A Project Report onPIPE BENDING MACHINE Submitted in the partial fulfilment of the requirements for the award of degree of BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING By (1) MAYATEET KUMAR (43) (2) MD. FIRDAUS ANSARI (44) (3) MOHAMMAD HASSAAN (45) (4) NASIMUL HODA (49) Under the valuable guidance of Amit Meena Asst. Professor DEPARTMENT OF MECHANICAL ENGINEERING FACULTY OF ENGINEERING AND TECHNOLOGY GURUKUL KANGRI UNIVERSITY, HARIDWAR, UTTARAKHAND NOVEMBER 2014. MOHAMMAD HASSAAN and MAYATEET KUMAR in partial fulfilment of the requirements for the award of the Degree of Bachelor of Technology in Mechanical Engineering from Faculty of Engineering and Technology Gurukula kangri University.FIRDAUS ANSARI. Amit Meena HOD. NASIMUL HODA.Mechanical Engineering GKV. Mr. Haridwar GKV. Prof. . The results embodied in this project have not been submitted to any other university or institute for the award of any degree or diploma. Mechanical Engineering Asst. Sanjeev Kumar Lamba Mr.CERTIFICATE This is to certify that the project report entitled “PIPE BENDING MACHINE” being submitted by MD. Haridwar. Uttarakhand is a record of bonafide work carried out by them under the guidance and supervision. AKNOWLEDGEMENT It is with immense pleasure and satisfaction that we present our first attempt in practical experience in the form of project work. We wish to express our gratitude to Mr. We would like to express heartfelt thanks to Mr. Mechanical Engineering for their guidance and encouragement they have given throughout the course of the project work. R. First of all we would like to express our sincere thanks to our Dean Dr. AMIT MEENA who guided us and supported us towards the completion of project. We would like to take this opportunity to thank one and all. November 2014 MD.D. SANJEEV LAMBHA Head of The Department. KAUSHIK. There are many people who helped us in successful completion of our project. for providing congenial atmosphere to carry out our project work. Firdaus Ansari Nasimul Hoda Mayateet Kumar Mohammad Hassaan . In our project Pipe Bending Machine various diameters of pipe is being bend with the help of this machine and various shapes is obtained like v-shape. Production and manufacturing process deals with conversion of raw materials inputs to finished products as per required dimension.ABSTRACT Mechanical Engineering without production and manufacturing is meaningless. The new development and requirements inspired us to think of new improvements in manufacturing field. circular. . specification and efficiently using recent technology. It is widely used in various industrial operation such as bending a tube to make coil or sheet metal to make certain shape such as ‘V’ shape. square. channel etc. 6 WORKING………………………………………………………………………………6 CHAPTER 5…………………………………………………………………………….2 2.2 2..1 Tube bending……………………………………………………………………….2 Specification…………………………………………………………………………5 CHAPTER 4……………………………………………………………………………...5 2...1 Overview………………………………………………………………………..10 CONCLUSION……………………………………………………………………………10 CHAPTER 8………………………………………………………………………………....11 REFERENCE…………………………………………………………………………….7 CHAPTER 6………………………………………………………………………………8 APPLICATION AND ADVANTAGES…………………………………………………8 6.………1 1.1 Design……………………………………………………………………………….II CHAPTER 1…………………………………………………………………………….1 Application………………………………………………………………………….2 Advantages…………………………………………………………………………….5 2...1 CHAPTER 2……………………………………………………………………………2 TYPES OF BENDING MACHINE……………………………………………………..12 .....1 1..2 Circle bending………………………………………………………………………..1 INTRODUCTION…………………………………………………………….….....3 Channel bending…………………………………………………………………….2 Need for pipe bending machine…………………………………………………….CONTENTS Content Page No List of Figures………………………………………………………………….4 Square bending………………………………………………………………………4 CHAPTER 3……………………………………………………………………………..8 6.9 CHAPTER 7……………………………………………………………………………….……….3 2.....5 DESIGN AND SPECIFICATION OF BENDING MACHINE……………………….11 FUTURE SCOPE…………………………………………………………………….7 CALCULATION……………………………………………………………………….2 2.. 2.3 Circle bending 3 2.4 Channel bending 3 2. Figure Name Page No.2 Tube bending operation 2 2.5 Square bending 4 4 Pipe bending machine 6 II .1 Tube bending 2 2. no.List of Figures Fig. type of the roller bender. 