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TW Woods has several hydraulic roll presses that are used to bend the steel plate into the
required shape.
The following videos show steel being pressed to form cylinders, angles and cones.
Cylinder being pressed
Angle being pressed
Cone being pressed
Note these are YouTube clips will need to have download copies saved
We hope to get equivalent clips from TW Woods.
Typically the finished products are accurate to within 1or 2 mm of specifications.
During the pressing process the steel is deformed in such a way that matter is squished along
the length from the inner surface of the steel plate to the outer surface. i.e. the inner half of the
steel is compressed as it is forced around the roller while the outer half is stretched. The section
of the plate that is exactly in the middle, (with regard to the thickness), is not affected.
The length of the middle section of the steel plate is called the mean running.
What are the implications of this?
We know that the label that wraps around a tin of peaches is very thin. The label is actually
printed on a rectangular sheet of paper which is then rolled to be glued to the tin. The length of
the rectangular piece of paper is equal to the circumference of the cylindrical can.
The diameter of the tin is approximately 73 mm. Confirm these results using C = d.
For a cylinder made from thin material such as paper, cardboard, or sheet metal, the internal and
external radii of the cylinder are virtually identical. (There is a difference, but it is so small as to
be negligible).
Flues take the waste gases and smoke from a gas or wood heater and vent them outside the
house.
A flue is made from cylindrical sections which are joined together. Sections are typically 900
mm or 1000 mm in length. The diameter may be from 100 mm to 305 mm (or more) depending
on the size of the heater. The sections are rolled from sheets of stainless steel, galvanized steel,
or copper depending mainly on the appearance required.
Similar cylindrical components may be used in ducting for air conditioning.
The picture shows part of the flue for a home fire place. It is
made from rolled stainless steel. It has a diameter of 230 mm
and is 900 mm in length.
Find the dimensions of the rectangle of stainless steel sheet
from which each section is made. (Allow an additional 5 mm
on the length to allow the edges of the rolled cylinder to be
overlapped and joined together).
Using C = d, we find the circumference of the cylinder to be 230 which is 723 mm (to the
nearest mm).
Now we need to add on the 5 mm joining allowance.
The stainless steel sheet would need to be cut to a length of 728 mm and a width of 900 mm.
However, for a cylinder made from steel which is 60 mm thick, or even 6 mm thick, the
difference between the internal and external radii cant be ignored.
When the thickness is 6 mm or more it is called plate steel rather than sheet steel.
60 mm
1500 mm
1800 mm
It is most important to have the steel plate cut very accurately, (within 1 mm), to the correct
length and width before it is pressed. The pressing process cant be adjusted to correct any errors
in the dimensions of the plate if we press an incorrectly sized plate we will get an incorrectly
sized cylinder.
We know that the steel plate will have to be 60 mm thick and 1500 mm wide, but how long must
it be?
It appears that the length of the plate will have to be equal to the outside circumference of the
cylinder C = 2 r = 2 900 = 5655 mm (correct to the nearest mm).
If we act on this calculation and cut a sheet of 60 mm thick steel into a rectangle of length 5655
mm by 1500 mm, then roll it, we will get a cylinder of the correct height but the radius will be
incorrect.
Why? In the rolling process the outside material is stretched as it is rolled, which means that the
outer circumference will be more than 5655 mm, which then means that the external radius will
be greater than 900 mm.
How do we solve the problem? We must work with a length measurement that does not change
during the rolling process, i.e. we must work with the mean running.
Step 1 Calculate the radius of the mean running
The radius of the circle produced with the mean running as its circumference is (900 30) mm or
870 mm. This was obtained from the formula RM = RE T, where RM is the radius of the
mean running, RE is the external radius and T is the thickness.
This was calculated by subtracting half of the thickness from the external radius.
Which explanation is better for the target students?
(Note that people in trades usually work with diameters rather than radii worth discussing with
students using calipers etc you measure diameter, not radius).
Step 2 Calculate the circumference of the mean running, which is the required length to cut
Using C = 2 RM we obtain C = 2 870 = 5466 mm (correct to the nearest mm).
Now we know that the 60 mm thick steel plate has to be cut to a length of 5466 mm and a width
of 1500 mm.
Note that when working with inside units, RM = RI + T. (i.e. the radius of the mean running
is the interior radius plus half the thickness).
Step 2
Length required
This pic from Jorgensen Metal Rolling site, do we acknowledge copyright. Would prefer to get
something similar from TW Woods.
We need to be familiar with some specific terminology, as shown in the following diagram.
A combination of these two videos might be useful to present and explain the terminology,and to
explain why the bend angle is equal to the angle at the centre of the circular arc.
