DESIGN AND FABRICATIONOF SHEET ROLLING MACHINE A PROJECT REPORT Submitted by K.FEROZE ALI 950612114030 S.ABDUL RHAMAN 950612114301 V.BALA SANKAR 950612114305 A.GURUVARAN 950612114306 In partial fulfilment of the award of the degree Of BACHELOR OF ENGINEERING in MECHANICAL ENGINEERING EINSTEIN COLLEGE OF ENGINEERING TIRUNELVELI ANNA UNIVERSITY: CHENNAI 600 025 APRIL-2015 1 ANNA UNIVERSITY: CHENNAI 600 025 BONAFIDE CERTIFICATE Certified that this project report “DESIGN AND FABRICATION OF SHEET METAL ROLLING MACHINE” is the bonafide work of “K.FEROZE ALI (950612114030), S.ABDUL RHAMAN (950612114301), V.BALA SANKAR (950612114305),A.GURUVARAN (950612114306)” who carried out the project work under my supervision. SIGNATURE SIGNATURE HEAD OF THE DEPARTMENT SUPERVISOR Mr. K. Arul Raj, M.E., (Ph.D.), Mr. R. Karthikeyan, M.E., Professor, Assistant Professor, Dept. of Mechanical Engineering, Dept. of Mechanical Engineering Einstein College of Engineering, Einstein College of Engineering, Tirunelveli – 627 012 Tirunelveli – 627 012 Submitted Viva Voce Examination held at EINSTEIN COLLEGE OF ENGINEERING, Tirunelveli, On……………………… INTERNAL EXAMINER EXTERNAL EXAMINER 2 DEDICATED TO OUR FOUNDER It is honour to be the ninth batch of student of Einstein College of Engineering K. Feroze Ali, S. Abdul Rhaman, V. BalaSankar, A. Guruvaran,of Third year of Mechanical Engineering takes this opportunity as a privilege to dedicate our project to ThiruAladiAruna M.A., B.L. 3 . We also thank God and our Parents for their immense help an support to make this project. Arul Raj M. We sincerely thank all the faculty members of our department and our lab in-charges for their immense help during the course of the project.Dr. Ramar Ph. 4 . A. We gratefully thank our guide Mr.I.E.). who gave us the opportunity to make a useful contribution to our project and to set a worthy present for the student’s community. We sincerely and whole heartedly thank our Head of the Department. for kind encouragement in carrying out this project.E. F.D.D. for his effective support for our project. K. My sincere thanks to our Principal Prof.M. (Ph.R.. Karthikeyan.ACKNOWLEDGEMENT It is our great privilege to express hearty thanks to our Managing Trustee Prof. Ezhilvanan MBA or kind encouragement throughout this project. M. Mechanical Mr.M.E..E.BALA RAMA MOORTHY. We gratefully thank our co-ordinator Mr.. K. who guided us to make a special contribution to the project.. From the year 2004. The institution was found by Late Mr. The College maintains a royal existence with its marvelou infrastructure and widely acclaimed for its meticulous planning. The College embarked on programs of the college offers 5 B. Govt. resource scheduling and institutional management. a prolific reader and great orator. was one of the senior most politician of Tamil Nadu with a great vision for providing high quality technical education to the rural and the weaker section. the college is situated in Sir.A.AladiAruna. He was a Member of Parliament and MLA for more than a decade and was also the Minister of Law. C. About 15 km away from Tirunelveli towards the well-known Courtralam.L... former Tamil Nadu Law Minister in 2004. a pinnacle of glory. Our founder son of the soil Thiru.V.E. B.E. degree courses. The College also offers 6 M.INSTITUTIOIN PROFILE An adobe of excellence. 5 . Einstein College of Engineering. Raman Nagar. of Tamil Nadu 19962001. courses in Engineering and Master of Business Management. The Institution is spread over an area of about 30 acres. a name that deserves mention whenever there initiates a discussion about the world of Engineering. with the sole purpose of providing cutting edge technical education that is both accessible and affordable. AladiAruna M. The project employee by using the roller for bending purpose by manual. In Sheet Metal working industry a wide range of power and hand operated machines are used. This project facilitates in making bending accurate in sheet metal with easy. Our project the sheet metal rolling is very simple in operation by using roller which is coupled with handle.ABSTRACT This project work titled “SHEET ROLLING MACHINE” has been conceived having studied the difficulties in making bending in sheet metal. This machine can be used in various fields. This machine is simple in construction and working. 