ProjectDESIGN AND FABRICATION OF SHEET ROLLING MACHINE Report

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DESIGN AND FABRICATION

OF SHEET ROLLING

MACHINE

A PROJECT REPORT

Submitted by

K.FEROZE ALI 950612114030

S.ABDUL RHAMAN 950612114301

V.BALA SANKAR 950612114305

A.URUVARAN 950612114306

In partial fulfilment of the award of the degree

Of

BACHELOR OF ENINEERIN

in

MECHANICAL ENINEERIN

EINSTEIN COLLEE OF ENINEERIN

TIRUNELVELI

ANNA UNIVERSIT!" CHENNAI 600 025

APRIL#2015

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ANNA UNIVERSIT!" CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report $DESIN AND FABRICATION OF

SHEET METAL ROLLIN MACHINE% is the bonafide work of

$K.FEROZE ALI &950612114030'( S.ABDUL RHAMAN &950612114301'(

V.BALA SANKAR &950612114305'(A.URUVARAN &950612114306'%who

carried out the project work under my supervision.

SINATURE SINATURE

HEAD OF THE DEPARTMENT SUPERVISOR

M). K. A)*+ R,-( M.E.( &P.D.'( M). R. K,)/,( M.E.(

Professor, Assistant Professor,

Dept. of Mechanical n!ineerin!, Dept. of Mechanical n!ineerin!

instein Colle!e of n!ineerin!, instein Colle!e of n!ineerin!,

"irunelveli # $%& '1% "irunelveli # $%& '1%

(ubmitted )iva )oce *amination held at

+("+ C-/ -0 /++/, "irunelveli,

-n222222222

INTERNAL EAMINER ETERNAL EAMINER

%


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DEDICATED TO OUR FOUNDER

+t is honour to be the ninth batch of student of instein Colle!e of

n!ineerin! 3. 0ero4e Ali, (. Abdul haman, ). 5ala(ankar, A. /uruvaran,of

"hird year of Mechanical n!ineerin! takes this opportunity as a privile!e to

dedicate our project to T)*A+,A)*, M.A.( B.L.

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ACKNO7LEDEMENT

+t is our !reat privile!e to e*press hearty thanks to our Mana!in!

"rustee P)8. A. E:+;,, MBA or kind encoura!ement throu!hout this

project.

My sincere thanks to our Principal P)8.D). K. R,


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INSTITUTIOIN PROFILE

An adobe of e*cellence, a pinnacle of !lory, a name that deserves

mention whenever there initiates a discussion about the world of n!ineerin!> ?@

"yes of bendin! operation are classified into

9Die bendin!

)9Die bendin!

oll bendin!

5endin! in the four slide machine

Curlin!

Dimplin!

0lan!in!

9Die bendin! with sprin! pad

2.1 R8++ ?@

A continuous form from of three9point bendin! is roll bendin!, where plates,

sheet and rolled on each end, one of the support can often be swun! clear to

permit the removal of closed shapes from the rollsshapes can be bent to a

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desired curvature on formin! rolls. "hese machines usually have three roll in the

of a pyramid, with the two lower rolls bein! driven and the position of the upper

roll bein! adjustable by a frame

3.PROCESS OF ROLLIN

+n the first sta!e the plate is kept between top roller and bottom rollers as shown

in 0i!ure%.1 and the top roller is !iven vertical displacement to !et the re>uired

bend. +n ne*t sta!e the bottom rollers are driven usin! motors in forward

direction to !et the roll bendin! of the plate. (imilarly the rollers are driven

inverse direction to !et better dimensional accuracy of the final product. "he

bent plate is than unloaded by raisin! the top roller. 0or continuous sin!le9pass

four roll thin plate bendin! a model was proposed considerin! the e>uilibrium

of the internal and e*ternal bendin! moment at and about the plate9top roller

contact.

"hey had considered varyin! radius of curvature for the plate between the

rollers and proposed mathematical model to simulate the mechanics in a steady

continuous bendin! mode for four9roll thin plate bendin! process and also

investi!ated +n se>uence of material strain hardenin! on the mechanics of

steady continuous roll and ed!e9bendin! mode in the four9roll plate bendin!

process 0or continuous multi9pass bendin! of cylinder on 69roller bendin!

machines EcylindricalF rollers, "hey incorporated the effect of chan!e of youn!

modulus durin! the deformation in the formulation to study the effect on sprin!

back prediction. 0or plane strain of sheet metal subjected to strain rate effects

durin! cyclic bendin! under tension.

