DESIGN AND FABRICATION OF 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
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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
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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.
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ACKNOWLEDGEMENT It is our great privilege to express hearty thanks to our Managing Trustee Prof. A. Ezhilvanan MBA or kind encouragement throughout this project. My sincere thanks to our Principal Prof.Dr. K. Ramar Ph.D., F.I.E., for kind encouragement in carrying out this project. We sincerely and whole heartedly thank our Head of the Department, Mechanical Mr. K. Arul Raj M.E., (Ph.D.), for his effective support for our project. We gratefully thank our co-ordinator Mr.M.BALA RAMA MOORTHY, M.E., who guided us to make a special contribution to the project. We gratefully thank our guide Mr.R. Karthikeyan,M.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 thank all the faculty members of our department and our lab in-charges for their immense help during the course of the project. We also thank God and our Parents for their immense help an support to make this project.
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INSTITUTIOIN PROFILE An adobe of excellence, a pinnacle of glory, a name that deserves mention whenever there initiates a discussion about the world of Engineering; Einstein College of Engineering. The institution was found by Late Mr.AladiAruna, former Tamil Nadu Law Minister in 2004, with the sole purpose of providing cutting edge technical education that is both accessible and affordable. From the year 2004, The College embarked on programs of the college offers 5 B.E. degree courses. The College also offers 6 M.E. courses in Engineering and Master of Business Management. About 15 km away from Tirunelveli towards the well-known Courtralam, the college is situated in Sir. C.V. Raman Nagar. The Institution is spread over an area of about 30 acres. The College maintains a royal existence with its marvelou infrastructure and widely acclaimed for its meticulous planning, resource scheduling and institutional management. Our founder son of the soil Thiru. AladiAruna M.A., B.L., 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. He was a Member of Parliament and MLA for more than a decade and was also the Minister of Law, Govt. of Tamil Nadu 19962001.
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ABSTRACT
This project work titled “SHEET ROLLING MACHINE” has been conceived having studied the difficulties in making 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 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.
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PROJECT OBJECTIVE To implement the skills acquired in previous semester to practical problems
as prescribed in ME-68 DESING AND FABRICATION
PROJECT,MECHANICAL curriculum
to
fulfil
the
ENGINEERING above,
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. We have designed and fabricated “SHEET METAL ROLLING MACHINE” and calculated the experimental results theoretically
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LIST OF FIGURE PAGE NO 1.1 Stress in bending
12
3.1: Process of rolling
14
4.1 Stress induced in sheet metal
15
5.1 Steps in rolling
16
6.1 Sheet rolling machine
17
8.1Shape rolling mechanism
19
8.2 Stress and Strain Curve for Steel20 8.3 Plastic Theory of Bending
21
8.4 Geometrical analysis
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LIST OF CONTENT Page No
1. Introduction
11
2. Bending
12
2.1 Roll bending
13
3. Process of rolling
13
4. Stress induced in sheet metal
15
5. Steps in rolling
16
6. Description of the machine
17
7. Working principle
18
8. Design
19
8.1 General design principles19 8.2 Stress and strain in steel
20
8.3 Plastic theory of bending
21
8.4 Design calculation
22
9. Synopsis
28
10. Application
29
11. Advantages
30
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12. Disadvantage
31
13. Estimation of cost analysis
32
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1. INTRODUCTION 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 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
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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
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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
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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. 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. 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
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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 sheet metal
5.STEPS IN ROLLING
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5.1 Steps in rolling
6. DESCRIPTION OF THE MACHINE 16
The Sheet Metal 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 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 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.
6.1 Sheet rolling machine
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7. WORKING PRINCIPLE The Sheet Metal, which is to be formed in cylindrical shape, is present at the edge by hammering. 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 providethe bendingforcewhilethebackbaseroller 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.
Thefreeendofthetopbearingblockis springloadedtoincrease or
toreducetop-baseroller clearance. Twootherboresoneach 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. Thelowerbackroller provides the necessary driving forces while the idler roller does the bending and material delivery. There are two crank levers, one on the toprollerand anotheronthefrontend roller. The lever (handle) couplinghead hasasquare configuration whichfitsinto thesquareendoftherollershaft. 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.
