DESIGN AND FABRICATION OF SHEET ROLLING

MACHINE
 ABSTRACT

This project work titled “SHEET ROLLING MACHINE” has been

conceived having studied the difficulties in making bending in sheet metal. This
project facilitates in making bending accurate in sheet metal with easy. The
project employee by using the roller for bending purpose by manual.

This machine can be used in various fields. Our project the sheet metal
rolling is very simple in operation by using roller which is coupled with handle.
In Sheet Metal working industry a wide range of power and hand operated
machines are used. This machine is simple in construction and working.
 LIST OF FIGURE
PAGE NO
1.1 Stress in bending 12
3.1: Process of rolling 14
4.1 Stress induced in sheet metal 15
5.1 Steps in rolling 16
6.1 Sheet rolling machine 17
8.1Shape rolling mechanism 19
8.2 Stress and Strain Curve for Steel20
8.3 Plastic Theory of Bending 21
8.4 Geometrical analysis 22
 LIST OF CONTENT
Page No

1. Introduction 11

2. Bending 12

2.1 Roll bending 13

3. Process of rolling 13

4. Stress induced in sheet metal 15

5. Steps in rolling 16

6. Description of the machine 17

7. Working principle 18

8. Design 19

8.1 General design principles19

8.2 Stress and strain in steel 20

8.3 Plastic theory of bending 21

8.4 Design calculation 22

9. Synopsis 28

10. Application 29

11. Advantages 30
 1. INTRODUCTION

Sheet Metal industry is a large and growing industry. There are many special
purposes machines used in this industry to-day. The proper selection of the
machines depends upon the type of the work under-taken by the particular
industry. There are many examples of Sheet Metal work, which can be seen in
our everyday lives. The metals generally used for Sheet Metal work include
black iron sheet, copper sheet, tin plate, aluminium plate, stainless sheet and
brass sheet.

Our project the “SHET METAL ROLLING MACHINE” finds huge

application in Sheet Metal industry. Rolling is the process of bending sheets to a
curved form. The article in the shape of cylinders is made by rolling roller.
Rolling operation can be done on hand or power operated rolling machines. In
forming cylindrical shapes a gradual curve is to be put in the metal rather than
sharp bends. The gap between the rollers can be regulated by hand operated
screws

Sheet metal is available in flat pieces or as a coiled strip. Various forming

process in sheet metal include

  Punching
  Roll forming
  Rolling
  Spinning
  Stamping
  Bending
  Deep drawing
  Expanding
  Curling
 Press brake forming
  Decambering
  Ironing
  Laser cutting
 Incremental sheet forming etc.

2. BENDING
Bending is one of the most common forming operations. We merely have to
look at the components in an automobile or at a paperclip to see how many parts
shaped by bending. Bending is usually defined as the deforming of the sheet
metal along the straight line around a straight axis called neutral axis, result in
the plane surface at an angle to the original plane. During bending the top layers
are subject to tension and the bottom layer are subjected to compression. The
width of the part in the outer region is smaller and in the inner region it is larger
than the original width because of the poisson ratio as shown in fig 1.1

1.1 Stress in bending

Tyes of bending operation are classified into

  U-Die bending
  V-Die bending
  Roll bending
  Bending in the four slide machine
  Curling
  Dimpling
  Flanging
 U-Die bending with spring pad
2.1 Roll bending
A continuous form from of three-point bending is roll bending, where plates,
sheet and rolled on each end, one of the support can often be swung clear to
permit the removal of closed shapes from the rollsshapes can be bent to a
desired curvature on forming rolls. These machines usually have three roll in
the of a pyramid, with the two lower rolls being driven and the position of the
upper roll being adjustable by a frame

3.PROCESS OF ROLLING

In the first stage the plate is kept between top roller and bottom rollers as
shown in Figure2.1 and the top roller is given vertical displacement to get the
required bend. In next stage the bottom rollers are driven using motors in
forward direction to get the roll bending of the plate. Similarly the rollers are
driven inverse direction to get better dimensional accuracy of the final product.
The bent plate is than unloaded by raising the top roller. For continuous single-
pass four roll thin plate bending a model was proposed considering the
equilibrium of the internal and external bending moment at and about the plate-
top roller contact.