1 . etc. power driven or manual and the size of the bending machine. Today. As far as industrial application is concerned it is used for piping purpose. without this bending device a machine can’t work properly. and iron angle. The bending machines found in the market come from variety of types. U-shape. or channel shape along a straight axis in ductile materials.1 Overview A bending is a process of bending a metal. brake presses. most of the machine uses roll bending type. Usually. This type of metal has its own thickness. The metal can be a sheet metal. most commonly sheet metal. roll bending machine and a folding machine. There are bending machine such as press brake bending machine. The sheet metal needs to put in the roller and then rolls around it until the desire shape is acquired. square hollow. tubes. It is also used in designing of various machine components.2 Need for Pipe Bending Machine As we know that pipe bends are used in various household things therefore it is necessary to build a economical pipe bending machine. Moreover. The reason to design a bending machine is because there is no proper bending machine to bend a solid or hollow pipe for small scale. 1. Many machine makers vary their products based on the capacity of the bending machine and power driven or manual. This type of machine has 3 rolls which is 1 roll is fixed and the other 2 are adjustable. 1. the difference of these types of bending machine is only on the capacity of the bending machine that can bend a sheet metal or tube. truncated cone.CHAPTER 1 INTRODUCTION Bending is a manufacturing process that produces a V-shape. Commonly used equipment includes box and pan brakes. The products that can be produced with this machine are coil. In bending machine designing several considerations is taken into including type of metal. the bending machine that available in the market is for the sheet metal and tube bending machine. rod. and other specialized machine presses. The Forming Roller and Radius Collar must be grooved to exactly fit the tube and the tube must not be allowed to slip during the bending operation as even a slight amount of slippage will cause distortion.1 Tube Bending The Forming Roller method of tube bending is recommended for all large bends where the centerline radius is at least 4 times the outside diameter of the tube. It can also be successfully employed for bending pipe or heavy wall tubing to smaller radii and is the most practical method of bending very small diameter tubing.1 Tube Bending. 2 .CHAPTER 2 TYPES OF BENDING MACHINE 2. Fig: 2. Fig: 2.2 Tube bending operation. if a sharp 90° bend is desired. as the “spring back” varies in different materials.4 Channel bending. Actual size can best be determined by experiment.3 Circle Bending. 2. To compensate for this. Fig: 2. Fig: 2. 3 . it can be obtained by cutting a notch out of the channel flanges before forming around a special Zero. it is often necessary to use a Radius Collar having a smaller diameter than that of the circle required. Material should be precut to exact length before forming.2.3 Channel Bending: The same general bending rules which cover the forming of channel with “flanges out” also apply when it is formed with “flanges in.” Since it is necessary to compress the flanges as they are bent inward. the operation shown below requires considerably more bending pressure than when forming with the “flanges out” and it is recommended that the largest possible radius be used to allow for compression of the material.2 Circle Bending: This operation is somewhat involved by the fact that most materials “spring back” after they have been formed. 