Description
ABSTRACT
This research presents the fabrication of steel bending machine. The aim of this project is to develop a portable steel bending machine to bend steel into curves and the other curvature shapes. In this research, shaft diameter is calculated by using ASME code equation. Mild steel shaft is selected for design to obtain high strength. The estimated diameter of rotating shaft is 31.75mm and main shaft is 25.4mm. Pillow block bearing UCP205 is selected. The estimated value of Factor of Safety is 3.32. Therefore, the determination of research design is totally safe. As a lot of time is consumed when metal bending is made by hand, so using bending machine will save the waste time. The size of machine is small and it is convenient for portable work. No skill worker is required to operate the machine.
TABLE OF CONTENTS
TITLE PAGE
APPROVAL PAGE
DEDICATION
ACKNOWLEDGEMENT
ABSTRACT
TABLE OF CONTENT
CHAPTER ONE
- INTRODUCTION
- BACKGROUND OF THE PROJECT
- PROBLEM STATEMENT
- AIM AND OBJECTIVES OF THE PROJECT
- APPLICATIONS OF THE PROJECT
- SCOPE OF THE PROJECT
- PURPOSE OF THE PROJECT
CHAPTER TWO
LITERATURE REVIEW
2.0 LITERATURE REVIEW
2.1 OVERVIEW OF METAL BENDING
2.2 PROCESS OF BENDING
2.3 HISTORICAL REVIEW AND CLASSIFICATION OF BENDING MACHINES
2.4 BENDING TECHNOLOGY
2.5 REVIEW OF THE RELATED STUDY
CHAPTER THREE
3.0 METHODOLOGY
3.1 DESIGN CONSIDERATION
3.2 MATERIAL SELECTIONS
3.3 PROPERTIES OF STEEL
CHAPTER FOUR
4.0 RESULT ANALYSIS
4.1 MAIN COMPONENTS AND FUNCTIONS
4.2 METHOD
4.4 DESIGN EQUATION
CHAPTER FIVE
- CONCLUSIONS
- RECOMMENDATION
CHAPTER ONE
1.0 INTRODUCTION
1.1 BACKGROUND OF THE STUDY
Steel is an alloy of iron and carbon in which the carbon content ranges up to 2 percent (with a higher carbon content, the material is defined as cast iron). By far the most widely used material for building the world’s infrastructure and industries, it is used to fabricate everything from sewing needles to oil tankers. In addition, the tools required to build and manufacture such articles are also made of steel. As an indication of the relative importance of this material, in 2013 the world’s raw steel production was about 1.6 billion tons, while production of the next most important engineering metal, aluminum, was about 47 million tons. The main reasons for the popularity of steel are the relatively low cost of making, forming, and processing it, the abundance of its two raw materials (iron ore and scrap), and its unparalleled range of mechanical properties.
Quite a large of steel is employed in the manufacturing industries, in building of aircrafts, automobiles and household appliances. Steel to a large extent is used in the building industries for roofing, heating, prefabricated structures and air conditioning casings.
The base metal iron and bronze were appreciated for their strength especially for weapons and tools; copper, tin and lead came to be used mainly for their utility or durability- for cooking, for storage or for strengthening wooden construction of any kind.
The particular property of metals that can be mixed or alloyed in various combinations and proportions to make a better materials for particular purposes was understood in the ancient world. Copper and tin produces bronze; copper and zinc produces brass; lead and tin produces pewter. This property has been exploited with ingenuity and increasing scientific knowledge while the designation iron, copper, lead, silver and gold are still commonly used (Surenda, 2019).
All metals shares certain characteristic: a uniform smooth complexion; great strength and tenacity; but also easily worked surface; and malleability (their capacity to assume any desired shape).
All these are carried out with the help of steel works, which involves fabrication of metallic objects by cutting, forming/ bending and fastening, welding etc. are referred as steel metal works. (Oyewole et al., 2010).
The term bending refers to an operation in which metal is deflected from its original form to a new position generally at an angle or a curve and it remains so permanently. Bending is a common metalworking technique to process steel. It is usually done by hand on a box and pan brake, or industrially on a press brake. Typical products that are made like this are boxes; such as electrical enclosures, rectangular ductwork and some firearm parts.
Usually, bending has to overcome both tensile stress as well as comprehensive stress. When bending is done the residual stresses make it spring back towards its original position, so we have to over bend the sheet metal keeping in mind the residual stresses.
The machine used for bending operation is called steel bending machine. This machine can be used to perform any type of bending. It consists of heavy beams, which are coupled together to bring about any shape of bending after the flat sheet has been marked out to a specific dimension of bending. This machine is extensively used in our community today by steel fabricators and production workshops for the fabrication of iron gates, security doors, burglary proofs, Louvre frames etc. (Oyewole and Agada 2010).
The steel metal bending machine has great importance. It is used for bending steel into shape and it is also used for giving out design.
1.2 PROBLEM STATEMENT
Traditional method of bending steel is by hand or by heating the steel with higher temperature and this wastes lot of time and is labour intensive. Steel Bending machine is used to overcome these challenges. This machine is used to bend steel into curve and the other curvature shapes. And it is convenient for portable work. This machine is the easy way to be carried and can be used at any time and any place. It eases human effort and no required skill workers to operate the machine.
1.3 AIM AND OBJECTIVES OF THE PROJECT
Bending machine is used to bend a metal sheet, plate and pipe. The aim of this project is to design and construct a portable steel bending machine. This machine is used to bend steel into curve and the other curvature shapes. The objectives of the study are:
- To make work easy and simple.
- To reduce the time for
- To make a low cost steel bending machine.
1.4 APPLICATIONS OF THE PROJECT
This machine works on simple kinematic system instead of complicated design. Due to its light weight and portable system, it can be used by small workshop, fabrication shop and small scale industry.
1.6 SCOPE OF THE PROJECT
The scope of this work covers building a steel bending machine that uses three rollers to bend steel. The common product of steel bending machine are pipe (square and circular) bending if separate attachment of die is provided, steel bending. During the roll bending process the plate or pipe is passed through consecutive rollers that gradually apply pressure on the pipe.
1.5 PURPOSE OF THE PROJECT
The purpose of this project is to therefore design a simple, easily operated steel bending machine that is sturdy and strong.
CHAPTER FIVE
5.1 CONCLUSION
At the end of the work a steel bending machine was fabricated, which is universal forming equipment for rolling steel/metal plate into curve, circle and shapes. Accordingly to the principle of the three-point forming circle, the relative position change and rotational motion of the working roll make the metal produce continuous plastic deformation to obtain the predetermined shape of the work piece. Finally it should be mentioned that at the sideways of the metal bender, roller can be placed to move it easily. Since these metal bender is manual, it has been widely used because of its simple structure, convenient and low cost. This innovation has made the more desirable and economical. This research is designed with the hope that it is very much economical and help full to some industries. Since the design is constructed by manual power, the large diameter or the heavy load cannot be accepted. The bending results are different according to the materials used and load position.
5.2 RECOMMENDATION
This innovation has made the more desirable and economical. The design and fabrication will be very useful for bending in small scale industries. There are many other steel bending machines based on hydraulic power but it has some demerits like large in size, costly, need skilled people to operate and it needs electrical input, I recommend that the next design should base on them. So, this design machine will overcome these demerits by compact in size, less cost, no need for electrical input and no need for skilled people.
