RH6

Design, Modeling And Analysis Of Motorized Pipe Bending Machine
2010
INTRODUCTION
1.1 INTRODUCTION TO BENDING MACHINE:

Pipe bending machines are seen in both small and large scale industries. Pipes of
varying cross section can be bent with this machine by varying the diameter of the die. It is
light weight, simple in operation, easy to handle, less area requirement. It does not require
enough skill and knowledge. A normal man can also operate the machine. Though the
operation is simple problems arise when high degree of accuracy and precision is needed.
Hence by analyzing the need statement of the above mentioned machine we have improved it
by having simple machine members.
1.2 SCOPE OF WORK:

Pipe bending machine are often seen in large scale and small scale industries. There are
many ways of bending the pipe, adopted by these industries.
E.g.: vertical, horizontal machine etc...
The scope of work is to make the operation ease. In the proposed pipe bending machine
we have introduced certain machine members with we are going to bend pipe. In our proposed
machine, we have two rollers to hold the job and another roller mounted through shaft to the
screw handle to bend the pipe. By the rotation of the screw handle, roller which is mounted to
the screw handle rotates due to the thread arrangement and guide plates guides the roller to
hold in to the job between the rollers. By the continuous application of force at the handle
roller moves forward bending the pipe at required angle. In this machine we also have the
backward movement. Around 30 mm diameter pipes can be bent with this bending machine.
Our machine is simple in operation for any normal man to carry out the bending process.
Dept. of Mechanical Engg. PESCE , Mandya Page 1

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2.1 OBJECTIVE
• To provide versatile and feasible pipe bending machine to local pipe bending
workshops.
• To minimize the human work and fatigue.
• To increase the bending rate.
• Feasible to various radius of curvature to bend.
• Intended to low skilled operators.
2.2 LITERATURE SURVEY AND CASE STUDY

From the previous study of research and progress on pipe bending accessories by
Iftekhar Ahmad ,Graduate Faculty of North Carolina State University in 2004, Ahmad and
Mirmiran.A in March (2004), Washington D.C. , Mansur.M, Ahmad and Paramasivam, P,
in (2001). Finally they concluded in design of machine components it is necessary that the
stress induced should be related to experimentally determined strength properties of material
under similar condition . However, it is not possible to determine mechanical properties of
materials for all combinations of load. Generally, mechanical properties of materials are
obtained from simple tension test in which the specimen is loaded axially. But for components
subjected to bi-axial and tri-axial loading condtions the designer is expected to design the
components.
Pipe bending processes are widely used to manufacture parts in aerospace,
automotive, oil and other industries. Pipes are used as components in manufacturing of parts in
numerous industries. Their application ranges from simple household items to sophisticated
aerospace parts. Wherever pipes are used, accurate bend angle and uniform cross section are
often desired. In the past decade, pipes have found many new applications in the automotive
industry.

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2.2.1 Pipe Bending Process:

There are many ways by which a pipe can be bent into the required radius. The main
techniques by which pipe can be bent into the desired shape are rotary draw pipe bending,
compression pipe bending, roll bending and stretch bending. The selection of technique
depends upon the following factors:
1. The quality of the bend and production rate desired.
2. Diameter, wall thickness and minimum bend radius desired.
2.2.1.1 Rotary Draw Pipe Bending:

Rotary draw pipe bending is the most flexible bending method and is used immensely
in industry on account of its tooling and low cost. The tooling consists of a bend die, clamp die,
pressure die and wiper die. In this bending technique the pipe is securely clamped to the bend
die by using the clamp die. The bend die rotates and draws the pipe along with it. The pressure
die prevents the pipe from rotating along with the bend die. The pressure die may be stationary
or it may move along with pipe. The pressure die provides a boost (pushes the material at the
extrados of the pipe) to reduce the thinning of the pipe and can be very helpful when the
bending angle is large and the bending radius is small. A mandrel along with wiper die may be
used to prevent the wrinkling and collapse of the pipe. But the use of mandrel should be
avoided if possible since it increases the production cost .Figure 1-1 shows the tooling of rotary
draw bending process. Rotary draw pipe bending provides close control of metal flow
necessary for small radius and thin walled pipe.