F@*) 3.1" P)8>> 8 )8++@

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"he roll bendin! process is used to be observed from the literature reviewed that

conical bendin! process is untouched area as far as force prediction is

concerned. ven in the industries the normal practice of plate roller bendin! still

heavily depends upon the e*perience and the skill of the operator. 7orkin! to

templates, or by trial and error.

4. STRESSES INDUCED IN SHEET METAL

"he workin! by bendin! of work9pieces creates inner of this in deformed 4one

stresses in tan!ential and radial directions. "he metal strata placed to curvin!

centre are pressed in tan!ential directions, becomin! shorter and in especially

cases are stretchin!in transversal direction. "he metal strata placed to e*ternal

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piece are stretchin! in tan!ential direction and in especially cases are pressed in

transversal direction, makin! the piece narrowin!. 5etween the stretchin! and

pressin! strata is founded the neutral status. "he neutral status with the radius is

foundin! displaced to the curvin! centre before the wei!ht centre,

4.1 S/)>> * >/


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5.1 S/> )8++@

6. DESCRIPTION OF THE MACHINE

1$


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"he (heet Metal ollin! Machine works accordin! to the principle of

three point bendin!. "he rotation of the driven rolls bein! utili4ed to feed the

metal throu!h the rolls by means of the frictional forces present between the

surface of the rolls and sheet. o lubricant is used at its presence interference

with the ability to !rip. (heet Metal ollin! Machine essentially consists of

three rollers, used to manufacture circular components like cylinders. (heet

Metal ollin! Machine is classified into two types based on the arran!ement of

the rollers. "hey are as follows.

1. Pinch type machine

%. Pyramidal type machine

"his 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.

6.1 S/ )8++@


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. 7ORKIN PRINCIPLE

"he (heet Metal, which is to be formed in cylindrical shape, is present at

the ed!e by hammerin!. "o start the operation easily and to avoid flats at the

be!innin! and at the ends of the rolled form. +n rollin! cylindrical shapes a

!radual curve is to be put in the metal rather than sharp bends. ow the sheet

metal is introduced between the top and the bottom rolls, the !ap between the

top and bottom rolls are adjusted as per the re>uired diameter by re!ulatin! the

screw rods.

"he rollers were arran!ed in trian!ular form< two sets of rollers below and

one above. "he upper roller providethe bendin!forcewhilethebackbaseroller

provides the re>uired drivin! force and the front end

oller bends the metal accordin! to set radius of bend. Aperture adjuster on

each block assembly ensure loadin! of workpiece and adjustment to re>uired

radius of bent. "hefreeendofthetopbearin!blockis sprin!loadedtoincrease or

toreducetop9baseroller clearance. "wootherboresoneach bearin! blocks provide

an adjustment for the roller !ap variability. "op roller

Provides the bearin! load Ebendin! forceFand also compliments the drivin!

roller when workin! on thick materials. "helowerbackroller provides the

necessary drivin! forces while the idler roller does the bendin! and material

delivery. "here are two crank levers, one on the toprollerand anotheronthefront9

end roller. "he lever EhandleF couplin!head hasas>uare confi!uration

whichfitsinto thes>uareendoftherollershaft.

"he frame structure made ofE='G='G=Fmm an!le iron for the purposes of

stren!th. "he tool table is provided below the rollers for safe keepin! of tools

and cranks. "herollerhead assembly is detachablefrom

theframeandcanbemountedonatable tobeused asatabletop machine fortinkerin!

works.

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=.DESIN

.1/eneral desi!n principles

0ollowin! basic shearin! operation on a sheetmetal, components

canberolled to !ive it a definite shape.

5endin!ofpartsdependsuponmaterial propertiesatthe location ofthebend.

