ABSTRCT

This project work titled “SHEET ROLLING BENDING MACHINE” has

been conceived having studied the difficulties in making V-bending in sheet
metal. This project facilitates in making bending accurate in sheet metal with
easy. The project employee by using the roller for bending purpose by manual.

This machine can be used in various fields. Our project the sheet metal
Two rolling is very simple in operation by using roller which is coupled with
handle. In Sheet Metal working industry a wide range of power and hand
operated machines are used. This machine is simple in construction and
working.
 CHAPTER -01

INTRODUCTION
A manual operated bearing press is a device which enables to fix the two roller.

It can be widely used in industries. It is easy to operate. This device is effective

for pressing the in this two roller in to the shaft. Nowadays roller are pressed

manually it is a time consuming process and also damages the sheet meatl. The

proposed system is easy to operate with help of manual and comfort sources and

time consumed is very less.

Sheet Metal industry is a large and growing industry. There are many
special purposes machines used in this industry to-day. The proper selection
of the machines depends upon the type of the work under-taken by the
particular industry. There are many examples of Sheet Metal work, which can
be seen in our everyday lives. The metals generally used for Sheet Metal
work include black iron sheet, copper sheet, tin plate, aluminium plate, stainless
sheet and brass sheet.

Our project the “SHET METAL V-BENDING ROLLING

MACHINE” finds huge application in Sheet Metal industry. Rolling is the
process of bending sheets to a curved form. The article in the shape of
cylinders is made by rolling roller. Rolling operation can be done on hand or
power operated rolling machines. In forming cylindrical shapes a gradual curve
is to be put in the metal rather than sharp bends. The gap between the rollers
can be regulated by hand operated screws.
Sheet metal is available in flat pieces or as a coiled strip. Various forming
process in sheet metal include
 Punching
 Roll forming
 Rolling
 Spinning
 Stamping
 Bending
 Deep drawing
 Expanding
 Curling
 Press brake forming
 Decambering
 Ironing
 Laser cutting
 Incremental sheet forming etc.

2. BENDING
Bending is one of the most common forming operations. We merely have to
look at the components in an automobile or at a paperclip to see how many parts
shaped by bending. Bending is usually defined as the deforming of the sheet
metal along the straight line around a straight axis called neutral axis, result in
the plane surface at an angle to the original plane. During bending the top layers
are subject to tension and the bottom layer are subjected to compression. 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 1.1
1.1 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

2.1 Roll bending

A continuous form from of three-point bending is roll bending, where plates,
sheet and rolled on each end, one of the support can often be swung clear to
permit the removal of closed shapes from the rollsshapes can be bent to a
desired curvature on forming rolls. These machines usually have three roll in the
of a pyramid, with the two lower rolls being driven and the position of the upper
roll being adjustable by a frame

3.PROCESS OF ROLLING

In the first stage the plate is kept between top roller and bottom rollers as shown
in Figure2.1 and the top roller is given vertical displacement to get the required
bend. In next stage the bottom rollers are driven using motors in forward
direction to get the roll bending of the plate. Similarly the rollers are driven
inverse direction to get better dimensional accuracy of the final product. The
bent plate is than unloaded by raising the top roller. 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.
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, They incorporated the effect of change of young
modulus during the deformation in the formulation to study the effect on spring
back prediction. For plane strain of sheet metal subjected to strain rate effects
during cyclic bending under tension.

Figure 3.1: Process of rolling v-Bending machine

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. Even in the industries the normal practice of plate roller bending still
heavily depends upon the experience and the skill of the operator. Working to
templates, or by trial and error.