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2.2.1.2 Compression Pipe Bending

The tooling for the compression pipe bending is similar to the rotary draw pipe
bending. It consists of the stationary bend die, a moving wiper shoe and a clamp. The only
difference between the rotary braw bending and compression bending process is that in rotary
draw pipe bending the bend die is movable whereas in the compression pipe bending the bend
die is stationary. In compression pipe bending the pipe is clamped to the bending die near the
rear tangent point. The wiper shoe pushes the pipe along the bending die as it rotates around it.
Figures (a) and (b) show the initial and final configuration of the compression pipe bending.

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2.2.1.3 Stretch Bending
Stretch bending is one of the newer bending techniques being used in industry. In
stretch bending both the inner and outer fibers of the pipe are in tension. The outer fiber is
stretched more than the inner fiber. In the other bending methods described above the outer
fibers are in tension whereas the inner fibers are in compression. The tooling for stretch
forming consists of a mandrel (bending die), jaws, and hydraulic actuators. In this process the
pipe is first gripped by the jaws which are mounted on hydraulic actuators. The grips also seal
the ends. The pipe is first stretched axially to a chosen value of tension, and then pressure is
increased to the desired level while the tension is kept constant. The mandrel then moves and
bends the pipe. Figures (a) and (b) show the initial and final configuration of stretch bending.
Fig.a.Initial configuration of stretch bending
Fig.b.Final configuration of stretch bending

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2.2.1.4 Roll Bending

The tooling for roll bending consists of three rolls of the same size arranged in a
pyramid pattern. Two rolls are fixed and the third (center) roll is movable. The pipe is passed
through the rolls and the center roll is lowered onto the pipe. This bending technique is usually
employed for bending pipes of large radius, spirals and pipe sections of different diameters.
Roll type
Power driven and pressurized rolls. This type is mainly used when creating spirals as
the equipment is not limited to 180 degrees elbows or to in-plane bending.
But we are intended to concentrate on roll type bending machine

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Manual Pipe bending machine
Problems faced by users:

• The middle roller rotation is given by the handle movement which was giving
heavy fatigue to workers during pipe bending.
• It was needed more than two workers for the desired bending operations.
• Presence of wrinkling effect.
In this machine the human power required for the movement of rollers is heavy so our
intension is to reduce that human power by incorporating the motor to drive the rollers. This
machine is used for Arch type, S-Type, L-shape, etc
PRINCIPLE OF WORKING:
The proposed pipe bending machine consists of a die fixed to the square threaded rod
which to turn is connected to the handle. It has two rollers to support the pipe which are driven
by motor. The handle can be rotated both in either direction that is in clockwise direction as
well as anticlockwise direction. By the clockwise direction of rotation of the handle the force is
transmitted to the roller through lead screw. This force exerted is enough for the pipe to bend.
By the continuous rotation of handle the roller get in contact with the pipe so that the load is
imparted on pipe which in turn obtaining the required shape.

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METHODOLOGY
Design of all the components of a Pipe Bending machine by using standard data hand
book.
Modeling the same using SOLID-EDGE V19.
Analyzing the deflections for different load stress induced and the moment is calculated
by using ANSYS11.
3.1 DESIGN
Today’s system designer is faced with the problem of keeping ahead when addressing system
performance and reliability.
3.1.1 POWER REQUIRED TO DRIVE ROLLERS:
DESIGN DATA HAND BOOK (DDHB): K Mahadevan & K Balaveer Reddy -2003
edition.
Pipe material – carbon steel C -30 – (page no-418)
σy = 294 N/mm2
BHN = 179
σt =490-588 N/mm2
E=2.1x105N/mm2
Outer diameter of pipe, D=31.75mm (Hollow pipe)
Inside diameter of pipe, d=28.75mm
For l = 300mm,
R1 R2