6 . we are ANNA focused UNIVERSITY in the area of “MANUFACTURING TECHNOLOGY” subject which we have studied in previous semester by getting basic ideas from it.MECHANICAL curriculum to fulfil the ENGINEERING above. We have designed and fabricated “SHEET METAL ROLLING MACHINE” and calculated the experimental results theoretically 7 .PROJECT OBJECTIVE To implement the skills acquired in previous semester to practical problems as prescribed in ME-68 DESING AND FABRICATION PROJECT. 1Shape rolling mechanism 19 8.1 Sheet rolling machine 17 8.1: Process of rolling 14 4.LIST OF FIGURE PAGE NO 1.1 Stress in bending 12 3.1 Stress induced in sheet metal 15 5.2 Stress and Strain Curve for Steel20 8.4 Geometrical analysis 22 8 .1 Steps in rolling 16 6.3 Plastic Theory of Bending 21 8. Description of the machine 17 7. Advantages 30 9 . Design 19 8. Steps in rolling 16 6.2 Stress and strain in steel 20 8.4 Design calculation 22 9.1 Roll bending 13 3. Synopsis 28 10. Stress induced in sheet metal 15 5.LIST OF CONTENT Page No 1. Application 29 11. Working principle 18 8. Process of rolling 13 4. Introduction 11 2.1 General design principles19 8. Bending 12 2.3 Plastic theory of bending 21 8. 12. Disadvantage 31 13. Estimation of cost analysis 32 10 . copper sheet.1. which can be seen in our everyday lives. aluminium plate. INTRODUCTION Sheet Metal industry is a large and growing industry. The article in the shape of cylinders is made by rolling roller. In forming cylindrical shapes a gradual curve is to be put in the metal rather than sharp bends. There are many special purposes machines used in this industry to-day. stainless sheet and brass sheet. Rolling operation can be done on hand or power operated rolling machines. tin plate. The gap between the rollers can be regulated by hand operated screws Sheet metal is available in flat pieces or as a coiled strip. There are many examples of Sheet Metal work. Rolling is the process of bending sheets to a curved form. Various forming process in sheet metal include Punching Roll forming Rolling Spinning Stamping Bending Deep drawing Expanding Curling Press brake forming 11 . The proper selection of the machines depends upon the type of the work under-taken by the particular industry. The metals generally used for Sheet Metal work include black iron sheet. Our project the “SHET METAL ROLLING MACHINE” finds huge application in Sheet Metal industry. where plates.1 1. Decambering Ironing Laser cutting Incremental sheet forming etc. During bending the top layers are subject to tension and the bottom layer are subjected to compression. BENDING Bending is one of the most common forming operations.1 Stress in bending Tyes of bending operation are classified into U-Die bending V-Die bending Roll bending Bending in the four slide machine Curling Dimpling Flanging U-Die bending with spring pad 2. one of the support can often be swung clear to permit the removal of closed shapes from the rollsshapes can be bent to a 12 . We merely have to look at the components in an automobile or at a paperclip to see how many parts shaped by bending. sheet and rolled on each end.1 Roll bending A continuous form from of three-point bending is roll bending. The width of the part in the outer region is smaller and in the inner region it is larger than the original width because of the poisson ratio as shown in fig 1. result in the plane surface at an angle to the original plane. 