4. RESEARCH GAB IN SHEET METAL

The working by bending of work-pieces creates inner of this in
deformed zone stresses in tangential and radial directions. The metal strata
placed to curving centre are pressed in tangential directions, becoming
shorter and in especially cases are stretchingin transversal direction. The
metal strata placed to external piece are stretching in tangential direction and
in especially cases are pressed in transversal direction, making the piece
narrowing. Between the stretching and pressing strata is founded the neutral
status. The neutral status with the radius is founding displaced to the curving
centre before the weight centre,

4.1 Stress induced in V Bend sheet metal

5.PRESENT STEPS IN ROLLER – METHODS

 5.1 Steps in rolling

6. DESCRIPTION OF THE MACHINE

The Sheet Metal V-Bending Rolling Machine works according to the

principle of three point bending. The rotation of the driven rolls being utilized
to feed the metal through the V-bend rolls by means of the frictional forces
present between the surface of the rolls and sheet. No lubricant is used at its
presence interference with the ability to grip. Sheet Metal Rolling Machine
essentially consists of three rollers, used to manufacture circular components
like cylinders. Sheet Metal V-bend Rolling Machine is classified into two types
based on the arrangement of the rollers. They are as follows.
 1. Pinch type machine
2. Pyramidal type machine

This 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.
 CHAPTER – 3
WORKING PROCESS

Figure 3.1 Working Process

The Sheet Metal, which is to be Sheet formed in V shape, is present at the
edge by rollering . To start the operation easily and to avoid flats at the
beginning and at the ends of the rolled form. In rolling cylindrical shapes a
gradual curve is to be put in the metal rather than sharp bends. Now the sheet
metal is introduced between the top and the bottom rolls, the gap between the
top and bottom rolls are adjusted as per the required diameter by regulating
the screw rods.
The rollers were arranged in triangular form; two sets of rollers below
and one above. The upper roller provide the bending force while the back
base roller provides the required driving force and the front end Roller bends
the metal according to set radius of bend. Aperture adjuster on each block
assembly ensure loading of workpiece and adjustment to required radius of
bent. The free end of the top bearing block is spring load edto increase or to
reduce top-base roller clearance. Two other research bearing blocks provide
an adjustment for the roller gap variability. Top roller Provides the bearing
load (bending force)and also compliments the driving roller when working
on thick materials. The lower back roller provides the necessary driving
forces while the idler roller does the bending and material delivery.
There are two crank levers, one on the toprollerand anotheronthefront-
end roller. The lever (handle) coupling head has as quare configuration
whichfitsinto the square end of the roller shaft.The frame structure made
of(50×50×5)mm angle iron for the purposes of strength. The tool table is
provided below the rollers for safe keeping of tools and cranks.
Therollerhead assembly is detachablefrom
theframeandcanbemountedonatable tobeused asatabletop machine
fortinkering works.
 CHAPTER -4
DESIGN PROCESS
Following basic shearing operation on a sheetmetal, components
canberolled to give it a definite shape.

Bending of parts depends uponmaterial propertiesatthe location

ofthebend. Toachievebending,thework materialmust be subjected to
twomajorforces; frictional forcewhich causesano-slip actionwhenmetalandroller
cameincontact anda bendingforceactingagainst the forward speed and the
torque applied to
move the material. Fig8.1

8.1Shape rollingmechanism

Where,
a=distancefromexitzonetotheno-slippoint(assumea=L/2);
F=forceappliedtorollers;T=torqueappliedtorollers;L=rollgap;
r=radiusofrollers;μ=frictionalforce;ho,hf=thicknessof thesheet before and
after timet.
8.2 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. Roll forming, [also
known as roll bending], is a process for forming plates, sheets, bars, beams,
angles or pipes into various shapes by passing the work piece between the
properly spaced rolls. Sheet and plate are the mill products often formed by the
roll bending process. Because of the elastic plastic behaviour of the sheet
material, deformation imposed on the sheet when it is forced to conform to the
rolls, has both elastic. 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.
 CHAPTER- 3
LITRATURE REVIEW
Attempts to systematically utilize and quantify reserve strength to
overcome the shortcoming of classical elastic analysis were made as early as
1914 (Heyman 1998). Significant advances were made after the 1930s. The
fundamental theorems available in the late 1940s to early 1950s (Horne 1950,
Greenberg and Prager 1952) eventually provided a foundation for the
widespread acceptance of the theory of plasticity.