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Moment of inertia, I = Π (D4-d4) ...............................Table 1.4(page no.9)

64
= Π(31.754-28.754)
64
I = 16345 mm4
For deflection, y = 1.25mm

y= wl3 ...........................................Table 1.4(page no.10)
48EI
Load, W = 1.25x48x16345
3003
W=7.62KN
R1 = R2 = W = 7.62x103 = 3.81KN
2 2
Mmax = WL ……………………………………………..Table 1.4(page no.10)

4
= 7.62x103x300
4
= 571.5x103N-mm
Z = I …………………………………………………Table 1.3(page no-8)

Y
= 16345
15.875 where, Y = D
2
Z = 1029.60mm3 = 31.75
2
Y = 15.875mm
σb = M ………………………………………………………..(1.16)page no-3
Z

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= 571.5x103
1029.60
= 555.06 N/mm2
σb > σy
σb < σt Material is safe
Co-efficient of running friction between roller and pipe for steel material
µ = 0.12 …………………….page no-110)
Frictional force,
F = µR
F = µR
= 0.12x3.81x103
= 457.2N
Torque = FD’ where,

2 D’= Diameter of roller
= 457.2x80 D’= 80mm
2
T = 18288N-mm
Required rpm = 60
Power = 2ΠNT …………………………………………….3.3a(42)
60x1000
= 2Πx60x18288
60x1000
P = 114.90W

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3.1.2 DESIGN OF LEAD SCREW:

Screw material C-40 Carbon Steel
σt = 570-667 N/mm2
σy = 324 N/mm2
BHN = 217
Allowable stress, σa = σy = 324 = 162N/mm2
2 2
Allowable shear stress, τa = σa = 162 = 81 N/mm2
2 2
For load W = 7.62KN
Core area, Ac = 284mm2 from DDHB (Page no - 121)
Do = 24
Di = 19
P =5
σc = W = 7.62x103
Ac 284
σc = 26.83N/mm2 < σa
Pitch diameter, d’ = Do+Di

2
= 43
2
= 21.5 mm
tanα = 2p (for double start)…………………………………..9.22 Page no-107
Πd’
α = tan -1((2x5) ÷ (Πx21.5))
α = 8.421
µ = 0.14 from DDHB (Page no -110)
Co-efficient of friction for power screws, µ = tan Φ
Φ = tan-1 µ
Φ = tan-1 0.14
Φ = 7.96

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Frictional Torque for square thread at roller radius T = W d’ tan (Φ + α)……9.84a (107)
2
= 7.62x103 x 21.5 x tan (8.421+7.96)
2
T = 24x103 N-mm.
Torsional sheer stress,
τ = 16T
Π D i3
= 16x24x103
Πx193
τ = 17.82 N/mm2 < τa
Combined stress,
τ max = √((σc÷2)2 + τ2)
= √((26.83÷2)2 + 17.82 2)
τ max = 22.30N/mm2 < τa
Principal stress,
σ max = (σc/2) + √ ((σc/2)2+ τ2)
= (26.83/2) + √ ((26.83/2)2 + 17.822 )
σ max = 35.71 N/mm2 < σa
Bearing pressure from (DDHB Page no - 110)
For Screw - steel
Nut - C I (Cast Iron)
Pb= 12.4 – 17.2 N/mm2
No. of threads n = 4w . ………………………………………..9.32 page-108
Pb Π (d’2+Di2)
= 4x7.62x103 .
17xΠ(21.52-192)
n = 5.63 ≈ 6

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3.1.3 DESIGN OF NUT:

Length of the Nut L = n x p
=6x5
= 30mm
Sheer stress due to axial load τscrew = W .

