BEST: International Journal of Management, Information

Technology and Engineering (BEST: IJMITE)

ISSN (P): 2348-0513, ISSN (E): 2454-471X,
Vol. 3, Issue 10, Oct 2015, 53-58
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DEVELOPMENT OF A HYDRAULICALLY OPERATED PIPE BENDING MACHINE

OLAFIMIHAN. E. O
Department of Mechanical Engineering, Ladoke Akintola University of Technology, Ogbomosho, Nigeria

ABSTRACT
A hydraulically operated pipe bending machine which bends pipe of different sizes has been successfully
designed, constructed and tested using locally available materials. The main features of the machine are frame, housing,
flaps, rollers, pins, ram and hydraulic jack. The lifting capacity of the jack was selected to be 5 tonnes. The maximum
efficiency of 97% and a 3% level of ovality were obtained when tested with a pipe of diameter12.5mm. When tested with a
pipe of diameter25 mm, 95% efficiency with 5 % level of ovality was obtained. The production cost of the machine was
$21, 230.00. The operating time was found to increase with increase in the size of the pipe and decrease in the angle of
bent.

KEYWORDS: Hydraulic, Pipe, Bend, Metal and Jack

INTRODUCTION
The metal age led to the invention of various working tools. Metal is extracted and purified after which various
objects are formed or moulded from it. Few of the tools formed from the metal in earlier parts of the metal age were axes,
hoes and cutlasses. The need for transporting (conveying) materials such as liquids and gases arose as time progressed. In
metal forming process, bending is considered to be an important operation. It could either be a sharp cornered angle or
composed of a more gradual curve. Angle bends may be made by hammering the metal over the edge of the anvil or over a
vice jaw while metal is being gripped (Ogunlowo, 1997). A simple bending bar is made from one piece of steel forged to
different shapes or bars. The pieces of metal to be bent is set in these bars carefully to ensure that bend line is in the correct
position with the vice firmly tightened. Very thin metals can be pressed over by hands, but thicker and stronger ones are
bent with the hide-faced mallet (Kolawole, 2000).
Bend blocks are used where specific internal bend radii are required. Both bending bars and bend blocks are used
for fairly small work pieces, but where larger bends are needed, a holding machine is more efficient. Precise bends are
possible when this machine is used in conjunction with radius block for making bends with large radii (Oshuntoki and
Popoola, 2000).Some of the pipe bending machines already developed includes lock forming machine where metal to be
bent passes through series of forming wheels to produce the required type of bend and this is very expensive
(Oguntowo, 1997).Hand operated bending machine is another type. This comprises of a gear train and has a complex
mechanism. The screw pipe bending machine requires very large force for its operation (Ogunlowo, 1997).
Series of efforts have been made in the study, design and development of machinery and tools for bending pipes
into required shapes. However, the choice of a bending process depends on the material type, tube diameter and bend
angle. Some of the processes are: rain, roll, rotary-draw, heat induction, sand-packing and hot-slab forming
(Kolawole, 2000).

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Olafimihan. E. O

The existing pipe bending machines are generally expensive and cumbersome to operate as well as energy and
time wasting for small scale industries. This gives rise to the development of hydraulic pipe bending machine (jack type).
This jack makes use of a ram for the bend, then hydraulic system to exert the bending force easily. The simplicity of design
makes it easier to fabricate from locally available materials.

MATERIAL SELECTIONS AND TESTING

Materials for construction were selected based on the availability, durability and purchasing costs. This is done
with a view to reducing the overall production cost of the machine. Angle Iron (Mild-steel) was used for the construction
of the base unit (the stands and the cross members). Metal plates were used for the construction of the housing unit and the
flap. Hollow-shaft was used for the construction of rollers and circular rod for the pins and ram.
Design Considerations
A 5 ton hydraulic jack was selected for the operation of the machine as an accessory selection of close-coiled
helical spring. A close coiled helical spring of stiffness 2.5kN/m was also selected as an accessory incorporated to the
hydraulic system to return the piston back into the cylinder of the hydraulic jack after each operation.
The bending force, F required can be calculated as
F=

(1)

Where L = Length of the ram (mm)

= d
d = diameter (mm)
M = Bending moment (Nmm)
From the relations,

(2)

and Z =

(3)

Where I = Second moment of area (m4)

= Allowable bending stress (N/m2)
y = Distance of neutral axis from the top surface of the (m)
Also,

I=

(d d )

(4)

Where do = outside diameter of the pipe

di = inside diameter of the pipe.
Sectional modulus isZ =

From equation (3) y = d and

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(5)

Development of a Hydraulically Operated Pipe Bending Machine

From equation (2) M =

From equation (1) F =

55

)
)

(6)

For maximum bending force:

do= 25mm, di = 20 mm, d = 100mm and
= 280 x 106N/m2 for mild steel,
= 3.142
Using equation (6), F = 513.8 N and using a factor of safety of 3
F = 1541.4 N
Machine Descriptions
The main components of the bending machine are described below.
The Frame
It consists of vertical member (made from 70x70x2240 mm angle iron), long horizontal bar (70x70x1020 mm),
short horizontal bar (70x70x230 mm) and leg brace (70x70x1620 mm) to brace the legs. The holes for fastening of the
lower flaps were drilled and the frame stand was mounted on the ground.