5 Square bending. when squares larger than 1” are needed. Forming Nose “leads” material between corners of the block.4 Square Bending: Forming zero radius bends around square. or other multisided blocks employs the same principle used in scroll bending. By following the procedure outlined on.Radius Block as illustrated. Fig: 2. In general. rectangular. Any number of zero radius bends can be obtained in one operation by this method in all types of solid materials. Both centered and off-center square eye can also be formed by following the same procedure outlined on. To form channel with the flanges facing upward it is necessary to first fill it with Cerro bend or some other commercial filler as it is not possible to support the flanges in this position with a radius Collar. they should be formed in progressive operations using the zero radius blocks. This method of bending is limited by the size of the square block and the ductility of the material. 4 . the circle can be formed in three operations. It is sometimes possible to make a circle in channel by using a segment of a Radius Collar similar. 2. 3.It is used to support the rod or pipe at other side. No Components Specification 1.It is located on the stand which provides strength to the rod. MOTOR power= . d) STAND. FRAME 2m x 1m 2.1 Design It consists of several parts namely:a) FRAME. b) MOTOR.5hp and speed= 40 rpm 3. c) DIE.CHAPTER 3 DESIGN AND SPECIFICATION OF BENDING MACHINE 3.2 Specification Sr.5m x 5m 4.The frame provides support to the entire machine components. STAND .A bending die consists of a vice which is welded to it and which is used to hold a pipe firmly. e) VICE.c source and it also consists of a bending die.It is fastened to the frame and draws power from a. DIE Radius=8cm and thickness=3cm 5 . the clamping block and the forming die. the wiper die and the pressure die. then the motor begins to produce torque and depending upon the dimension of the rod it is bend. Various die can be used as per requirements namely v-die. A pipe bending machine is a simple bending machine which is operated by a a. 6 .CHAPTER 4 WORKING Pipe bending as a process starts with loading a tube into a pipe bender and clamping it into place between two dies.c motor. The tube is also loosely held by two other dies.c or d. Fig: 4 Pipe bending machine. The power from the motor is transferred which rotates the circular plate in anticlockwise direction and bend the rod for given radius. roller die. First of all the rod to be bend is set in the vice of the machine and then power supply is put on. wiping die. The motor is attached to the frame of the machine and also consist of a circular die on which a vice to hold the rod is welded. etc. P = .8W P= (2ΠNT) /60 W T=89000 N-m Applying bending equation.5hp = 372. Using. M/I=E/R. Torque produced by motor = T Minimum diameter of rod = d Therefore P=.5hp Speed of motor.CHAPTER 5 CALULATION Given. Power of motor. N = 40rpm Radius of circular die = 8cm Modulus of Elasticity of iron rod = 210GPa To find. where M=moment or torque produced by motor I =polar moment of inertia of rod E =modulus of elasticity of rod 7 . 8 cm Diameter of rod.91*10-7 d = .8 cm 8 .R=radius of bend or die radius Therefore. I = (π÷64) ×d4 89000/[(π÷64) ×d4] =(210 * 109)/(8*10-2) d4 = (64*89000*8*10-2)/(3. d ≤ 2.0288 m d = 2.14*210*109) d4 = 6. Scroll Bending 6. U Hook 4. Rigid construction 9 .2 Advantages 1. Low cost 4. Simple construction 3. Easily operated 2.CHAPTER 6 APPLICATION AND ADVANTAGES 6.1 Applications: 1. Marine Tube 5. Metal Folding 3. Angle Bending 2. Heat Exchanger 6. In this project various pipe shape that is square. the various pipe bending machines consisting of various dies used for production in Industries are known in this project This bending tool is very useful in household application as it runs at very low cost and very efficient. a iron rod is efficiently bend for a given power of motor. whose diameter is 2.CHAPTER 7 CONCLUSION In this project . channel bend. 10 . v-shape.8 cm. circular shape are bend the rod at any angle. 11 . Although there is higher initial cost involved we have tried to make the system cost effective and also add different enhancements to make the system more efficient so that it may work around the year.CHAPTER 8 FUTURE SCOPE In the next stage we are trying to make a pipe bending machine which will be helpful in easy bending of pipes. 12 . Design of hydraulic pipe bending machine No.Bending Machine (tube bending) [2]Clifford M. Eastwood D. [3] Strength of Material – Er. 77 pp. for calculating minimum diameter of rod.J.269-280.REFERENCE [1] Wikipedia . (2006).. Rk Rajput.