CONSTRUCTION OF A MANNUAL ROLLER BENDING MACHINE

STUDENT’S DECLARATION
I, Daniel kariuki Gitonga, declare that this is my original work and has not been submitted to
any other college, institution or university other than Chuka Technical and Vocational
College.

Signed: ____________________________ Date: _____________________

Daniel kariuki Gitonga
ACKNOWLEDGEMENT
First and foremost, I would like to thank the Lord Almighty for giving me the grace and
strength to complete this project. Secondly, I would like to acknowledge my lectures Henry
Murimi and Erick Miriti for their support, insight and remarks in the study. I would also like
to acknowledge my classmates for the comradely and support as we did this project together.
I would also like to acknowledge the special role played by chuka technical and vocational
college, through their very resourceful staff library and e-resources; I had more than enough
literature materials and guidance. Finally, I would like to acknowledge my parents, family
and friends for being supportive and input during this project. God Bless you all.
Abstract
The aim of this paper is to develop a roller bending machine which is useful to bend a metal
strips in workshop. This project is to design and construct a portable roller bending machine.
This machine is used to bend metal strips into curve and the other curvature shapes. The size
of machine is very convenient for portable work. It is fully made by steel. Moreover, it is
easy to carry and use at any time and any place. It reduces human effort and also required less
skill to operate this machine. We are designing manually operated roller bending machine
with use of rollers, support (frame), bolts and bearings. The roller bending machine is
manually operated. Therefore, our objective is to increase accuracy at low prize without
affecting the bending productivity. This machine works on simple kinematic system instead
of complicated design. Due to its portability it can be used by small workshop or fabrication
shop. Bending machine is a common tool in machine shop that is used to bend a metal.
DEDICATION
A special dedication to my family members for the faith they had in me in all my endeavours
and encouraging me to pursue this mechanical course and also, to my father Mr j Charles, as
my friend and colleague for the encouragement assistance and financial support towards the
achievement of this project
Contents
1Chapter one
1.1Introduction
1.2Problem definition
2Chapter two
2.1Literature review
3Chapter three
3.1Rolling process
3.2 Design process
3.3Advantages
3.4 Disadvantages
3.5 Application
3.6 Component design
3.7 Requirements
4Chapter four
4.1 Explanations
4.2Concept of iterations
4.3Definition state
4.4Assumption
4.5Preliminary stage
4.6Conclusion
4.7References
Chapter 1
1.1 Introduction

It has been seen that the manual roller bending machines are widely used in many industries
for many different applications such as, sheets are bent and rolled to form a shell like
structure which are used in pipe line. I & L channel are bending to a required angle used to
form structural stress (roofing) in construction industries. Some of them are used for conical
bending which are costly to produce using conventional machines.

Figure 1.1: metal roller bending machine

Various cylindrical sections are widely used. Such cylindrical sections are manufactured by
various methods and metal roller bending process is one such process. It consists of two
bottom rollers and a top roller. The plate undergoes plastic deformation and it is cold forming
process and hence it has higher dimensional accuracy. This can be done through

1. static
bending,

2. forward
rolling,

3.backward
rolling
1.2 PROBLEM DEFINATION

By reviewing all the above paper brings further experimental study on 3-roller bar bending
machine. This study shows the bending of bar into required radius of curvature having greater
thickness with shorter width. Bending of this thick sheet executes higher load on centre roller
of machine. As the thickness of the sheet increases the load acting on the top roller also
increases, thus for rolling of thick material brings changes in design parameter (mainly on
sheet thickness t). Hence, this problem can be related to bending of rectangular bar at the mid
span and bending moments.

Thus the steps executing on this problem are listed below:

• Analytical calculation of load and stress acting on the rollers.

• Calculation of required deflection at the mid span which is required to bent the bar to
obtain radius of curvature R.

• Design of roller trains.

• Calculation of speed reduction factor from input to the output

• Modelling parts and assembly of manual roller bar bending machine.

• Analysing of stress distribution across rollers.