Central to the idea of all plastic analysis methods is an implicit assumption that
the
structure being analyzed is made from ductile materials. Most civil
engineering
materials possess ductility to a certain degree. However, in this article, the
discussion
will be limited to steel. Ductile nature of steel makes it one of the most suitable
candidates for plastic analysis.
 A typical stress-strain curve of structural steel is shown in Figure 1. The
stress-strain relationship can be largely divided into elastic, plastic, and strain
hardening regions. In structural design, it is customary to neglect the strain
hardening of the material and to utilize mainly the elastic and plastic parts of
the stress-strain relationship. To this end, a simple bilinear approximation is
usually adopted. This results in the elastic-perfectly plastic stress-strain model
as shown by the dashed line in Figure 1. This model is assumed for all
subsequent analyses in this chapter. More complex models can be used in the
analyses, if preferred, using the same basic principles. As can be seen from
Figure 1, large deformation can occur beyond the elastic limit. This ability to
undergo significant inelastic deformation allows a structure made from a
ductile material to maintain stable behavior beyond the elastic limit and to
redistribute the loads to other
parts of the structure that are less stressed.

The analysis is carried out by using the

following assumptions:
1) Plane section remains plane implying that the strain distribution is linear.
2) Deformation is small.

Concepts of Plastic Analysis

One goal of plastic analysis and design is to utilize the reserve strength beyond
the elastic limit due to the redistribution of internal forces. Therefore, the
analysis focuses on the internal forces at the limit level when the yield
mechanism forms. Plastic analysis procedures are based on the considerations
of equilibrium, yield mechanism, and plastic strength conditions. There are
three fundamental plastic theorems regarding theses three conditions as
applied to plastic analysis of frames consisting of flexural members. The
theorems can be stated as follows (Neal 1977):
1) Upper Bound Theorem (Kinematic Theorem) “For a given frame subjected
to a set
of loads, the value of load which corresponds to any assumed mechanism must
be
either greater than or equal to the collapse load.” 2) Lower Bound Theorem
(Static Theorem) “If there exists any distribution of bending moment
throughout a frame which is both safe and statically admissible with a set of
loads, the value of loads must be less than or equal to the collapse loads.”
3) The Uniqueness Theorem “If for a given frame and loading at least one safe
(strength greater than moment demand condition) and statically admissible
bending moment distribution (equilibrium condition) can be found, and in this
distribution the bending moment is equal to the fully plastic moment at enough
cross-sections to cause failure of the frame as a mechanism due to rotations of
plastic hinges at these sections (mechanism condition), the corresponding load
will be equal to the collapse (ultimate) load”
It should be mentioned that terms such as “ultimate”, “failure”, and “collapse
load” are traditionally used in plastic analysis and design for static loads,
where formation of mechanism is indicative of “failure” of structures to carry
any further load. In the context of modern seismic design, where plastic
analysis plays an important role, structures are expected to form mechanism
during strong ground motions. But that does not mean “failure” or “collapse”
in the dynamic sense, until the displacements become excessively large.
Therefore, the terms “yield mechanism” and “limit load” are more appropriate
and have been used herein. Based on the fundamental theorems stated above,
two common analysis methods exist that can be utilized to computed the limit
load for a given structure. These two methods are generally referred to as the
“mechanism method” and the “statical method.”

Plastic Bending Of Beams

As the load on a particular beam is gradually increased, the greatest Stresses

will occur at the extreme fibres of the "weakest" section (Note : In some Steels
when the elastic limit is reached there is a marked reduction in Stress and in
any calculations the lower Yield Stress is taken - See graph). These outer fibres
are said to be in the plastic state, and any increase in loading will result in a
considerable increase in Strain and hence deflection at that section of the
Beam. There will also be a redistribution of Stress. With Mild Steel this
increase in Strain can take place without the Stress rising above the yield point
(i.e. any Strain Hardening effects can be neglected and the plastic Strain at
yield is in the order of 10 - 20 times the Elastic Strain).
It can therefore be assumed that the Stress in the plastic region is Constant.
When the whole cross section at any point in a structure becomes Plastic, no
further increase in the moment of resistance is possible without excessive
Strain (equivalent to an increase in the Curvature at that section) and a plastic
hinge has been developed; one or more such hinges are required for a complete
collapse. The number depends upon the type of structure and whether it is, for
example, a simply supported beam, a built-in beam or a rigid frame. The value
of the load required to produce this state is called the Collapse Load, and the
ratio of the Collapse Load to the Working Load is called the Load Factor. In
plastic design this factor is used instead of the normal Factor of Safety.
 CHAPTER- 4

THEORY OF SHEET METAL PLASTICITY

In physics and materials science, plasticity describes the deformation of a

material undergoing non-reversible changes of shape in response to applied
forces. For example, a solid piece of metal being bent or pounded into a new
shape displays plasticity as permanent changes occur within the material itself.
In engineering, the transition from elastic behavior to plastic behavior is called
yield.

