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AKNOWLEDGEMENT
ACKNOWLEDGEMENT
1. ABSTRACT
2. INTRODUCTION
3. LITERATURE SURVEY
4. BASIC OF HYDRAULICS
5. POWER DRIVING MECHANISM
6. COMPONENTS AND DESCRIPTION
7. DESIGN CONCEPT
8. MANUFACTURING PROCESS
9. WORKING PRINCIPLE
10.LIST OF MATERIALS
11.COST ESTIMATION
12.FEATURES
13.ADVANTAGES AND DISADVANTAGES
14.APPLICATIONS
15.CONCLUSION
BIBLIOGRAPHY
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CHAPTER 1
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ABSTRACT
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CHAPTER-1
ABSTRACT
is the perfect machine shop tool for the pipe bender. Our bending machine consists
of a hydraulic cylinder, hydraulic pump, die holder, ram and die. This is a hand
operated one. The hydraulic pump is supplying pressurized oil to the hydraulic
cylinder. The hydraulic cylinder consists of piston, and piston rod. The ram is fixed
at the end of the hydraulic cylinder. The pressurized oil pusses the hydraulic
cylinder piston forward due to oil pressure. Already the pipe is fixed at the die
holder. The ram is striking the pipe forcely, due to the movement of the hydraulic
piston. In this project we created 3D model & Animation by using CREO 1.0
Software.
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CHAPTER 2
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INTRODUCTION
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CHAPTER-2
INTRODUCTION
The hydraulic bending press is one of the most flexible machines on the
market, allowing the fabricator or ironworker to shear, punch, bend, scroll, and
press thousands of different parts. When considering industrial machinery, the
hydraulic bending press is the perfect machine shop tool for the metal fabricator.
industry when machinery for large-scale production must necessarily make way for
hydraulic pipe bending machine is simple when compared to other pipe bending
machine.
Biggest improvements were placing the hydraulic cylinder near the die
holder. The hydraulic pipe bending press is most bend accuracy due to less
deflection in the table. The die holder is used to hold the die in the proper position.
We have to change the die to produce different shape of pipe such as ‘V’ type, ‘L’
type etc.
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CHAPTER 3
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BASIC OF HYDRAULICS
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CHAPTER-3
BASIC OF HYDRAULICS
HYDRAULIC SYSTEM:
In the development of the submarine from pre-war classes, many changes
and improvements have occurred. One of the outstanding differences is the large
variety of submarine devices which are now operated by hydraulic power. In early
classes, there was no hydraulic system, and power requirements were met by
means of air or electricity. Along with constantly improving submarine design has
power operation. They are light in weight; they are simple and extremely reliable,
sensitive, and afford precise controllability. Because of the low inertia of moving
parts, they start and stop in complete obedience to the desires of the operator, and
Therefore, in spite of the presence of the two power sources just described,
hydraulic power makes its appearance on the submarine because of the fact that its
operational advantages, when weighed against the disadvantages enumerated for
electricity and air in the preceding paragraphs, fully justify the addition of this
Mechanism solenoids
Maintenance Constant attention Difficult, requiring Simple
to personnel and
equipment
Response Slow for both starting and Rapid starting, slow Instant starting
Operation
common, everyday needs, Opening a faucet to fill a sink with water a practical
known principles of fluid motion. There are hydraulic principles that explain the
enclosed liquids under pressure, and the harnessing of the forces existing in fluids
to do some practical task such as steering a submarine or opening the outer door of
a torpedo tube.
placed on a hydraulic rack for a grease job. Stepping on the brake pedal in an
automobile creates the hydraulic power which stops the rotation of the four wheels
basic principles, or laws, of hydraulics, that is, of confined liquids under pressure.
A thin bottle is filled to the top with a liquid and tightly corked. A lever is
exerted, the bottle will suddenly shatter into a number of pieces, showing that:
directions
system. Two cylinders each are having a base whose area is 1 square inch, are
connected by a tube. The cylinders are filled with liquid to the level shown, and a
piston with a base of the same area (1 square inch) is placed on top of each column
of liquid. Then a downward force of 1 pound is applied to one of the pistons. Since
this piston has an area of 1 square inch, the pressure upon it is 1 pound per square
inch; and since the other piston is of equal area, the same pressure, 1 pound per
Multiple units
It is not necessary to confine our system to a single line from the source of
multiple jobs.
force against the piston in the large cylinder. The pressure from the large cylinder
power
system (see Figure 4). The foot pressure on the brake pedal (1) depresses a piston
Fluid is forced through the lines (4) into each of the brake cylinders (5). At
the brake cylinder, two opposed pistons (6) attached to the brake shoes are forced
outward, pressing the brake bands (7) against the inside of the wheels (8) to stop
their rotation by friction. Removal of the foot pressure allows springs (9) at each
wheel to restore the pistons to their original positions and returns the fluid to the
master cylinder where it is stored in preparation for the next braking operation.