They had considered varying radius of curvature for the plate between the
rollers and proposed mathematical model to simulate the mechanics in a steady
continuous bending mode for four-roll thin plate bending process and also
investigated In sequence of material strain hardening on the mechanics of
steady continuous roll and edge-bending mode in the four-roll plate bending
process For continuous multi-pass bending of cylinder on 3-roller bending
machines (cylindrical) rollers, They incorporated the effect of change of young
modulus during the deformation in the formulation to study the effect on spring
back prediction. For plane strain of sheet metal subjected to strain rate effects
during cyclic bending under tension.
Figure 3.1: Process of rolling

The roll bending process is used to be observed from the literature reviewed that
conical bending process is untouched area as far as force prediction is
concerned. Even in the industries the normal practice of plate roller bending still
heavily depends upon the experience and the skill of the operator. Working to
templates, or by trial and error.
4. STRESSES INDUCED IN SHEET METAL
The working by bending of work-pieces creates inner of this in deformed zone
stresses in tangential and radial directions. The metal strata placed to curving
centre are pressed in tangential directions, becoming shorter and in especially
cases are stretchingin transversal direction. The metal strata placed to external
piece are stretching in tangential direction and in especially cases are pressed in
transversal direction, making the piece narrowing. Between the stretching and
pressing strata is founded the neutral status. The neutral status with the radius
is founding displaced to the curving centre before the weight centre,

4.1 Stress induced in sheet metal

5.STEPS IN ROLLING

5.1 Steps in rolling

6. DESCRIPTION

The Sheet Metal Rolling Machine works according to the principle of three
point bending. The rotation of the driven rolls being utilized to feed the metal
through the rolls by means of the frictional forces present between the surface
of the rolls and sheet. No lubricant is used at its presence interference with the
ability to grip. Sheet Metal Rolling Machine essentially consists of three
rollers, used to manufacture circular components like cylinders. Sheet Metal
Rolling Machine is classified into two types based on the arrangement of the
rollers. They are as follows.

1. Pinch type machine

2. Pyramidal type machine

This machine is of pinch type here only the top roll serves as a driven,
bottom roller are idler and rotates on friction with the work metal blank.
8.DESIGN
8.1General design principles
Following basic shearing operation on a sheetmetal, components
canberolled to give it a definite shape.

Bendingofpartsdependsuponmaterial propertiesatthe location ofthebend.

Toachievebending,thework materialmust be subjected to twomajorforces;
frictional forcewhich causesano-slip actionwhenmetalandroller cameincontact
anda bendingforceactingagainst the forward speed and the torque applied to
move the material. Fig8.1

8.1Shape rollingmechanism

Where,a=distancefromexitzonetotheno-slippoint(assumea=L/2);
F=forceappliedtorollers;T=torqueappliedtorollers;L=rollgap;
r=radiusofrollers;μ=frictionalforce;ho,hf=thicknessof thesheet before and
after timet.

Atleast two rollers were involved in flatrolling dependingonthe thicknessand

properties ofmaterial whilethreeormultiplerollersystem isrequiredinshape
rolling. A work material under bending load is subjectedtosomeform
ofresidualstressanddeformation asit bends. Materials at the outerbend
radiusundergo tensile plastic deformation whilethematerial at theinner
bendradiusundergoescompressiveplasticdeformation.
8.2 Stress and Strain in steel:
Bending is a process by which a metal can be deformed by plastically
deforming the material and changing its shape. The material is stressed beyond
the yield strength but below the ultimate tensile strength. Roll forming, [also
known as roll bending], is a process for forming plates, sheets, bars, beams,
angles or pipes into various shapes by passing the work piece between the
properly spaced rolls. Sheet and plate are the mill products often formed by the
roll bending process. Because of the elastic plastic behaviour of the sheet
material, deformation imposed on the sheet when it is forced to conform to the
rolls, has both elastic. The plastic part of the deformation is permanent and it is
not recovered when the sheet is unloaded by removing it from the roll system.
The elastic part of the deformation is recovered up on removal of the load.
This phenomena is known as “spring back” or elastic recovery
8.4 Design Calculation:

8.4 Geometrical analysis

FORCE ANALYSIS:
The material selected for analysis is mild steel. The mild steel
plate Properties are

Young’s Modulus, E=207GN/ m2

σ
Elastic limit (yield stress) y =515MN/ m2

Poisson’s ratio=0.34
Given data from the specification of the machine
 The plate thickness t=1mm
Upper roller diameter, du=50mm
Lower roller diameter dl=50mm
Lower rolls centre distance 2f=120mm
Theplate rolling speed v =5.5m/s
Using a geometrical analysis based on the assumption that the deflected form of
the plate is an arc of a circle and this analysis is used to predict the upper roll
vertical force, the torque required for bending and other requirements