ΠxnxDixt
Where, t = p = 5
= 7.62x103 2 2
Πx6x19x2.5 = 2.5mm
τscrew = 8.5 N/mm2 < τa
For Nut ,
Cast Iron…. …………………………………………………(page no - 427)
Gray ordinary,
σu (tension) = 124N/mm2
σu (compression) = 557N/mm2
BHN = 100-150
Yield stress in tension, σyt = σut = 124 = 62N/mm2
2 2
Sheer stress, τyt = σyt = 62 = 31N/mm2
2 2
Yield stress in compression, σyc = σuc = 557 = 278.5N/mm2
2 2
Shear stress, τyc = σyc = 278.5 = 139.25N/mm2
2 2
Allowable stress in tension, σat = σyt = 62 = 31N/mm2
2 2
Allowable sheer stress, τat = σat = 31 = 15.5N/mm2

2 2
Allowable stress in compression, σac = σyc = 278.5 = 139.25N/mm2

2 2

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Allowable shear stress in compression τac = σac = 139.25 = 69.62N/mm2
2 2
τnut = W .
ΠxnxDoxt
= 7.62x103
Πx6x24.5x2.5
τnut = 6.6N/mm2 < τat
< τac
Tearing strength of Nut,
W = Π (Do2 – Di2) σt x n
4
σt = 7.62x103x4
Π(24.52-192)x6
σ t = 6.75N/mm2 < σac
< σat
3.1.4 DESIGN OF HANDLE:

Torque = BM = 24x103 N-mm
σb = σa = 162N/mm2
d = ((32xM)/ (Πxσa))1/3
= ((32x24x103)/ (Πx162))1/3
d = 11.47mm
Load, P = Ts
l
= 24x103
300
P = 80N

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3.1.5 DESIGN OF SHAFT:
Fig shows shaft supported by bearings

W=3.81x103N
Neglect weight pulley, roller etc
M max = Wl = 3.8x103x120 ………………………………….Table 1.4 page no-10
4 4
Mmax = Ms =114300N-mm
Torque, T = 18288N-mm
Equivalent torque,
Te = √ (Ms 2 + T2)
= √ (1143002 + 182882 )
Te = 115753.79N-mm
Permissible shear, τ = 42 N/mm2
Stress for shaft with allowance for key commercial steel material
ds= 3(16x Te ) = 3 (16x115753.79)
Πxτ Πx42
ds = 24.12mm
3.1.6 KEY DESIGN :
Key material is same as that of shaft material

τk = τ = 42N/mm2
Torque transmitted by shaft Te = 112496.44 N-mm

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Width of key, b = ds/4 = 25/4 = 6.25 mm
From DDHB for diameter of shaft,

b = 10 mm
Thickness of key, tk = 8 mm
tk = ds/6 = 25/6= 4.2 mm
Shearing strength of key,

Te = lkxbx τ x d
2
lk = 112496x2
10x42x25
lk = 21.42 ≈ 22mm
For, l = 500 mm
y = 3.5mm
y = Wl3 ……………………………………………Table 1.4 page no-10
48EI
W = 3.5x48x2.1x105x16345
5003
W = 4613.21N
R1 = R2 = R = 2306.60N
Mmax = WL = 4613.21x500
4 4
= 576.65KN-mm
Z = 1029.60mm3
σb = M ……………………………………………………….(1.16)page no-3
Z
= 576.65x103
1029.60
σb = 560.07 N/mm2
σb > σy

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σb < σt material is safe
Torque, Ts = W x d’ x tan (Φ + α)……………………………..page no-107…9.24a

2
= 4613.21 x 21.5 x tan (8.421+7.96)
2
Ts = 14577.85N-mm
Load required to rotate handle, P = Ts where, l = handle length= 500 mm
l
= 14577.85
500
P = 29N
3.1.7 V-BELT AND PULLEY DESIGN:

Type of belt –A
Power range 0.7-3.5KW
Minimum Pitch diameter of pulley D = 75mm
Top width b = 30mm
Thickness t =8mm
Dimension of Standard V-grooved pulley

GROOVE DIMENSIONS IN MM
V-
BELT Angle of Groove in
A B C D E V T U W
degrees
12. 19.0 4.4 5.2 15.5 12.8 3.4 6.0 15.5
A-Type 34
7 5 5 3 5 3 9 4 5