Figure 4 Automobile
hydraulic-brake system
1) Brake pedal; 2)
piston; 3) master
cylinder; 4) hydraulic
line; 5) brake cylinder; 6) brake piston; 7) brake band; 8) wheel; 9) return spring.
possible to construct a simple, workable hydraulic system which will operate some
mechanical device. For example, such a system might open and close a door, and
basic equipment, which, in one form or another, will be found in every hydraulic
system:
A reservoir, or supply tank, containing oil which is supplied to the
system as needed and into which the oil from the return line flows.
Figure 5 A simple
hydraulic system
other.
The supply tank must have a capacity large enough to keep the entire system
filled with oil and furnish additional oil to make good the inevitable losses from
leakage. The tank is vented to the atmosphere; thus atmospheric pressure (14.7
pounds per square inch) forces the oil into the inlet, or suction, side of the pump, in
accordance with the principle explained in connection with Figure 3. The tank is
generally placed at a higher level than the other units in the system, so that gravity
The Single Acting hydraulic cylinder (see Figure 6), which is the simplest
type of hydraulic motor, contains a spring-loaded piston, with a piston Rod that
extends through one end of the cylinder. In our project, this single acting hydraulic
cylinder is used.
which opens and closes the door. The surface of the piston in contact with the
The cut-out valve is hand-operated. When closed, it shuts off the line
between the actuating cylinder and the supply tank, preventing the oil under
pressure in the cylinder from escaping into the return line; when opened, it releases
this pressure, allowing the loading spring inside the cylinder to expand, and the oil
usually found in actual service. It has the obvious disadvantage that instantaneous
opening of the door is not possible because pressure is built up slowly by hand
pumping.
the hand pump, a double acting actuating cylinder for the spring-loaded single
acting cylinder in Figure 5, and including a control valve, an unloading valve, and
an automatic relief valve, in addition to the supply tank, or reservoir, and the return
line check valve, which are the same as in the first system.
Figure 7. Power-driven
hydraulic system
Automatic pumping will give immediate pressure for use at the actuating
In the simplified system, the door was actuated by a single acting cylinder.
Oil was kept in or released from the cylinder by a simple "on-and-off" valve. For
more efficient and positive actuation, this will be replaced by a double acting
cylinder (see Figure 8). In such a cylinder, the piston can move in either direction
The piston is locked in the desired position by the hydraulic fluid, which
enters either side of the piston as required and remains there until forced out. Since
the flow of the fluid must be directed to either of two sides, a valve, which selects
the direction of flow, is installed in the line. This is called a control valve. Control
valves vary with the specific application, but generally they are equipped with four
ports. Two are connected to the actuating cylinder at either side of the piston. A
third port is the pressure port and receives fluid from the pump. The fourth port
returns surplus fluid either back to the reservoir or elsewhere in the system.
1-15. Here the inlet and outlet ports in the cylinder, or pump body, are both in the
same side of the piston. The piston makes a close sliding fit within the cylinder,
a pump. Both the inlet and outlet ports are equipped with check valves which
permit the liquid to flow in one direction only, as shown by the arrows.
Assume that the intake side of the pump is connected to a supply of liquid.
When we move the piston to the right, lower pressure is created in the chamber
Higher pressure on the fluid outside the chamber forces fluid in through the
inlet port and fills the chamber. Moving the handle forward in the opposite
direction forces the fluid out. A check valve at the inlet port prevents flow there
and, since the fluid must find an outlet somewhere, it is forced out through the
discharge port.
The check valve at the discharge port prevents the entrance of fluid into the
piston in the pump is referred to as reciprocating motion and this type of pump is
pressures.
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CHAPTER 4
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COMPONENTS AND DESCRIPTION
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CHAPTER-4
Hydraulic Cylinder
Hydraulic Pump
Ram
Die
Stand
1. HYDRAULIC CYLINDER:
This is known as the input component of this project i.e. from the power is
transmitted to the right of the cylinder, the oil is draw from the reservoir through
pumping the handle provide at the right side of the pump plunger.
The hydraulic oil is provided in the hydraulic jack inside. The hydraulic
system requires the oil to work the system. So we have to provide the oil tank.