Chapter 2

2.1 LITERATURE REVIEW

Himanshu: Has done bendability analysis for bending of steel on a manual roller bending
machine. In this experiment they found out the equivalent thickness, equivalent width and
maximum width analytically based on material model.
Ahmed Ktari: Have done Modelling and computation of the manual roller bending process of
iron, steel- sheets. This experiment consists of two-dimensional finite element model of this
process was built under the Abaqus /Explicit environment based on the solution of several
key techniques, such as contact boundary condition treatment, material property definition,
meshing technique, and so on.
Jong GyeShin:
Has done the experiment on Mechanics-Based Determination of the centre roller
displacement in manual roller bending for smoothly curved metals and sheet. The objective of
this paper is to develop a logical procedure to determine the centre roller displacement, in the
manual roller bending process, which is required in the fabrication of curved metallic objects
with a desired curvature.
M. B. Bassett, and W. Johnson:
The bending of metals using roller bending machine, brings about analysis which include:
Process manual, maintenance manual, machine capacity chart and technical specification of
rolling machine.
Chapter 3

3.1 PROCESS OF ROLLING

In the first stage the plate, sheet, rod or metal is kept between top roller and bottom rollers
and the top roller is given vertical displacement to get the required bend. Bauschinger factors
in the model for stress reversal. The roll bending process is used for years, it can be observed
from the literature reviewed that metal 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.

Align the plate using the alignment groove in

the lower rolls against rear roll .The pre-bending
is accomplished by clamping the material to be
rolled between the top roll and one of the lower
roll.

The metal is bent towards the top roll by other

roll and the metal edge is pre-bent to minimum
flat end possible, a length of the plate is rolled
and radius is checked.

Roll the plate through the machine and bend to

desired diameter

Lower the clamping roll and raise the other roll

until the metal is clamped again. roll the metal
in to a closed cylinder and pre-bend the second
metal edge

Finished cylinder is released from the machine

by lowering the drop end.
FINAL SHAPE OF THE DRAWIMG

3.2 Design process

 develop a
definate the select an
design
problem approach
proposal

explore model or
brainstorm
posibilities phototype

identify
research and test and
criteria and
generate ideas evaluate
constraints
3.3 ADVANTAGES

 Very Useful in Fabrication

 Easy To Make Curved Parts
 Supports a Variety of Soft Metals

 Portable

 Low initial cost

 Low maintenance cost  Simple Design

3.4 DISADVANTAGES

 As it is a prototype model, here bending is limited up to the thickness of 4mm. For

higher thickness of specimen this machine size should be increased.

 Chances of accident due to improper concentration on work.

3.5 APPLICATIONS

 Fabricating/Rolling
  Boilers, Pressure Vessels

 Storage Tanks, Silos

 Tubes and Pipelines

 Heating and Ventilation

 Wind Towers, Power Generation

 Gates, doors, windows and grills

3.6 DESIGN COMPONENT REQUIREMENTS

No. Name of the Material Quantity
parts

1 Bending Mild steel 1

rollers

2 Bearings Steel 4

3 Elevating Stainless steel 1

Screw

4 bolt Mild steel 10

5 Supporting Mild steel 2

frame

6 nuts Mild steel 10

3.7 explanation

Following basic shearing operation on a sheet metal, components can be rolled to give it a
definite shape. Bending of parts depends upon material properties at the location of the bend.
To achieve bending, the work material must be subjected to two major forces; frictional force
which causes a noslip action when metal and roller came in contact and a bending force
acting against the forward speed and the torque applied to move the material.

Where,

a = distance from exit zone to the no-slip point (assume a = L/2); F = force applied to rollers;
T = torque applied to rollers; L = roll gap; r = radius of rollers; μ = frictional force 0.4 Nm-
1; ho, hf = thickness of the sheet at least two rollers are involved in flat rolling depending on
the thickness and properties of material while three or multiple roller system is required in
shape rolling. A work material under bending load is subjected to some form of residual
stress and deformation as it bends. Materials at the outer bend radius undergo tensile plastic
deformation while the material at the inner bend radius undergoes compressive plastic
deformation.

4 Chapter four
4.1 Introduction

The notion of useful work is basic to machines functioning, as there is always some energy
transfer involved. The mention of forces and motion is critical to our concern as in converting
energy from one form to another, machine creates motion and develop forces. It is engineers
task to define and calculate those motion, forces and changes in the energy in order to
determine the size shape and material needed for each of the interrelated parts of the machine.
The goal in machine design is to size and shape the parts(machine elements) and choose
the appropriate material for manufacturing process so that machine is expected to perform its
intended function without failure .In this design project there is negligible acceleration so
static force analysis will be suffice . Static force analysis deals with structure which are to be
designed against failure to external loading. The process of design is essentially an exercise in
applied creativity. Various design process have been defined to help organize to attack upon
un-constructed problem definition is vague for which many solution exist .some of this design
process as shown below consist of 10 steps but can be extended to 25 steps.