2. Bending is usually defined as the deforming of the sheet metal along the straight line around a straight axis called neutral axis. 1 and the top roller is given vertical displacement to get the required bend.desired curvature on forming rolls. These machines usually have three roll in the of a pyramid. They incorporated the effect of change of young modulus during the deformation in the formulation to study the effect on spring back prediction. For continuous single-pass four roll thin plate bending a model was proposed considering the equilibrium of the internal and external bending moment at and about the plate-top roller contact. with the two lower rolls being driven and the position of the upper roll being adjustable by a frame 3. In next stage the bottom rollers are driven using motors in forward direction to get the roll bending of the plate. Figure 3. The bent plate is than unloaded by raising the top roller.PROCESS OF ROLLING In the first stage the plate is kept between top roller and bottom rollers as shown in Figure2. Similarly the rollers are driven inverse direction to get better dimensional accuracy of the final product. For plane strain of sheet metal subjected to strain rate effects during cyclic bending under tension.1: Process of rolling 13 . They had considered varying radius of curvature for the plate between the rollers and proposed mathematical model to simulate the mechanics in a steady continuous bending mode for four-roll thin plate bending process and also investigated In sequence of material strain hardening on the mechanics of steady continuous roll and edge-bending mode in the four-roll plate bending process For continuous multi-pass bending of cylinder on 3-roller bending machines (cylindrical) rollers. STRESSES INDUCED IN SHEET METAL The working by bending of work-pieces creates inner of this in deformed zone stresses in tangential and radial directions. Even in the industries the normal practice of plate roller bending still heavily depends upon the experience and the skill of the operator. The metal strata placed to curving centre are pressed in tangential directions. 4.The roll bending process is used to be observed from the literature reviewed that conical bending process is untouched area as far as force prediction is concerned. The metal strata placed to external 14 . becoming shorter and in especially cases are stretchingin transversal direction. or by trial and error. Working to templates. Between the stretching and pressing strata is founded the neutral status. making the piece narrowing. The neutral status with the radius is founding displaced to the curving centre before the weight centre.STEPS IN ROLLING 15 .1 Stress induced in sheet metal 5.piece are stretching in tangential direction and in especially cases are pressed in transversal direction. 4. 1 Steps in rolling 6. DESCRIPTION OF THE MACHINE 16 .5. The Sheet Metal Rolling Machine works according to the principle of three point bending.1 Sheet rolling machine 17 . Pyramidal type machine This machine is of pinch type here only the top roll serves as a driven. They are as follows. Sheet Metal Rolling Machine essentially consists of three rollers. 6. Pinch type machine 2. 1. used to manufacture circular components like cylinders. bottom roller are idler and rotates on friction with the work metal blank. Sheet Metal Rolling Machine is classified into two types based on the arrangement of the rollers. No lubricant is used at its presence interference with the ability to grip. The rotation of the driven rolls being utilized to feed the metal through the rolls by means of the frictional forces present between the surface of the rolls and sheet. the gap between the top and bottom rolls are adjusted as per the required diameter by regulating the screw rods. which is to be formed in cylindrical shape. There are two crank levers. The rollers were arranged in triangular form. Now the sheet metal is introduced between the top and the bottom rolls. Top roller Provides the bearing load (bending force)and also compliments the driving roller when working on thick materials. The lever (handle) couplinghead hasasquare configuration whichfitsinto thesquareendoftherollershaft. The upper roller providethe bendingforcewhilethebackbaseroller provides the required driving force and the front end Roller bends the metal according to set radius of bend. The tool table is provided below the rollers for safe keeping of tools and cranks. 