A

PROJECT REPORT

ON

“3D WIRE BENDING MACHINE”

Submitted In Partial Fulfillment of the

Requirements Of the degree of

Mechanical Engineering

BY

Name of Student Roll Number

ADITYA BRID 56

HITESH KHILLARI 49

SARVESH CHAUDHARI 50

ABHISHEK GUPTA 38

Under The Guidance Of

Prof. Mahesh Kadam

DEPARTMENT OF MECHANICAL ENGINEERING

B.R. Harne College of Engineering & Technology Karav, Vangani (W) Dist –Thane 421503

[2019-2020]
 CERTIFICATE
This is to certify that the project entitled

“3D WIRE BENDING MACHINE.”

Is a bonafide work of

NAME OF STUDENT ROLL NO

1. ADITYA BRID 56

2. HITESH KHILLARI 49

3. SARVESH CHAUDHARI 50

4. ABHISHEK GUPTA 38

Submitted to the University of Mumbai in partial fulfilment of the requirement for the award of the
degree of “B.E. in Mechanical Engineering”

PROF. MAHESH KADAM

Project guide Examiner

Prof. Amarkumar Modi Dr. V.A. Patil

Head of the department Principal

 DECLARATION
We declare that this written submission represents our ideas in our own words and

we have adequately cited and referenced the original sources. We also declare that we

have adhered to all principles of academic honesty and integrity and have not

misrepresented or fabricated or falsified any idea, data, fact, source in our submission.

We understand that any violation of the above will be cause for disciplinary action by

the Institute and can also evoke penal action from the source which has thus not been

properly cited or from whom proper permission has not been taken when needed.

Name of the student Roll No. Signature

1) ADITYA BRID 56 --------------------------

--
2) HITESH KHILLARI 49 --------------------------
--
3) SARVESH CHAUDHARI 50 --------------------------
--
4) ABHISHEK GUPTA 38 --------------------------
--

Date: / /
 ACKNOWLEDGEMENT
This project would not have been possible without the support of Prof. Mahesh Kadam. His
sincere efforts in explaining the subject & related topics helped us to be acquainted with the
subject & management field easily.

We are thankful to them for the project they gave us since it enhances our ability to work
in groups. We also like to thank Prof. Amarkumar Modi, HOD of Mechanical Department who
gave us the permission to use the Workshop & gave us all the information for the ongoing
project. We would also like to thank our helping us to complete project.

ROLL NO. NAME SIGN

56 ADITYA BRID -------------------------

49 HITESH KHILLARI -------------------------

50 SARVESH CHAUDHARI -------------------------

38 ABHISHEK GUPTA -------------------------

4
 CONTENTS

CHAPTER TITLE PAGE NO.

1. ABSTRACT 8

2. INTRODUCTION 9

3. LITERATURE REVIEW 11

4. PROBLEM STATEMENT 13

5. METHODOLOGY 16

6. MATERIAL ESTIMATION 23

7. 24
PROJECT FLOW CHART

8. EXPECTED RESULTS 25

9. REFERENCES 26

5
 LIST OF FIGURES

Figur Figure Name Page

e No. No.

4.1 MECHANICAL 2D PIPE BENDER 13

4.2 MIND MAP 14

5.1 RACK 17

5.2 PINION 18

5.3 MOTOR 18

5.4 BENDER NOZZLE 19

5.5 LIMIT SWITCH 19

5.6 BENDER GEAR 20

5.7 PILLOW BLOCK 20

5.8 AUTOMATIC 3D WIRE BENDING 21

MACHINE

5.9 ARDUINO CIRCUIT 22

7.1 FLOW CHART 24

6
 LIST OF TABLES

Table No. Figure Name Page No.