Terminology used in bending
Bend angle and angle at centre
Suppose that we have to make a right angle bend in 10 mm steel plate
such that the finished product is 800 mm wide, the mold line
measurements are 200 mm on one side and 300 mm on the other, and the
bend radius is 20 mm.
What are the dimensions of the steel plate that has to be pressed?
Clearly the steel plate will be 10 mm thick and 800 mm wide. The problem is in calculating the
length of plate required, because there will be the same type of compression on the inside and
stretching on the outside of the arc formed by pressing as there was when rolling a cylinder.
Notice the term bend allowance shown on the diagram. It is the length of the arc of the mean
running.
Step 1
Calculate the distance from the edge of the steel plate to each bend line
Step 3
Length required
Note that this is significantly less than the sum of the two mold line distances (200 + 300 = 500
mm).
The 10 mm thick steel plate has to be cut to a length of 479 mm and width of 800 mm.
Bend allowance
Step 2
Length required
The 20 mm thick steel plate has to be cut to a length of 2645 mm and width of 700 mm.
Students would now be given Activity 1(or the parts of it suited to their ability).
Background information
The following video shows how a cone can be rolled from a sector of a circle.
video of making a paper cone (need to record the equivalent of first 3 minutes of video)
The radius of the circle is the slant height of the cone. The video shows that when the circular
sector is rolled to make the cone the radii on each end of the sector are taped together along the
sloping side of the cone.
We find the slant height of the cone using Pythagoras theorem.
s2= 1202 + 502
= 14400 + 2500
= 16900
120 mm
s
s =
= 130
The slant height of the cone is 130 mm, so we will need to
draw a circle of radius 130 mm.
50 mm
Step 2
Find the size of the angle at the centre of the newly drawn circle
1380
130 mm
2. Carefully cut out the annulus (the part between the two concentric circles). Keep the
annulus, put aside the piece of paper which was the small inner circle, and discard the
piece of paper which was the outside part of the big outer circle.
3. Now cut along the radius lines that are on the annulus.
4. The annulus has now been cut into two strips of paper. Each is a sector of the annulus.
Roll each strip into a section of a cone.
5. Reassemble the 3 pieces of paper and use the colours of the different sides and arcs to
confirm that the arcs of the concentric circles become the circumferences of the top and
bottom circles of the conical frustum and that the slant height of the frustum is formed by
the radius section of the original sector.
The picture shows some additional rolling on the top and bottom. We
will ignore this.
Find the dimensions of the shape which will have to be rolled to form the
required section.
We know that the shape that has to be rolled is a sector of an annulus. We need to work out the
radii of the concentric circles and the sector angle.
Step 1
Note that
i.e.
(
(
)
)
Step 2
Method 1
circles, R is the larger radius of the cone, r is the smaller radius of the cone and l is the slant
height of the cone.
(to the nearest mm)
We now need to find the radius of the smaller of the concentric circles.
This radius will be equal to
i.e. the radius of the smaller circle is 635 381 = 254 mm.
The concentric circles will have radii of 635 mm and 254 mm.
Method 2
Use trigonometry
In AQB,
We dont need to work out the value of .
In OPB,
We now need to find the radius of the smaller of the concentric circles.
This radius will be equal to
i.e. the radius of the smaller circle is 635 381 = 254 mm.
The concentric circles will have radii of 635 mm and 254 mm.
Step 3
Angle of sector =
3600.
= 1540
The cone section will be 900 mm in height and will have external diameters of 1200 mm and
1000 mm.
Find the dimensions of the annular sector that will be rolled to form the cone section.
Remember that, when rolling thick steel, we must use the mean running to calculate the length,
but not to calculate the slant height.
This means that we have to work out the radius of the mean running at both the top and bottom
of the cone section, then use the mean running radii in the formulae.
Step 1
Calculate the slant height of the cone and the radii of the mean running
At the larger end of the cone piece, the outside radius is 600 mm and the thickness is 60 mm, so
R = 570, obtained from 600 60.
At the smaller end of the cone piece, the outside radius is 500 mm and the thickness is 60 mm, so
r = 470, obtained from 500 60.
Step 2
SA =
SA =
Students would now be given Activity 2 (or the parts of it suited to their ability).
Activity 1
1. Find the length of steel plate required to make each of the following cylinders, answer to the
nearest mm :
a)
b)
c)
d)
height 950 mm, outside radius 670 mm, inside radius 620 mm
e)
f)
g)
h)
height 950 mm, outside radius 1600 mm, inside radius 1540 mm
2. Write down a formula which will calculate the length of steel plate required to make a cylinder
when given:
a)
b)
c)
Check that your formula is correct by using Question 1 and its answers as test data.