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3.2 MODELING
3.2.1 INTRODUCTION TO SOLID EDGE
Solid Edge with Synchronous Technology combines the speed and flexibility of direct
modeling with precise control of dimension-driven design to provide the fastest, most flexible
design experience possible. With superior part and assembly modeling, drafting, transparent
data management and built-in finite element analysis, Solid Edge with Synchronous
Technology is a core component of the Velocity Series portfolio that eases the growing
complexity of product design. Solid Edge modeling and assembly tools enable your
engineering team to easily develop a full range of products, from single parts to assemblies
containing thousands of components. Tailored commands and structured workflows accelerate
the design of features common in specific industries and you ensure accurate fit and function of
parts by designing, analyzing and modifying them within the assembly model. With Solid
Edge, your products come together right first time, every time. Solid Edge is the only
mainstream mechanical system that merges design management capabilities with the CAD
tools that designers use every day.
3.2.2 FEATURE BASED MODELING
A feature is defined as the smallest building block that can be modified individually. A
model created in SOLID EDGE-V19 is a combination of a number of individual features and
each feature is related to the other directly or indirectly. These features understand their fit and
function properly and therefore can be modified any time during the design process. If proper
design intent is maintained while creating the model, then these features automatically adjust
their values to any change in their surroundings. This provides greater flexibility to the design.
3.2.3 PARAMETRIC MODELING
The parametric nature of a software package is defined as its ability to use the standard
properties or parameters in defining the shape and size of a geometry. The main function of
this property is to derive the selected geometry to a new size or shape without considering its

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original dimensions. We can change or modify the shape and size of any feature at any stage of
design process. This property makes the designing process very easy.
3.2.4 DRAWINGS:
350 24
O
19
410
2D VIEW OF LEAD SCREW

25
O
300
25
2D VIEW OF SHAFT

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30
120
30 O 24
140
2D VIEW OF NUT PLATE

6
R1
80
O
R 12,5
80
80
2D VIEW OF ROLLER

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600
500
400
815
220
120
ALL DIMENSIONS ARE IN MM
Fig : 2D View of Assembled Pipe Bending Machine

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BEARING
A bearing is a machine element which supports another moving element. It permits a
relative motion between the contact surfaces of the members, while carrying the load.
The ball bearing consists of an inner race which is mounted on the shaft and outer race
which is carried by the housing. In between the inner and outer race there are balls. A number
of balls are used and these are held at proper distance by retainers so that they do not touch
each other. The ball bearings are used for light loads.
NUTPLATE

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It is the mating part of the lead screw and it is mounted between the two slits. It guides
the lead screw and avoids the buckling of lead screw. It is made up of CI having ultimate
stress of 124 N/mm2 and 557 N/ mm2 in tension and compression respectively and having
hardness of 100-150BHN
LEAD SCREW
It is square threaded rod used for transmitting the load on roller by means of handle. It
is made up of C40 carbon steel having tensile strength of 570-667N/mm2 and yield strength of
324N/mm2 and having hardness of 217BHN.
SLIDER

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It is used for mounting the roller and for sliding between slits as varies with application
of load. The sliding movement is obtained by the rotation of lead screw.
ROLLER
It is used for the support of pipe and it is mounted on shaft for the movement of pipe on
either side. It is made up of 15Cr3 Mo55 having tensile strength of 785-932N/mm2 and yield
strength of 588N/mm2 and having 229-277BHN .
SHAFT

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A shaft is a rotating machine element which is used to transmit power from one place to
another. The material used is carbon steel of grades 40 C 8 having ultimate tensile strength
560-670N/mm2 and yield strength 320N/mm2 .
SLIT
It is the main part of the machine where all the parts are mounted. It is made up of
structural steel and it must be rigid to withstand loads.
BEARING HOUSING

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Assembled Pipe Bending Machine

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EXPLODED VIEW OF PIPE BENDING MACHINE