1 PROTOTYPE VS. EXISTING WIRE 11

BENDERS

2 REFERENCE PAGES 12

3 RAW MATERIALS 23

7
 ABSTRACT

Prototyping is a vitally important stage in the product development cycle. Rapid prototyping
tools allow designers and engineers to quickly and inexpensively create functional models,
fixtures, or products. The market for these tools has grown immensely in the past 20 years.
New additive technologies like 3D printing and subtractive manufacturing tools like laser
cutters and CNC mills and lathes allow fast and accurate manufacturing of many different
prototype components. These technologies allow designers to bring their ideas into the real
world much faster than was previously possible. Despite their advantages, current rapid
prototyping technologies are limited by the maximum sizes of parts they can create and their
often-high cost.

Wire bending is another emerging method of manufacturing that has enhanced the ability of
designers to make use of negative space and frames in assemblies. Performing market
research and user interviews showed us that current wire bending tools are either very
expensive, or limit the user to two dimensional structures. We believe that this market gap
can be filled by an affordable, desktop scale, three-dimensional wire bender. With this in
mind we were able to develop the needs that we felt were important to achieve in a
prototype version of this 3D wire bender.

INTRODUCTION

8
This study proposes the idea of automated 3D wire bending mechanism which is flexible and
capable of making any Manual wire bending has a huge tendency to create errors, thus affecting the
efficiency of the wire for the specified treatment, in parallel with the elongation of the treatment
time. Besides, it can simultaneously increase the bending time due to some additional major
adjustments and leads to bender fatigue. In general, the accuracy of the bend is inconsistent and
depends on many factors, mostly on the expertise of the bender. Hence, due to these limitations in
the manual wire bending and some urgency to decrease the dependency on the bender’s
competency, this article introduces a theoretical framework of the 3D linear segmentation algorithm
to realize the proposed bending mechanism.

This is actually a typical Mechatronic system because it involves mechanical, electrical and
computer engineering. So therefore, I believe many engineering students or anyone who is new into
Mechatronics found this project interesting. Here’s the working principle of this 3D wire bending
machine. So, first, the wire goes through a series roller, or strengtheners. Using a stepper motor the
wire is precisely fed to the wire bending mechanism which also uses a stepper motor as well as a
small servo for the bending process.

Wire bending is another emerging method of manufacturing that has enhanced the ability of
designers to make use of negative space and frames in assemblies. Performing market research and
user interviews showed us that current wire bending tools are either very expensive, or limit the
user to two dimensional structures. We believe that this market gap can be filled by an affordable,
desktop scale, three-dimensional wire bender. With this in mind we were able to develop the needs
that we felt were important to achieve in a prototype version of this 3D wire bender.

Automated wire bending machines are used to create accurate and complex bends in a variety of
materials, cross-sectional shapes, and sizes. Automated wire bending machines may be operated,
for example, through computer numerical control (CNC). CNC wire bending machines allow a user
to design a shape using a computer or other processing device, and have the machine create the
shape consistently according to a part program. By automating the wire-forming process,
complicated parts can be made beyond the capabilities of ordinarily skilled human craftsmen.
Further, CNC wire bending machines may be used to create precise parts repeatedly, reducing the
need to inspect or rework individual parts. For instance, the creation of wire grocery carts requires
many precise bends which are not easy to manually execute.

Automated wire bending machines are used with various kinds of wire. Wire may be fed directly
from coil stock to the wire bending machine, or may be supplied in straight segments.

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A variety of automated wire benders are known in the art. These include two-dimensional
machines, in which the finished wire is substantially flat because each bend forms the wire in a
single plane; and three-dimensional machines, in which the finished wire is more complex and may
have bends defining multiple planes in space.

In automated (e.g., CNC) wire bending machines, the wire feeding mechanism, clamping
mechanism, means for rotating, bending mechanism, and cut off mechanism are each driven by one
or more actuators through a series of sequential operations defined in a part program. The actuators
may be servo motors, stepper motors, hydraulic or pneumatic cylinders, or any other device that
may be commanded electronically through circuits integrated with a computing device. Each
actuator may further be associated with one or more feedback devices that provide position
information associated with the respective actuator. These feedback devices might include
encoders, resolvers, limit switches, proximity switches, or any other device that may provide
position data electronically through circuits integrated with a computing device.