Figure 1: The Stand Frame

The Housing
This is made up of the metal plate welded together to form the housing. This accommodates the hydraulic jack.
A slot is made on the plate to allow the movement of the handle. The dimensions of the housing are: Length = 340mm,
Breadth = 200mm, height = 210mm and thickness = 3mm. These dimensions are chosen to accommodate the hydraulic
system.

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Olafimihan. E. O

The Flaps
This is made up of mild steel with T shape structure. There are upper and lower flaps. The upper one is movable
with the help of a hinge while he lower one is stationary. Two holes of 20 mm diameter are drilled at the edges of the flaps
to hold the rollers in position during the bending operation. This is as shown in Figure 2.

90

120o

Figure 2: The Flap

The Rollers
The rollers were made up of hollow shaft machined to the required length of 100mm and 75mm diameter.
A groove of radius 15mm was also made on each roller to accommodate the pipe to be bent. The two rollers were secured
between the upper and lower flaps with the help of the securing pins. This is shown in Figure 3.

R15
100mm

Figure 3: The Roller

The Pins
The pins were constructed from a circular rod of 25mm diameter and 240 mm long. The required size of the pins
is shown in Figure 4.
5mm
115mm

Figure 4: The Pin

The Ram
This ram has a diameter of 100mm. A groove of radius 15mm was cut on it to secure the pipe to be bent. The ram
was attached to the hydraulic jack through the help of ram neck Figure 5.
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Development of a Hydraulically Operated Pipe Bending Machine

57

Figure 5: The Ram

OPERATION PROCEDURES
The operating procedure of hydraulic pipe bending machine is simple when compared to other pipe bending
machine. The upper flap is opened up while the pipe to be bent is positioned in the groove on the two rollers and the ram.
The upper flap is then closed and secured with the two pins at both ends. With the aid of the hydraulic jacks handle,
non-return valve is locked so that the ram moves against the two rollers to bend the pipes as its actuates up to the
calibrations on the lower flap, which shows angle 90o and 120o respectively by the reciprocating movement of the jack
handle. The close-coiled helical spring incorporated, enables the piston on which the ram is attached to return to its initial
position.

TEST RESULTS AND DISCUSSIONS

Two different sizes of hollow pipes of diameters (12.5 mm) and (25mm) were used to test the efficiency of the
machine. The bender gave efficiencies of 97% and 95% when pipes of diameters 12.5mm and 25mm were used. The levels
of ovalityobserved in each of the pipe were 3% and 5%, respectively.The average time taken for 12.5mm pipe to bend
through angles 120o and 90o are 15 s and 19 s, respectively. Also the average time taken for the 25mm pipe to bend through
angles 120o and 90o are 18 s and 23 s, respectively. It can be deduced that the operating time of the machine increases as
the diameter of the pipe to be bent increases and increases as the angle of bent decreases.

CONCLUSIONS
The hydraulically operated pipe bending machine was designed, fabricated and tested. The machine performed
best at an efficiency of 97 % when tested with 12.5 mm pipe with a 3% level of ovality.

REFERENCES
1.

Khurmi, R.S. and Gupta, J.K. (2004) Machine Design 13th Edition Eursia Publishing House Ltd., New Delhi.

2.

Khurmi, R.S. and Gupta, J.K. (2006) Workshop Technology (Manufacturing Processes) 6th Edition Publication
Division of Nirja Construction and Development Co Ltd New Delhi

3.

Kolawole, J. A. (2000) Modification and Construction of a pipe bending machine. An unpublished B. Tech.
Thesis in the Department of Mechanical Engineering LadokeAkintola University of Technology Ogbomoso
Pp. 8 12

4.

Ogunlowo, S. F. (1997) Design of a hand operated bending machine. An unpublished B. Tech Thesis in the
Department of Mechanical Engineering, LadokeAkintola University of Technology Ogbomos Pp. 4-8

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58

Olafimihan. E. O

5.

Oshuntoki, A. C. and Popoola,P. T. (2000) Design and Construction of a pipe bending machine. An unpublished
B. Tech Thesis in Department of Mechanical Engineering, LadokeAkintola University of Technology Ogbomoso
Pp. 5 -11

6.

Rayput, R. K. (2002) The strength of Materials Schand and Company Ltd, Ram Nagar, New Delhi Pp. 727 728.

7.

Shigley, J.E. and Mischke, C.R. (1989) Mechanical Engineering Design 5th Edition McGraw Hill Book Co.
Singapore

8.

Townsends, A. L. (1969) Plumbing II, 2nd edition, Hutchinsm and Co. Limited, London Pp.161

9.

Whitlow, R. (1978) Materials and structure, Longman group limited, Longman house, Burnt Mill, Harlow, Essex,
U. K. Pp. 190 196.

10. Wilson, E. C. (1975). Machine Design Macmillan Publishing Company, New York, United States of America.
APPENDICES

Figure 6: Hydraulically Operated Pipe Bending Machine

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