• Identification of need

• Background research

• Goal statement

• Task specification

• Synthesis

• Analysis

• Selection

• Detailed design
 • Prototyping and testing

• Production

The initial step is Identification of need, usually consist of an ill-defined and vague
problem statement. The development of the Back ground Research is necessary to fully define
and understand the problem after which it is possible to re-state the goal in a more reasonable
and realistic way than the original problem statement. Step (4) calls for the creation of
detailed set of task specification which bound the problem and limit the scope .The synthesis
step (5) is the one in which as many alternative possible design approaches are sought,
usually without regards of quality and value .We can also state this step as ideation and
invention step in which largest number of creative solution are generated.
In step (6) the solution of the previous steps are analysed and they are accepted, rejected
and modified the most promising solution is selected at step (7) once the acceptable design
are filtered and once the way is finalised then the Detailed design is done where all the loose
ends are tied up complete engineering drawing is made, vendors are identified and
manufacturing specification is defined. The actual construction of the working design is first
done as a proto type in step (9) Finally in quantity in production at step (10)

4.2Concept of Iteration
The above description may give an erroneous impression that this process can be
accomplished in a linear fashion as listed .on the contrary iteration is required within the
entire process moving from any step back to any previous step in all possible combination
and doing this repeatedly. The best ideas are generated at the step (5) will invariably be
discovered to be flawed when later analysed. Thus the step of the ideation will be necessary
in order to generate more solution thus the return to the background phase may be necessary
to gather information. The task specification may need to be refined if it turn out to be
unrealistic.
4.3Definition Stage
The first definition of the project in clear and concise manner is sheet metal rolling machine
that means bending long rectangular bars, sheet and rods into cylinders. Machine should be
operated manually. Bending of the sheet should be based on the three roller bending
concept.

4.4Assumptions
• Plate, sheet or metal is always having line contact with the roller which is parallel to
roller axis during the process.

• The forces acting during the bending are larger than the self- weight of the plate. So
these-self weight of the plate is neglected.
 • The shift of the neutral plane is zero, i.e., it is considered to be at the centre-line of the
plate, sheet or desired metal thickness.

• Frictional force at the bottom roller and the plate interface is always tangent to the roller
surface.

• Rollers are assumed to be rigid. Roller material and plate material is assumed to have
stable microstructure throughout the deformation process.

• Deformation occurs under isothermal conditions and E, i.e., Modulus of Elasticity

Remains constant during the process.

• Plane section remains plane, before and after the bending. Blank thickness (t) remains
constant during and after the bending.

• Some effect are neglected. Blank is having uniform/constant radius of curvature for the
supported length of the blank between two bottom rollers.

• Further simplifying assumptions are discussed as and when required during the
Formulation.

4.5 Preliminary stage

• This stage we will define the experimental setup and the design outline that we have to
go with.
The reasons and justification for these decisions are documented.

• The design sketches so submitted will clearly explain the intentions of a designer and
will be understandable to another engineer or even to one self after the time has passed.

• It is an observed and experienced fact.

• The purpose of the PDR is to insure that the project is on schedule for going into the
detailed design phase. Having others from outside your group look over your project
will hopefully result in an improved product. The design review is informal, but
sloppiness in presentations will not be viewed favourably.

• In this stage we have studied various products in the market and then defined our criteria
of going further with the design so intended for the purpose

• This machine is available in different types and shapes depending on the type of metal to
be rolled
5 Chapter five.
5.1 CONCLUSION
The mechanism is widely used in workshops, industries for roll 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.

5.2 REFERENCES
[1] V. B. Bhandari,“Design of Machine Elements” Mc Graw Hill, ISBN, 2012.

[2] Hiroyuki goto, Kenichiru, Hidenobusaitro, Yuuishikura and Yutaka tanaka,

"Applications with a new 6- dof bending machine in tube forming processes".

[3] Jose Vitor Souze, International Journal of Machine Tools &Manufacture, 2002.

[4] Z. Hu, R.Kovacevic, M.Labudovic, “Experimental and numerical modelling of

buckling instability of laser sheet forming”, International Journal of Machine Tools &
Manufacture, 2002.

[5] Nayyar, P.E., Mohinder L. "A1". In Mohinder L. Nayyar, P.E...Piping Handbook (7th
Ed.). New York: McGraw-Hill. ISBN, 2000.

[6] Effect of internal pressure and shape imperfections on plastic loads of pipe bends
under in-plane closing moment. Christo Michael, A.R.Veerappan, S. Shanmugan,
Engineering Fracture Mechanics 105(2013)1 – 15.

[7] Cherniy.V.P. Effect of Curved Bar Properties on Bending of Curved Pipes. Journal of
Applied Mechanics, Vol. 68, pp.650 – 655, 2001.

[8] Cherniy. V. P. The Bending of Curved Pipes With Variable Wall Thickness. Journal
of Applied Mechanics, Vol.
70, pp. 253 – 259, 2003