Known three-dimensional wire bending machines generally have a limited range of rotation for the
wire or the bending mechanism. This limited range of rotation typically results from designs in
which cables or hoses related to the actuators or feedback devices restrict the rotation of the
bending mechanism, or designs in which a mechanical element simply cannot be rotated beyond a
certain range. It is desirable for automated wire bending machines to allow unlimited rotation of the
wire or the bending mechanism.

LITERATURE REVIEW

10
A. History:
In order to outline our goals more specifically, we performed market research into what technology
already existed. Table 1 benchmarks our initial idea against the wire bending technologies
mentioned. From this benchmarking table, it became clear we would have difficulties trying to scale
the gripping technology down to desktop sizes. The simpler “rotating pin” method was more
scalable. The challenge then simply became turning this existing two-dimensional technology into a
three-dimensional prototype.

Table 1. Prototype Vs. Existing Wire Benders

WHAT
SR. AUTHOR DESCRIPTION INFORMATION WE
NO. USE FROM THIS
FOR OUR PROJECT?
1. Mohan Krishna S. A Experimental Design and The aim of this paper is to
11
 Fabrication of a Portable
Pipe Bending
Machine
2. P. S. Thakare, P. G. Mehar, Productivity Analysis of
Dr. A. V. Vanalkar and Manually Operated and
Dr. C. C. Handa Power Operated Sheet
Bending Machine: A
Comparative Study
3. Dharmender Aswal, Karn The Study of Stepper
Singh, Vikas Yadav Motors
4. Tang, W. X., Zhu, H., Zhu, Research on Key
M. X., Li, Q. F., & Zhang, Technology of Wire-
J. (2016). Bending and Equipment
Development
5. Leo Louis Working Principle of
Arduino and using it as a
tool for Study and Research
6. J.R. Davis & Associates Gear materials, properties,
and manufacture
7. Rajeshkumar Selvaraj Development of Thermo
Muthu Kannan Plastic Gears for Heavy
Bakkiyaraj Velu Duty Applications
8. PSG Design data book
Table 2. Reference Pages
PROBLEM STATEMENT
We broke down our prototype into the most important needs. These included how it would feed the
wire, avoid collisions, and different ways for it to rotate and bend the wire. Once we chose these
higher-level concepts, we brainstormed different ways that we could accomplish each task. The
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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.
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 this paper, a case study for
implementation of the
stepper motors is presented.
This paper focuses on 3D
wire modelling and
machining simulation,
consisting of software
design, wire modelling,
Machining simulation and
collision detection by
utilizing both Visual C++
and OpenGL.
This paper explores the
working principle and
applications of an Arduino
board.
In this paper all the
properties of different
materials used for gears are
given.
The aim of this project to
evaluate the contact stress of
plastic material in gear for
heavy duty loading
condition.
To design gears of different
sizes as per standard values
additions at the furthest branches of this mind map portray the actual solutions to each need shown
in the internal nodes.

Fig.4.1 MECHANICAL 2D PIPE BENDER

13
Fig.4.2 Mind Map

14
 SCOPE

To accomplish the goal outlined in our problem statement we had to ideate, sketch, and model how
our prototype was going to look and work. We broke down the needs and requirements and
conceptualized solutions to each problem posed. After brainstorming in the form of memory mind
mapping, we sketched some individual ideas. To decide which solutions we would develop further,
we used decision matrices to compare different solutions to the same concepts. Finally, we
performed a risk assessment of the entire solution to gauge how risky our design would be.