Plastic deformation is observed in most materials including metals, soils,

rocks, concrete, foams, bone and skin. However, the physical mechanisms that
cause plastic deformation can vary widely. At the crystal scale, plasticity in
metals is usually a consequence of dislocations. In most crystalline materials
such defects are relatively rare. But there are also materials where defects are
numerous and are part of the very crystal structure, in such cases plastic
crystallinity can result. In brittle materials such as rock, concrete, and bone,
plasticity is caused predominantly by slip at microcracks.

For many ductile metals, tensile loading applied to a sample will cause it to
behave in an elastic manner. Each increment of load is accompanied by a
proportional increment in extension, and when the load is removed, the piece
returns exactly to its original size. However, once the load exceeds some
threshold (the yield strength), the extension increases more rapidly than in the
elastic region, and when the load is removed, some amount of the extension
remains.
However, elastic deformation is an approximation and its quality depends on
the considered time frame and loading speed. If the deformation behavior
includes elastic deformation as indicated in the adjacent graph it is also often
referred to as elastic-plastic or elasto-plastic deformation.

Perfect plasticity is a property of materials to undergo irreversible deformation

without any increase in stresses or loads. Plastic materials with hardening
necessitate increasingly higher stresses to result in further plastic deformation.
Generally plastic deformation is also dependent on the deformation speed, i.e.
usually higher stresses have to be applied to increase the rate of deformation
and such materials are said to deform visco-plastically.

Stress-strain curve showing typical yield behavior for nonferrous alloys. Stress
( ) is shown as a function of strain ( )
1: True elastic limit
2: Proportionality limit
3: Elastic limit

Elastic Design Vs.Plastic Design

Basically there are two approaches to provide adequate strength of structures

to support a given set of design loads: Elastic Design and Plastic Design. Drift
checks are also required in actual design practice, but the focus of discussion
herein will be limited to strength consideration only.
Elastic design is carried out by assuming that at design loads structues behave
in a linearly elastic manner. An elastic analysis is performed by applying the
design loads and required internal forces in the structural elements (members
and connections) are determined and adequate design strength is provided.
Since the element forces are determined based on elastic behavior, the design
is governed by elastic stiffness distribution (ratios) among the system
elements.
It is commonly understood that most structures designed by elastic method
possess considerable reserve strength beyond elastic limit until they reach their
ultimate strength. The reserve strength is derived from factors, such as
structural redundancy, ability of structural members to deform inelastically
without major loss of strength (i.e., ductility), etc. One drawback of using
elastic method for designing such structures with ductile members is that the
reserve strength beyond elastic limit is neither quantified nor utilized
explicitly. But more importantly, the yield state (mechanism) of the structure at
ultimate strength level is also not known. The yield mechanism may involve
structural members that could lead to undesirable system performance under
accidental overloading or extreme events, such as strong earthquake ground
motion, blast, impact, etc.

Assumptions In The Plastic Theory.

The requirement is to calculate the Bending Moment needed to form a Plastic
hinge in any particular cross section, and to determine the distribution of
Bending Moment along the beam at the Collapse Load. To do this it is normal
to make the following assumptions:-
  That the material exhibits a marked yield and can undergo considerable
Strain at Yield without any further increase in Stress. In effect this limits
the theory to applications using Mild Steels as the material has a drop in
Stress at Yield. The lower yield stress is used in calculations.
 The Yield Stress is the same in Tension and Compression.

 Transverse cross-sections remain plane so that the Strain is proportional

to the distance from the Neutral Axis. However, in the Plastic region the
Stress will remain Constant and is not proportional to the Strain.