3. Use a spreadsheet to make an Instant Length Calculator which displays the correct length to
cut the steel plate which is to be rolled into a specified cylinder.
There should be three independent sections of the spreadsheet to calculate length required from:
a)
b)
c)
Check that your spreadsheet is correct by using Question 1 and its answers as test data.
4. Find the length of steel plate required to make each of the following bends:
a)
plate thickness 50 mm, distance of 400 mm to each of the bend lines, bend radius 260
mm, and the plate is to be bent at an angle of 700.
b)
plate thickness 10 mm, bend line distances of 1000 mm and 800 mm, bend radius 60 mm,
and the plate is to be bent back on itself so that the two faces form an angle of 300. (i.e. the bend
angle is 1500.)
c)
plate thickness 30 mm, mold line distances of 1200 mm and 800 mm, bend radius 180
mm, and the plate is to be bent at 900.
5. We have to make a bend in 20 mm steel plate as part of an access ramp at a golf course to
allow golfers to drive their buggies into a shed. The ramp is to be 1500 mm wide. The ramp
consists of a 500 mm long flat section leading to a 100 bend with a bend radius of 1200mm,
followed by a flat section of 2000mm. Draw a diagram to illustrate this information, then find the
dimensions of the steel plate required.
6. Use the dimensions given on the picture to find the length of steel plate required to make one
of these structural supports.
900 bend at
100 mm radius
200 mm
50 mm
900 bend at
900 mm
300 mm radius
1000 mm
500 bend at
1200 mm
100 mm radius
7. A mathematician analysed the problem of calculating the bend allowance and produced the
formula BA = (0.0175 R + 0.0087 T ) .
In this formula BA is the bend allowance, R is the bend radius, T is the thickness of the steel
plate, and is the bend angle.
a)
Confirm that the formula is correct by using Questions 4, 5 and 6 and their answers.
10. Suppose that a friend asked you for help with working out the dimensions of metal plate
needed to make cylinders. Write a response to your friend in which you explain the process, in
your own words, so that your friend will be able to work out the required measurements.
Activity 2
1. Make the following from paper or cardboard:
a)
c)
d)
a section of a cone with height 50 mm and radii of 70 mm and 60 mm (needs A3 and
some thinking to make it fit similar to what happens in industry centre of concentric circles is
not on the actual steel plate that is going to be marked and cut could be metres away for a cone
with only very slight taper leads into use of sagitta or versines will do as a separate
resource)
2. Find the dimensions of the shape that has to be rolled to make:
a)
180 mm
200 mm
400 mm
b)
95 mm
100 mm
c)
250 mm
180mm
170 mm
3. Use a spreadsheet to make an Instant Cone Calculator which displays the correct radius and
angle to cut the sheet of material which is to be rolled into a specified cone.
Use questions 1a and 1b and your answers to check that your spreadsheet is correct.
4. Use a spreadsheet to make an Instant Conical Section Calculator which displays the correct
radii and angle to cut a thin sheet of material which is to be rolled into a specified conical
section.
Use questions 1c and 1d and your answers to check that your spreadsheet is correct.
5. Calculate the dimensions of the shape required to roll the following from steel plate:
a)
a conical piece from 20 mm plate with height 1000 mm and diameters of 900 mm and
700 mm
b)
mm
a conical piece from 50 mm plate with height 800 mm and diameters of 500 mm and 350
6. Modify your spreadsheet from question 4 so that it also includes a calculator for working with
plate steel.
Answers
Activity 1
1. (a) 3613 mm (b) 3236 mm (c) 4273 mm (d) 4053 mm (e) 5246 mm (f) 4901 mm (g) 3707
mm (h) 9865 mm
T
T
R RE
5. 2711 mm
6. 4553 mm
7. (b) The formula to give the exact value of the bend allowance is BA
360
2 R 0.5T or
2
0.017453292 and
0.008726646 , hence the
BA
R
T . Now
360
360
360
360
mathematicians formula gives an approximate value.
8. (i) 8.0 m3
Activity 2
1. (a) sector of circle of radius 100 mm, sector angle 2160 (b) sector of circle of radius 144 mm,
sector angle 3000 (c) sector of annulus of radii 112 mm and 58 mm, sector angle 2250 (d) sector
of annulus of radii 357 mm and 306 mm, sector angle 710
2. (a) sector of annulus of radii 415 mm and 187 mm, sector angle 1730 (b) sector of annulus of
radii 251 mm and 157 mm, sector angle 1150 (c) sector of annulus of radii 575 mm and 391 mm,
sector angle 780
5. (a) sector of annulus of radii 4422 mm and 3417 mm, sector angle 360 (b) sector of annulus of
radii 2412 mm and 1608 mm, sector angle 340