"oachievebendin!,thework materialmust be subjected to twomajorforcesue applied to

move the material. 0i!.1

.1(hape rollin!mechanism

7here,aHdistancefrome*it4onetotheno9slippointEassumeaHLI%Fuare to ei!ht times internal radius

H(0.0824 )2

80.048

H'.'1&m

%;


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"he plate will under!o elastic sprin! back after the ma*imum bendin! moment

has been applied. "he rela*ed radius, after sprin! back, of the plate may be

determined from the followin! e>uation.

MHb t

2

4

=594.67106 N

m2

M H594.6710

60.450.001

2

4 H$$.? m

+Hb t

3

12 H0.40.001

3

12 H6.666 1011

1

e=

66.89

2071093.33310

11 H?.&';m

p H Ri+t

2 H'.$6N'.'''=H'.$6=m

1

r=

1

0.08635

1

0.103= 1.&%m

r= '.=6;m

pper roll vertical force applied on the plate EPvF

%=


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$$.?H P

v

(1

4

+0.017

2

tan48.7

)PV= %=&.=?

"he lower rolls force to drive the plate is

Pl= 257.59

2 cos 48.7 H1?=.1;

"he side thrust force on the plate is

Ps H1?=.1;48.7= sin 1;$.$'

Power re>uired for drivin! the machineB

PH(MpVr ) H(66.890.0215

0.534 ) H%.$?kw

"he tor>ue re>uired to roll the plate is calculatedB

"H(Mp rlr ) H(66.8925

0.534 )= 6161.==9mm

(haft diameterB

0or !reater stren!th ;=c EsteelF is common for shafts

%$


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(yt H ='N

mm2

(ut H &&'N

mm

2

sin! ma*imum shear stress theory of failureB

max

H( ) ( )

ttbb MKMk

d+

%

6

1$

Mt

H n

P

%

F1'$'E $

H0.09260

2 0.025= 6=rpm

0or roller speed of 6=rpm O with %.$?kw

Mt H( (60106 )2.69

235 ) H&.66 105 9mm

Kb H1.=, Kt H1

max '.6sytH '.6E='F H 1&;Imm%

max H '.1sut

H '.1E&%'F H 16.$Imm%

%&


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"akin! the min value of 16.$ Imm%

d3 H ( 16 138.6 )(1.51942300 )2+(1733931.65 )2

dH;&.?&mm let d be ='mm EstandardF

9.S!NOPSIS

+n (heet Metal workin! industry a wide ran!e of power and hand operated

machines are used. As the sheet metal industry is a lar!e and !rowin! industry

different type of machines are used for different operations. -ur project the

sheet metal rollin! is very simple in operation by usin! roller which is coupled

with handle. "his machine produces cylindrical objectives of different

diameters. "his machine can be used in various fields. "his machine consist of

three roller which is coupled with a handle and connectin! the handle shaft withworm shaft. "his machine is simple in construction and workin!.

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10.APPLICATIONS

(heet Metal rollin! machine is used to make,

-uter cylindrical casin! for motors employed in submersible

pumps.

8ydraulic and pneumatic cylinders

5odies of shells and condensers

Dairy e>uipment

Compressors stora!e tanks etc2

+t is also used to make cylinders of different diameters

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11.ADVANTAES

-peration of this machine is very simple

nit is compact so less space is re>uired

o hand tools are re>uired

Cylindrical shaped objects of dia ='mm to %%=mm can be

produced

"he dia can be easily operate this machine

"he machine is hand operated. (o the cost of the finished

product will be less.

"he total cost of the machine is less.

Maintenance of this machine is very easy.

asy to handle

ess effort O productive

asy to install at any were

(killed workers are not re>uired

Convenient for mass production ess in wei!ht

6'


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12.DISADVANTAES

"his machine has a hand operated one

Production time is hi!h.

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13.ESTIMATION AND COST ANAL!SIS"

(.

-

AM -0 MA"+A( A"+"L AM-"

1.

%.

6.

;.

=.

$.

&.

(teel 8ollow (haft

(teel (>uare Pipe

5ase

ut and 5olt

5earin!

7eldin! 7ork

Cuttin! 7ork

6

%

1

$

$

TOTAL

1=''

=''

=''

1''

;''

=''

=''

;'''I9

6%


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66


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6;


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6=


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ProjectDESIGN AND FABRICATION OF SHEET ROLLING MACHINE Report

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