18 . In rolling cylindrical shapes a gradual curve is to be put in the metal rather than sharp bends.7. To start the operation easily and to avoid flats at the beginning and at the ends of the rolled form. The frame structure made of(50×50×5)mm angle iron for the purposes of strength. is present at the edge by hammering. Thelowerbackroller provides the necessary driving forces while the idler roller does the bending and material delivery. Therollerhead assembly is detachablefrom theframeandcanbemountedonatable tobeused asatabletop machine fortinkering works. one on the toprollerand anotheronthefrontend roller. Aperture adjuster on each block assembly ensure loading of workpiece and adjustment to required radius of bent. WORKING PRINCIPLE The Sheet Metal. two sets of rollers below and one above. Twootherboresoneach bearing blocks provide an adjustment for the roller gap variability. Thefreeendofthetopbearingblockis springloadedtoincrease or toreducetop-baseroller clearance. 1 8.T=torqueappliedtorollers. Toachievebending. A work material under bending load is subjectedtosomeform 19 .L=rollgap.DESIGN 8.μ=frictionalforce. Bendingofpartsdependsuponmaterial propertiesatthe location ofthebend.8. frictional forcewhich causesano-slip actionwhenmetalandroller cameincontact anda bendingforceactingagainst the forward speed and the torque applied to move the material.1Shape rollingmechanism Where.hf=thicknessof thesheet before and after timet. components canberolled to give it a definite shape. Atleast two rollers were involved in flatrolling dependingonthe thicknessand properties ofmaterial whilethreeormultiplerollersystem isrequiredinshape rolling.a=distancefromexitzonetotheno-slippoint(assumea=L/2).1General design principles Following basic shearing operation on a sheetmetal.ho. F=forceappliedtorollers. Fig8.thework materialmust be subjected to twomajorforces. r=radiusofrollers. The plastic part of the deformation is permanent and it is not recovered when the sheet is unloaded by removing it from the roll system. is a process for forming plates. The elastic part of the deformation is recovered up on removal of the load.2 Stress and Strain in steel: Bending is a process by which a metal can be deformed by plastically deforming the material and changing its shape. The material is stressed beyond the yield strength but below the ultimate tensile strength. bars. sheets.ofresidualstressanddeformation asit bends. beams. has both elastic. [also known as roll bending]. angles or pipes into various shapes by passing the work piece between the properly spaced rolls. This phenomena is known as “spring back” or elastic recovery 20 . deformation imposed on the sheet when it is forced to conform to the rolls. Materials at the outerbend radiusundergo tensile plastic deformation whilethematerial at theinner bendradiusundergoescompressiveplasticdeformation. Because of the elastic plastic behaviour of the sheet material. Roll forming. Sheet and plate are the mill products often formed by the roll bending process. 8. the plastic moment of the rectangular section 21 . Thus at plastic hinge.2Stress and Strain Curve for Steel 8. Further each of these loads acts at a distance d/4 from the neutral axis. The total loads above and below the neutral axis NA are both equal to in magnitude but opposite in direction.8.3 Plastic Theory of Bending: (a) Fully elastic state(b) partially plastic state (c) fully plastic state Fully Plastic Rectangular Section: For the rectangular section of width b and depth d the plastic moment of the resistance of plastic hinge can easily be found. E=207GN/ m 2 Elastic limit (yield stress) σ y =515MN/ m Poisson’s ratio=0.4 Geometrical analysis FORCE ANALYSIS: The material selected for analysis is mild steel.4 Design Calculation: 8. The mild steel plate Properties are 2 Young’s Modulus.34 Given data from the specification of the machine 22 .8. 