
moving roll, usually the top roll. Double pinch type roll benders have to adjustable
rolls, usually the bottom rolls, and a fixed top roll this method of bending causes
very little deformation in the cross section of the pipe. This process is suited to
producing pipe which is in require shape as well as long gentle bends like those use
in making structure of pipe.

The reason to design a bending machine for pipe bending is because there is
no proper bending machine to bend a metal pipe for small scale. The bending
machines found in the market come from variety of types. There are bending
machine such as press brake bending machine, roll bending machine and a folding
machine. Moreover, the design for the bending machine for pipe bending is to bend
a metal pipe. It produces sheet metal bending with desire degree of bending except
90°. Other reason regarding to the bending machine design, the bending machine in
the market come with big size and the bending machine is expensive. The existing
bending machine in the market is created for huge capacity for bending a metal pipe.
With the capacity of bending machine that exists in the market, the existing bending
machine is not fulfilling the requirement of the usage. The requirement of operation
of bending machine is simple. Thus it is not suitable to purchase existing bending
machine to be used for simple bending machine operation. Moreover, the machine
is heavy and use up a lot of space. In addition, the problem will arise when to move
and put the bending machine due to heavy and space.
 CHAPTER II
LITERATURE SURVEY
This literature is about the work of designing a roller bender to bend a pipe. A
bending is a process of giving curvature to a metal. The metal can be a sheet metal,
tubes, square hollow, rod, and iron angle. This type of metal has its own thickness.
The roller bender designer will take into consideration a number of factors including
type of metal, type of the roller bender, power driven or manual and the size of the
bending machine.

M. Hua et al [1] developed, in the paper, an analytical model to study the mechanics
of continuous plate edge bending mode of the four roll bending process, solving
governing differential equation for the large deflection of an elastic plastic thin plate
with an arbitrary strain hardening law for the material. The effect of material strain
hardening on the mechanics is also studied and compared with those for a perfectly
plastic material.

M. Hua et al [2] discussed design consideration, working principle and bending

mechanisms the four roller bending machine. Generalised procedure of four roller
bending machine is also explained.

Jong Gye Shin et. Al [3] in the paper, developed a logical procedure to determine the
center roller displacement, in the three roll bending process, which is required in the
fabrication of curved rectangular plates with a desired curvature. To this end, the
mechanics of the process was analyzed by both analytical and finite element
approaches. Comparisons of the results reveal that a simple analytical procedure,
based on the beam theory, yields a reasonably accurate relationship between the
center roller displacement and residual curvature. With further development and
refinement, the procedure proposed in this work has great promise for practical
application, particularly for the automation of the process.
Dr. C. C. Handa et. al [4] discussed about the productivity analysis of manually and
power operated sheet bending machine considering time required to complete one
pipe, total expenditure required to manufacture one pipe, number of operators and
labors required during both operations, etc. Limitations of the manually operated
sheet bending process over power operated sheet bending machine is also discussed.

P.G. Mehar [5] in his M. Tech Thesis studied the manually operated and power
operated sheet bending machine. Experimentations were conducted on sheet in order
to measure actual no. of passes, time required to complete bending process etc. Also,
productivity of sheet bending process is analyzed in depth. Design of various
components of power operated sheet bending machine considering various theories
of failure in elastic region and values for bending force, power required, spring back
radius etc. for different diameters, thicknesses and width of sheet metal has been
determined.

P. S. Thakare et al, Proposed a model that, The paper dealt with manufacturing of
pipes which use power operated sheet roller bender 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 roller bender is
higher paper deals.

V. Senthil Raja et al, (2014)Author told in recent year’s pipe roller bender was used
in both industry and domestic purpose for bending the pipe under the required angles
and dimensions. Sometimes Heat treatment is used for pipe bending but the heat
treatment technique is not safe and have problems are produced in the pipes, such as
wrinkling, curve forming, reduced thickness, whole forming, reduced strength, easy
breakable. In the hydraulic pipe roller bender having good advantage compared to
heat treatment method.

H. A. Hussainet al, (2014)Designed a machine which was a bicycle integrated pipe

bending mechanism was 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.

Mohan Krishna S. A. et al, (2014) Proposed model that, 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 roller 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 roller bender
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.

Mahesh Gadekar et al, (2015) Proposed a report that , Metal forming is a process in
which the desired shape and size are obtained through plastic deformation of a
material without any loss of material. Bending is a metal forming process in which
straight length is transformed into a curved length. Roller forming process is a
continuous bending operation in which a long strip of metal is passed through typical
roller adjustments, until the desired curvature shape is obtained. The bending
changes according to material and according to the loading condition and thickness
of sheet.

Prashant P. Khandare et al, (2016) The main aim of this paper was to develop a pipe
roller bender which was useful to bend a pipe in workshop. This project was to
design and construct a portable pipe bending machine. This machine was used to
bend steel pipes into curve and the other curvature shapes. The size of machine was
very convenient for portable work. It was fully made by steel. Moreover it was easy
to be carry and use at any time and any place. It decreased human effort and required
low skill labours for operating the machine. In this paper they designed manually
operated pipe roller bender with use of gears, motors, pulley, and frame.