 Once a Plastic Hinge has developed at any cross section, the Moment of
Resistance at that point will remain Constant until the collapse of the
whole structure has taken effect. This will only happen when the
required number of Plastic Hinges at other points have developed.

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. The
total loads above and below the neutral axis NA are both equal to in
magnitude but opposite in direction. Further each of these loads
acts at a distance d/4 from the neutral axis. Thus at plastic hinge,
the plastic moment of the rectangular section.

8.4 Design Calculation:

8.4 Geometrical analysis

 FORCE ANALYSIS:
The material selected for analysis is mild steel. The mild steel
plate
Properties are
Young’s Modulus, E=207GN/
2 m
Elastic limit (yield stress)σ y =515MN/ m
2
  Poisson’s ratio=0.34
o Given data from the specification of the machinehe plate thickness
t=1mm
 Upper roller diameter,
du=50mm
 Lower roller diameter
dl=50mm
 Lower rolls centre distance 2f=120mm
 The plate rolling speed v =5.5m/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, the torque required for bending and other
requirements

In Sheet Metal working industry a wide range of power and hand operated
V-bend rolling machines are used. As the sheet metal industry is a large and
growing industry different type of machines are used for different operations.
Our project the sheet metal rolling is very simple in operation by using roller
which is coupled with handle. This machine produces cylindrical objectives of
different diameters. This machine can be used in various fields. This machine
consist of Two roller which is coupled with a handle and connecting the handle
shaft with worm shaft. This machine is simple in construction and working to
execution V-bending process.
Application
Sheet Metal V-bending rolling machine is used to make,

1. Outer cylindrical casing for motors employed in submersible pumps.

2. Hydraulic and pneumatic cylinders
3. Bodies of shells and condensers
4. Dairy equipment
5. Compressors storage tanks etc…
6. It is also used to make cylinders of different diameters.
 CHAPTER – 5

ADVANTAGES & DISADVANTAGES

a. Operation of this machine is very simple

b. Unit is compact so less space is required
c. No hand tools are required
d. Cylindrical shaped objects of dia 50mm to 225mm can be produced
e. The dia can be easily operate this machine
f. The machine is hand operated. So the cost of the finished product will be less.
g. The total cost of the machine is less.
h. Maintenance of this machine is very easy.
i. Easy to handle
j. Less effort & productive
k. Easy to install at any were
l. Skilled workers are not required
m. Convenient for mass production
n. Less in weight

DISADVANTAGES
 This machine has a hand operated one.
 Production time is high.
 CHAPTER -6
CONCLUSION & FUTURE SCOPE

We have successfully completed this project. we had challenging experience to overcome

practical difficulties and carrying out of the work with the suggestions and guidelines of our

staff and the positive help of our well wishes.

We gained good knowledge regarding the development of v-roller bending machine, as

new to proceed and make successfully a good project.

We are immensely pleased to have the satisfaction of carrying out of useful project at this

stage of the course we have actually become a fall fledged technician by the satisfactory

completion of this work, which gave us a best knowledge to design a fabrication of roller

bending -V- profile . it was more useful for our further study or for our job and we get the self

confidence and also creative things for taking up any bold step in the course of our professional

career.

SCOPE FOR FURTHER DEVELOPMENT

This documentation can be implemented by demonstrating the system with the actual functioning

of the electrical motor wile applying there is any opportunity by programming logic controller
[plc] in the circuit size can be minimized and also more number of operation can be performed

according to the program ,while using it. Since it is very costly we are not trying for it .
 CHAPTER- 7

ESTIMATION AND COST ANALYSIS

SL.N NAME OF MATERIALS QUANTITY AMOUNT

O
1. Steel roller Shaft 3 2500
2. Steel Square Pipe 2 500
3. Base 1 900
4. Nut and Bolt 6 100
5. Bearing 6 400
6. Welding Work 500
7. Cutting Work 500

TOTAL - 4000
 REFERENCE DETAILS
Website link
www.4shared.com
www.wikipedia.com
www.housestufeworks.com
Video link
www.youtube.com
Reference books:
Reference machine design “dicer”.