Hydraulic fluids
will not chemically injure the hydraulic equipment. For example, an acid, although
destroying pipes and other equipment. Also, it rusts steel parts; and it is rather
flowing lubricating oil, which does not freeze or even lose its fluidity to any
marked degree even at low temperatures, and which possesses the additional
advantage of lubricating the internal moving parts of the hydraulic units through
which it circulates.
rubber, synthetic rubber is specified for use in these systems as packing and oil
seals.
3. RAM:
The ram is used to strike the pipe forcely due to hydraulic cylinder piston
4. DIE:
The die is fixed between the die holders. The die shape is varied depends
upon the required shape of the pipe such pipe bending shapes are “V”-type, “L”-
type, etc.
5. DIE HOLDER:
The die holder is used to hold the die in the proper dimension. The strength
of the die holder is depends upon the pipe dimension, diameter and thickness.
6. SUPPORTING STAND:
cylinder.
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CHAPTER 5
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MANUFACTURING PROCESS
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CHAPTER-5
MANUFACTURING PROCESS
Manufacturing processes are the steps through which raw materials are
transformed into a final product. The manufacturing process begins with the
creation of the materials from which the design is made. These materials are then
modified through manufacturing processes to become the required part.
tests and checks for quality assurance during or after the manufacturing, and
METAL CUTTING:
Usually, the portion that is fractured away is in small sized pieces, called chips.
drilling, grinding, turning and milling. Although the actual machines, tools and
processes for cutting look very different from each other, the basic mechanism for
causing the fracture can be understood by just a simple model called for orthogonal
cutting.
In all machining processes, the work piece is a shape that can entirely cover
the final part shape. The objective is to cut away the excess material and obtain the
final part. This cutting usually requires to be completed in several steps – in each
step, the part is held in a fixture, and the exposed portion can be accessed by the
tool to machine in that portion. Common fixtures include vise, clamps, 3-jaw or 4-
jaw chucks, etc. Each position of holding the part is called a setup. One or more
cutting operation may be performed, using one or more cutting tools, in each setup.
To switch from one setup to the next, we must release the part from the previous
fixture, change the fixture on the machine, clamp the part in the new position on
the new fixture, set the coordinates of the machine tool with respect to the new
location of the part, and finally start the machining operations for this setup.
should try to do the entire cutting process in a minimum number of setups; the task
minimum number of) setups, and determination of the fixture used for each setup,
SAWING:
Cold saws are saws that make use of a circular saw blade to cut through
various types of metal, including sheet metal. The name of the saw has to do with
the action that takes place during the cutting process, which manages to keep both
the metal and the blade from becoming too hot. A cold saw is powered with
electricity and is usually a stationary type of saw machine rather than a portable
type of saw.
The circular saw blades used with a cold saw are often constructed of high
speed steel. Steel blades of this type are resistant to wear even under daily usage.
The end result is that it is possible to complete a number of cutting projects before
there is a need to replace the blade. High speed steel blades are especially useful
when the saws are used for cutting through thicker sections of metal.
Along with the high speed steel blades, a cold saw may also be equipped
with a blade that is tipped with tungsten carbide. This type of blade construction
also helps to resist wear and tear. One major difference is that tungsten tipped
blades can be re-sharpened from time to time, extending the life of the blade. This
type of blade is a good fit for use with sheet metal and other metallic components
WELDING:
Welding is a process for joining similar metals. Welding joins metals by
melting and fusing 1, the base metals being joined and 2, the filler metal applied.
Welding employs pinpointed, localized heat input. Most welding involves ferrous-
based metals such as steel and stainless steel. Weld joints are usually stronger than
works, tanks, furniture, boilers, general repair work and ship building.
OPERATION:
Several welding processes are based on heating with an electric arc, only a
few are considered here, starting with the oldest, simple arc welding, also known
electrical machine (which may be DC or AC, but nowadays is usually AC) supplies
with a mixture of chemicals or flux. An earth cable connects the work piece to the
welding machine to provide a return path for the current. The weld is initiated by
tapping ('striking') the tip of the electrode against the work piece which initiates an
electric arc. The high temperature generated (about 6000oC) almost instantly
produces a molten pool and the end of the electrode continuously melts into this
The operator needs to control the gap between the electrode tip and the work piece
In the shielded metal arc welding process (SMAW) the 'stick' electrode is
covered with an extruded coating of flux. The heat of the arc melts the flux which
generates a gaseous shield to keep air away from the molten pool and also flux
ingredients react with unwanted impurities such as surface oxides, creating a slag
which floats to the surface of the weld pool. This forms a crust which protects the
weld while it is cooling. When the weld is cold the slag is chipped off.
The SMAW process cannot be used on steel thinner than about 3mm and
widely used in jobbing shops and for onsite steel construction work. A wide range
of electrode materials and coatings are available enabling the process to be applied
to most steels, heat resisting alloys and many types of cast iron.