048m 23 .The plate thickness t=1mm Upper roller diameter.025 2 0.5m/s Using a geometrical analysis based on the assumption that the deflected form of the plate is an arc of a circle and this analysis is used to predict the upper roll vertical force. du=50mm Lower roller diameter dl=50mm Lower rolls centre distance 2f=120mm Theplate rolling speed v =5.025 0.06 2 K=0. the torque required for bending and other requirements K= √(R i+ r l)2 −f 2 = 0. 06−2 ¿ l=0.048 δ =0.025+0.025+ 0.06 2−0.025 sin ¿ ¿ 2∗0.7 o To find the length: 48.0824 )2 8× 0.863+ 0.0824m The deflection of the plate below its support point is calculated by taking the ratio of length square to eight times internal radius = ( 0.0863m To find the shift of contact angle(θ) of bend plate with rolls: sin θ= f (R i+ r l+ t) −1 θ=sin 0.025−0.0262 = 2 ( 0.017m 24 .048−0.025 )2 +0.001) = 48. 2 f 2 t rl K ru Ri 2 2 ru rl t K ( 0.7 0.048 ) =0.06 (0. 45 ×0.08635 0. M= σ =594.0005=0.89 = 9 ρe 207 ×10 ×3.0013 12 1 66.333 ×10−11 ρp = Ri + t 2 =66. The relaxed radius.103 ρr =¿ σb t 2 4 1.534m Upper roll vertical force applied on the plate (Pv) 25 .0012 M= 4 I= b t3 12 = 0.67 × 106 × 0.872m 0. of the plate may be determined from the following equation.4 ×0. after spring back.333 ×10−11 =9.67× 106 N m2 594.704m =0.8635m 1 1 1 = − =¿ ρr 0.89 Nm =3.863+0.The plate will undergo elastic spring back after the maximum bending moment has been applied. 7 ( PV =¿ ) 257.017 66.69kw The torque required to roll the plate is calculated: T= M p rl ρr ( )=( 66.59N The lower rolls force to drive the plate is Pl= 257.59 2× cos 48.89× 25 =¿ 0.1 0.7 =195.89= Pv 4 + 2 tan 48.534 ) =2.14 48.534 ) Shaft diameter: For greater strength 45c8 (steel) is common for shafts 26 3131.7=¿ × sin ¿ 146.89× 0.0215 0.60N Power required for driving the machine: P= MpV ρr ( )=( 66.55N-mm .14N The side thrust force on the plate is Ps =195. 33 ×105 N-mm =1 = 0.6N/mm2 ut 27 .5.69kw ( ( 60 ×106 ) ×2.092 ×60 =¿ 2 × π ×0.3(580) = 174N/mm2 τ max = 0. τ max 2× π ×35 Kt ) =7.18(720) = 138.69 Mt = Kb =1.18s = 0.3syt = 0.025 35rpm For roller speed of 35rpm & with 2.Syt = 580 Sut = 770 N 2 mm N mm2 Using maximum shear stress theory of failure: τ max Mt = = 16 d 3 kb M b 2 K t M t (60 10 6 ) P 2n = 0. Our project the sheet metal rolling is very simple in operation by using roller which is coupled with handle. This machine consist of three roller which is coupled with a handle and connecting the handle shaft with worm shaft.5 ×1942300 ) +( 1 ×733931.SYNOPSIS In Sheet Metal working industry a wide range of power and hand operated machines are used.65 ) 2 2 d=47. This machine produces cylindrical objectives of different diameters. This machine can be used in various fields.6 ) √( 1. This machine is simple in construction and working. As the sheet metal industry is a large and growing industry different type of machines are used for different operations.Taking the min value of 138.6 N/mm2 d 3 = 16 ( π ×138.97mm let d be 50mm (standard) 9. 28 . 10. Hydraulic and pneumatic cylinders Bodies of shells and condensers Dairy equipment Compressors storage tanks etc… It is also used to make cylinders of different diameters 29 .APPLICATIONS Sheet Metal rolling machine is used to make. Outer cylindrical casing for motors employed in submersible pumps. The total cost of the machine is less.ADVANTAGES Operation of this machine is very simple Unit is compact so less space is required No hand tools are required Cylindrical shaped objects of dia 50mm to 225mm can be produced The dia can be easily operate this machine The machine is hand operated. So the cost of the finished product will be less.11. Easy to handle Less effort & productive Easy to install at any were Skilled workers are not required Convenient for mass production Less in weight 30 . Maintenance of this machine is very easy. 31 .DISADVANTAGES This machine has a hand operated one Production time is high.12. 6. 5. NAME OF MATERIALS QUANTITY Steel Hollow Shaft Steel Square Pipe Base Nut and Bolt Bearing Welding Work Cutting Work 3 2 1 6 6 TOTAL 32 AMOUNT 1500 500 500 100 400 500 500 4000/- .13.ESTIMATION AND COST ANALYSIS: SL. 7. 4.N O 1. 2. 3. 33 . 34 . 35 . 36 .
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