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7/25/2019 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
1
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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.
6
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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
1%
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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++@
16
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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
1;
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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.
1
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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.
61
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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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