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8.DESIGN 8.1General design principles Following basic shearing operation on a sheetmetal, components canberolled to give it a definite shape. Bendingofpartsdependsuponmaterial 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. Atleast two rollers were involved in flatrolling dependingonthe thicknessand properties
ofmaterial
whilethreeormultiplerollersystem
isrequiredinshape
rolling. A work material under bending load is subjectedtosomeform
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ofresidualstressanddeformation asit bends. Materials at the outerbend radiusundergo tensile plastic deformation whilethematerial at theinner bendradiusundergoescompressiveplasticdeformation. 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. The elastic part of the deformation is recovered up on removal of the load. This phenomena is known as “spring back” or elastic recovery
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8.2Stress and Strain Curve for Steel
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. 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
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8.4 Design Calculation:
8.4 Geometrical analysis FORCE ANALYSIS: The material selected for analysis is mild steel. The mild steel plate Properties are 2 Young’s Modulus, E=207GN/ m
2 Elastic limit (yield stress) σ y =515MN/ m
Poisson’s ratio=0.34 Given data from the specification of the machine
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The plate thickness t=1mm
Upper roller diameter, du=50mm
Lower roller diameter dl=50mm
Lower rolls centre distance 2f=120mm Theplate 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
K= √(R i+ r l)2 −f 2
=
0.025 0.025 2 0.06 2 K=0.048m
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2
f 2 t rl
K ru
Ri
2
2 ru rl t K
( 0.048−0.025 )2 +0.06 2−0.0262 = 2 ( 0.025+ 0.025−0.048 )
=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
0.06 (0.863+ 0.025+0.001)
=
48.7 o
To find the length: 48.7 0.025 sin ¿ ¿ 2∗0.06−2 ¿
l=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
=
( 0.0824 )2 8× 0.048
δ =0.017m
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The plate will undergo elastic spring back after the maximum bending moment has been applied. The relaxed radius, after spring back, of the plate may be determined from the following equation.
M=
σ =594.67× 106
N m2
594.67 × 106 × 0.45 ×0.0012 M= 4
I=
b t3 12
=
0.4 ×0.0013 12
1 66.89 = 9 ρe 207 ×10 ×3.333 ×10−11
ρp
=
Ri +
t 2
=66.89 Nm
=3.333
×10−11
=9.704m
=0.863+0.0005=0.8635m
1 1 1 = − =¿ ρr 0.08635 0.103 ρr =¿
σb t 2 4
1.872m
0.534m
Upper roll vertical force applied on the plate (Pv)
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1 0.017 66.89= Pv 4 + 2 tan 48.7
(
PV =¿
)
257.59N
The lower rolls force to drive the plate is
Pl=
257.59 2× cos 48.7
=195.14N
The side thrust force on the plate is
Ps
=195.14
48.7=¿ × sin ¿
146.60N
Power required for driving the machine: P=
MpV ρr
( )=(
66.89× 0.0215 0.534
)
=2.69kw
The torque required to roll the plate is calculated: T=
M p rl ρr
( )=(
66.89× 25 =¿ 0.534
)
Shaft diameter: For greater strength 45c8 (steel) is common for shafts
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3131.55N-mm
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
=
0.092 ×60 =¿ 2 × π ×0.025
35rpm
For roller speed of 35rpm & with 2.69kw
(
( 60 ×106 ) ×2.69
Mt
=
Kb
=1.5,
τ max
2× π ×35
Kt
) =7.33
×105
N-mm
=1
= 0.3syt = 0.3(580) = 174N/mm2
τ max = 0.18s = 0.18(720) = 138.6N/mm2 ut
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Taking the min value of 138.6 N/mm2 d
3
=
16 ( π ×138.6 ) √( 1.5 ×1942300 ) +( 1 ×733931.65 ) 2
2
d=47.97mm let d be 50mm (standard)
9.SYNOPSIS In Sheet Metal working industry a wide range of power and hand operated 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 three roller which is coupled with a handle and connecting the handle shaft with worm shaft. This machine is simple in construction and working.
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10.APPLICATIONS
Sheet Metal rolling machine is used to make, Outer cylindrical casing for motors employed in submersible pumps. 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
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11.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. The total cost of the machine is less. Maintenance of this machine is very easy. Easy to handle Less effort & productive Easy to install at any were Skilled workers are not required Convenient for mass production Less in weight
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12.DISADVANTAGES This machine has a hand operated one Production time is high.
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13.ESTIMATION AND COST ANALYSIS: SL.N O 1. 2. 3. 4. 5. 6. 7.
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
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AMOUNT 1500 500 500 100 400 500 500
4000/-
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35
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