K =√(Ri+rl)2 −f 2

= 0.0250.02520.062
K=0.048m
 2

K  ru  f 2  t  r l  2
R 
i
2r rtK
u l

(0.048−0.025)2 +0.062−0.0262
= =0.0863m
2 (0.025+0.025−0.048)

To find the shift of contact angle(θ) of bend plate with rolls:

f
sin θ= (Ri+rl+t )

−1 0.06
θ=sin (0.863+0.025+0.001)

= 48.7o
To find the length:

48.7
0.025 sin ¿
¿ 2∗0.06−2 ¿

l=0.0824m

The deflection of the plate below its support point is calculated by taking the
ratio of length square to eight times internal radius

(0.0824 )2
= 8× 0.048

δ
=0.017m
The plate will undergo elastic spring back after the maximum bending
moment has been applied. The relaxed radius, after spring back, of the plate
may be determined from the following equation.

σb t2
M= 4

N
σ =594.67× 106 m 2

594.67 × 106 × 0.45 ×0.0012

M= 4 =66.89 Nm
bt3 0.4 ×0.0013 −11

I= 12 = 12 =3.333 ×10

1 66.89
ρe = 207 ×109 ×3.333 ×10−11 =9.704m

ρ
p = Ri +2t=0.863+0.0005=0.8635m

1 1 1
=¿
ρr = 0.08635 − 0.103 1.872m
ρ =¿
r 0.534m

Upper roll vertical force applied on the plate (Pv)

 66.89= Pv (14 + 0.0172 tan 48.7)

P =¿
V 257.59N

The lower rolls force to drive the plate is

Pl= 257.59
2× cos 48.7 =195.14N

The side thrust force on the plate is

P 48.7=¿
s =195.14 146.60N
× sin ¿

Power required for driving the machine:

P= (Mρ V ) = (66.890.534×0.0215 ) =2.69kw

p
r

The torque required to roll the plate is calculated:

T= (Mρ r ) = (660.89.534×25 )
p l
r =¿ 3131.55N-mm

Shaft diameter:
For greater strength 45c8 (steel) is common for shafts
 N
Syt = 580 mm 2

N
Sut = 770 mm2

Using maximum shear stress theory of failure:

τ
16
3 kb M b 2  Kt M t 

max =d
(60106 )P

Mt
= 2n

0.092 ×60
=¿
= 2 × π ×0.025 35rpm

For roller speed of 35rpm & with 2.69kw M t

(60 ×106 )×2.69
=( 5
) =7.33 ×10 N-mm
2× π ×35

K
b =1.5, K t =1

τ
max = 0.3syt = 0.3(580) = 174N/mm2

τmax = 0.18sut = 0.18(720) = 138.6N/mm2

Taking the min value of 138.6 N/mm2

d3 = (π ×16138.6 )√(1.5 ×1942300) 2

+(1 ×733931.65)2

d=47.97mm let d be 50mm (standard)

9.SYNOPSIS
In Sheet Metal working industry a wide range of power and hand operated
machines are used. As the sheet metal industry is a large and growing industry
different type of machines are used for different operations. Our project the
sheet metal rolling is very simple in operation by using roller which is coupled
with handle. This machine produces cylindrical objectives of different
diameters. This machine can be used in various fields. This machine consist of
three roller which is coupled with a handle and connecting the handle shaft
with worm shaft. This machine is simple in construction and working.
 10.APPLICATIONS

Sheet Metal rolling machine is used to make,

Outer cylindrical casing for motors employed in

submersible pumps.
Hydraulic and pneumatic
cylinders Bodies of shells and
condensers Dairy equipment
Compressors storage tanks etc…
It is also used to make cylinders of different diameters
 11.ADVANTAGES
Operation of this machine is very
simple Unit is compact so less space is
required No hand tools are required
Cylindrical shaped objects of dia 50mm to 225mm can be
produced
The dia can be easily operate this machine
The machine is hand operated. So the cost of the finished
product will be less.
The total cost of the machine is less.
Maintenance of this machine is very
easy. Easy to handle
Less effort & productive
Easy to install at any were
Skilled workers are not
required Convenient for mass
production Less in weight
 12.DISADVANTAGES

  This machine has a hand operated one

 Production time is high.