15
 METHODOLOGY

Once we knew the required forces were relatively low and this would be a feasible load to design
for, we broke up the machine into three parts. We decided that the most important part of the design
was the nested gears and cylinders so the majority of the modeling was done on this assembly. The
overall support and feeding mechanism for the device was also considered, but many of the parts
required could be found around campus or at local hardware stores so they were not modelled as
accurately.
The CAD model that we created was purely visual. We were trying to evaluate the feasibility and
complexity of the bend head and its major components. It was very quick but it allowed us to see
what needed to move and when to execute bends and add a 3D element. No specific parts or
dimensions were used to build this model, but it was helpful for making sure everybody on the team
had the same vision for the overall mechanism. A basic 4-view rendering of this model can be seen
in Figure.
The CAD model was used to get an idea of the overall layout and size. In this model, the key
rotating parts of the concentric tubes were accurately modelled using ball bearings. This model gave
us a general sense of scale and layout. It was the first time we thought about interactions between
moving parts, basic power transmission from motors to the bend head, and the path the wire must
travel.

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 DESIGN OF PARTS

SOLID MODELING

The entire model has been designed with the help of designing software solid works.

Fig.5.1 RACK

Gear racks are utilized to convert rotating movement into linear motion. A gear rack has straight
teeth cut into one surface of a square or round section of rod and operates with a pinion, which is a
small cylindrical gear meshing with the gear rack. Generally, gear rack and pinion are collectively
called “rack and pinion”.

17
 Fig.5.2 PINION
A pinion is a round gear—usually the smaller of two meshed gears—used in several applications,
including drivetrain and rack and pinion systems.

Fig.5.3 MOTOR
NEMA 17 is a hybrid stepping motor with a 1.8° step angle (200 steps/revolution). Each phase
draws 1.2 A at 4 V, allowing for a holding torque of 3.2 kg-cm. NEMA 17 Stepper motor is
generally used in Printers, CNC machines and Laser Cutters.

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 Fig.5.4 BENDER NOZZLE

Fig.5.5 LIMIT
In electrical engineering a limit switch is a switch operated by the motion of a machine part or
presence of an object.
Limit switches are used in a variety of applications and environments because of their ruggedness,
ease of installation, and reliability of operation. They can determine the presence or absence,
passing, positioning, and end of travel of an object. They were first used to define the limit of travel
of an object; hence the name "Limit Switch".

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 Fig.5.6 BENDER GEAR

Fig.5.7 PILLOW BLOCK

A pillow block (or Plummer block) is a pedestal used to provide support for a rotating shaft with the
help of compatible bearings & various accessories. Housing material an for a pillow block is
typically made of cast iron or cast steel.

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Fig.5.8 AUTOMATIC 3D WIRE BENDING MACHINE

21
 ARDUINO CIRCUIT
Arduino is an open-source hardware and software company, project and user community that
designs and manufactures single-board microcontrollers and microcontroller kits for building digital
devices.
Arduino board designs use a variety of microprocessors and controllers. The boards are equipped
with sets of digital and analog input/output (I/O) pins that may be interfaced to various expansion
boards (For prototyping) and other circuits. The boards feature serial communications interfaces,
including Universal Serial Bus (USB) on some models, which are also used for loading programs
from personal computers. The microcontrollers can be programmed using C and C++ programming
languages.
The three stepper motors are controlled using the three DRV8825 stepper drivers. For powering the
steppers and the whole project we will use 12V power supply with at least 3A of current rate.
For powering the servo motor, we could use the 5V coming from the Arduino, but the MG996R
servo can be power hungry and the 5V voltage regulator of the Arduino might not be able to handle
it. Therefore, we decided to use a separate 5V voltage regulator, the LM7805, which is good
enough to power the servo for this project. There is also a limit switch for the bender which has a
pull up resistor it’s connected to a digital pin of the Arduino board.
CIRCUIT DIAGRAM:

Fig.5.9 Arduino Circuit

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 MATERIAL ESTIMATION

It includes the material in the form of the Material supplied by the “Steel Authority of India
Limited” and ‘Indian Aluminum Co.,’ as the round bars, angles, square rods, plates along with the
strip material form. We have to search for the suitable available material as per the requirement of
designed safe values. We have searched the material as follows: -