DRILLNG:
Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of
circular cross-section in solid materials. The drill bit is a rotary cutting tool, often
multipoint. The bit is pressed against the workpiece and rotated at rates from
hundreds to thousands of revolutions per minute. This forces the cutting edge
against the workpiece, cutting off chips (swarf) from the hole as it is drilled.
OPERATION:
The geometry of the common twist drill tool (called drill bit) is complex; it
has straight cutting teeth at the bottom these teeth do most of the metal cutting, and
it has curved cutting teeth along its cylindrical surface. The grooves created by the
helical teeth are called flutes, and are useful in pushing the chips out from the hole
as it is being machined. Clearly, the velocity of the tip of the drill is zero, and so
this region of the tool cannot do much cutting. Therefore it is common to machine
a small hole in the material, called a center-hole, before utilizing the drill. Center-
holes are made by special drills called center-drills; they also provide a good way
for the drill bit to get aligned with the location of the center of the hole. There are
hundreds of different types of drill shapes and sizes; here, we will only restrict
Titanium Nitride coated steel); for cutting harder materials, drills with hard inserts,
In general, drills for cutting softer materials have smaller point angle, while
those for cutting hard and brittle materials have larger point angle;
need a special guiding support for the drill, which itself has to be very long; such
operations are called gun-drilling. This process is used for holes with diameter of
few mm or more, and L/D ratio up to 300. These are used for making barrels of
guns;
Drilling is not useful for very small diameter holes (e.g. < 0.5 mm), since the
tool may break and get stuck in the work piece; - Usually, the size of the hole made
by a drill is slightly larger than the measured diameter of the drill – this is mainly
For tight dimension control on hole diameter, we first drill a hole that is
slightly smaller than required size (e.g. 0.25 mm smaller), and then use a special
type of drill called a reamer. Reaming has very low material removal rate, low
inspected into a product") the role of inspection is to verify and validate the
variance data; it does not involve separating the good from the bad.
ASSEMBLY:
the semi-finished assembly moves from work station to work station where the
parts are added in sequence until the final assembly is produced. By mechanically
moving the parts to the assembly work and moving the semi-finished assembly
from work station to work station, a finished product can be assembled much faster
and with much less labor than by having workers carry parts to a stationary piece
for assembly.
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CHAPTER 6
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WORKING PRINCIPLE
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CHAPTER-6
WORKING PRINCIPLE
PRINCIPLE:
described. It remains to discuss how a liquid will behave when confined, for,
Hydraulic pump consists of piston, piston rod and oil. The hydraulic
The hydraulic cylinder consists of piston and piston rod. The end of the
piston rod the ram is fixed. The compressed oil pushes the hydraulic cylinder
piston forward. Already the pipe to be bended is fixed in between die and ram. The
produce different shape of bended pipe such as “V” type, “L” type etc. The ram is
strike the pipe forcely, so that the pipe is bended according to the shape of the die
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LIST OF MATERIALS
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LIST OF MATERIALS
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CHAPTER 87
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COST ESTIMATION
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COST ESTIMATION
1. MATERIAL COST:
2. LABOUR COST
Cost =
3. OVERHEAD CHARGES
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CHAPTER 9
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ADVANTAGES & DISADVANTAGES
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CHAPTER-9
ADVANTAGES:
1. Hydraulic pipe bending machine develops greater forces than mechanical
pressure and hence it is for forming, bending, and drawing and extrusion
operations.
2. The hydraulic pipe bending machine can exert its full forces at any
position of the ram stroke whereas the force is maximum at the end of
DISADVANTAGES
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CHAPTER 10
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APPLICATIONS
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APPLICATION
The hydraulic pipe bending machine brakes can be fitted with hundreds of
tooling options for acting as a press brake (using the table as the level for
accuracy),
Ram bender (for pipe or solids),
Rotary draw tubing bender
Shear, punch, ornamental iron twisting machine, straightener, etc.
This machine tool is great for any welding shop, fabricator, or general job
shop.
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CHAPTER 11
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CONCLUSION
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CHAPTER-11
CONCLUSION
We feel that the project work is a good solution to bridge the gates between
We are proud that we have completed the work with the limited time
maintaining the tolerances and also quality. We have done to our ability and skill
In conclusion remarks of our project work, let us add a few more lines about
Before concluding a point to note is that the particular pipe bending machine
which we have designed for multiple operation. To facilitate the above, there is a
provision in the frame to change the table if necessary. Thus if we want to perform
any press operations using die and punch, than a table having a provision to hold a
die can be used and corresponding punch can be fixed to the ram end.
BIBLIOGRAPHY