Hence the quantity of the raw material required for project is as follows: -

SR NO. PART NAME MATERIAL QUANTITY

1 Stepper Motor STD 1 NO
2 Micro Limit Switch STD 1 NO
3 Shaft MS 1KG
4 12v 2a Adapter STD 1 NO
5 MS Angle MS 10 KG
6 Round Pipe MS 1 KG
7 Power Jack STD 1 NO
8 Bearing CI 6 NOS
10 Nut Bolt Washer M10 MS 20 NOS
11 Arduino Board STD 1 NOS.
12 Servo Motor STD 3 NOS
13 MS Sheet Metal 16 Gauge MS 1 STEET
14 Aluminium Wire 3mm AL 1KG
15 Plastic Material for Gears PLA 1000GM
16 Bender Nozzle CU 1 NO
Table 3. Raw Materials

PROJECT FLOW CHART

From the flow chart, this project started with the objective of the project. The objective of the
project must follow the title. The objective must fulfill the title Then follow up with design review
about folding table and then study a lot of investigation about folding table. This is including study
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about several of stage, type of stage, types of material which suitable to make a stage. These tasks
have been done through study on internet, books and others resources. After all information had
been collected and gathered, the project continued with the design process. All the knowledge and
lessons had been applied to make a suitable design for the project. After several design sketched,
design consideration has been made and one of the designs have been chosen by using Pugh’s
concept selection. The solid modeling and engineering drawing by using solid works software the
fabrication process progress use drawing as a reference. The process consist fabrication to all parts
that have been designed by the dimension using various type of manufacturing process. The
manufacturing process includes welding, drilling, bending, cutting and etc. During the fabrication
process, if there have error occur, such as fabrication error, so the process needs to modification the
process needs to go back to the previous step and the process flow again, until no error occur the
process can been continued smoothly until the final product finished. Then, the draft report needs to
be submitted to the supervisor for double checking if there had an error.

LITERATURE PROBLEM OBJECTIVE

DEFINATION
SURVEY

OPTIMIZATION MATERIAL DESIGN OF

SELECTION PHYSICAL MODEL

FABRICATION CONFIRMATION CONCLUSION

TEST

FIG.7.1 FLOW CHART

EXPECTED RESULTS

1). Firstly, the feeding mechanism should reset itself without being adjusted manually when
the feeding speed is different from the receiving speed of the processing equipment.

24
2). The angle between the standard the stand base will be changed when the straightening
mechanism feeds the wire, then the angle transducer will send a signal to the stepper motor to drive
the wire supporting device to turn. Make the storing mechanism push the wire forward to the
straightening mechanism.
3). Secondly, the bilateral bending device and the centre clamping device of the wire-bending
mechanism are joint to bend the wire. The bilateral bending device with double-heads can achieve
asymmetric bending on two sides at the same time to bend the wire to any angle.
4). Finally, the rotate gear in the centre clamping device will rotate to the perspective of
presupposition which should makes the wire-bending mechanism more stable and higher
rotational accuracy.

REFERENCE

25
To complete the project, report the use of various book and reference papers is important. The
following are number of reference pages used for our project.

1). Mohan Krishna S. A. “Experimental Design and Fabrication of a Portable Pipe Bending
Machine”.

2). 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”.

3). Dharmender Aswal, Karn Singh, Vikas Yadav “The Study of Stepper Motors”.

4). Tang, W. X., Zhu, H., Zhu, M. X., Li, Q. F., & Zhang, J., “Research on Key Technology of
Wire-Bending and Equipment Development”.

5). Leo Louis, “Working Principle of Arduino And Using It

As A Tool for Study and Research”.

6). J.R. Davis & Associates, “Gear materials, properties, and manufacture”.

7). Rameshkumar Selvaraj, Muthu Kannan, Bakkiyaraj Velu, “Development of Thermo Plastic
Gears for Heavy Duty Applications”.

8). R.S. Khurmi, “Theory of Machine”.

9). S.K. Hajra, Chaudhary, “Work Shop Technology”.

10). PSG, “Design Data Book”.

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