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ASSEMBLED PIPE BENDING MACHINE WITH MOTOR SET UP

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3.3 ANALYSIS
3.3.1 INTRODUCTION TO FINITE ELEMENT ANALYSIS
Finite Element Analysis (FEA) has been developed simultaneously with the increasing
use of high-speed electronic digital computers and with growing emphasis on numerical
methods for engineering analysis. FEA is a numerical technique for finding approximate
solutions of partial differential equations (PDE) as well as of integral equations.
3.3.2 NUMERICAL METHODS TO SOLVE THE PROBLEM
Numerical methods like FEM are based on discretization of integral form of equation.
Basic theme of all numerical methods is to make calculations at only limited number of points
and then interpolate the result for entire domain, even before getting the solution we assume,
how the unknown is going to vary over a domain.
A variety of specializations under the umbrella of the mechanical engineering discipline
(such as aeronautical, biomechanical, and automotive industries) commonly use integrated
FEM in design and development of their products. Several modern FEM packages include
specific components such as thermal, electromagnetic, fluid, and structural working
environments. In a structural simulation, FEM helps tremendously in producing stiffness and
strength visualizations and also in minimizing weight, materials, and costs.
3.3.3 SUMMARY OF ANALYSIS PROCEDURE

DISCRETIZATION OF THE DOMAIN
All real life objects are continuous, means there is no physical gap between any two
consecutive particles. As per material science, any object is made up of small particles,
particles of molecules, molecules of atoms and so on and bonded together by force of
attraction.
Solving a real life problem with continuous material approach is difficult and basic of
all numerical methods is to simplify the problem by discretizing it. In simple words nodes
work like atoms and with gap in between filled by an entity called element. Calculations are
made at nodes and results are interpolated for elements.

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All th numerical methods including FEM follow discrete approach. Meshing is nothing
but discretization of a continuous system with infinite degree of freedom to finite degree of
freedom.
SELECTION OF DISPLACEMENT MODEL
This is the stage where basic approximation is introduced. The assumed displacement
function or model represents approximately the actual or exact distribution of displacements.
There are three interrelated factors influencing the selection of displacement model.
First is the type and degree of the displacement model. Second, the particular displacement
magnitude that describes the model must be selected, these are usually displacements at nodal
points, but they must also include derivatives of the displacement at some or all nodes. Third,
the model should satisfy certain requirements which ensure that the numerical approach the
correct solution.
DERIVATION OF ELEMENT STIFFNESS MATRIX
The stiffness matrix consists of the co-efficient of the equilibrium equations derived
from the material and geometric properties of an element and obtained by use of the principle
of minimum potential energy.
The stiffness relates the displacement at nodal points to the applied forces at nodal
points. The distributed forces applied to the structure are converted into equivalent
concentrated loads at nodes. The equilibrium relation between the stiffness matrix [K], nodal
force vector {Q}, and nodal displacement vector {q} is expressed as a set of simultaneous
linear algebraic eqn
[K] {q} = {Q}

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GENERATION OF ALGEBARIC EQUATIONS FOR OVERALL DISCRETIZED

CONTINUUM
This process includes the assembly of the overall or globalized stiffness matrix for the
entire body from individual stiffness matrix. One of the most commonly used assembly
technique is known as direct stiffness method.
The overall equilibrium relations between the total stiffness matrix [K], the total load
vector{R}, and the nodal displacement vector for entire body{r} is expressed as
[K] {r} = {R}
These equations cannot be solved until the geometric boundary conditions are taken
into account by appropriate modifications of the equation.
SOLUTION FOR UNKNOWN DISPLACEMENT
The algebraic equations assembled in above procedure will be solved for unknown
displacements. For linear equilibrium problems matrix algebra techniques are used. However
for non-linear problems the desired solutions are obtained by a sequence of steps.
COMPUTATION OF ELEMENT STRAINS AND STRESSES FROM NODAL

DISPLACEMENT
In general, the stresses and strains are proportional to the derivative of the displacement
and in the domain of each element meaningful values of the required quantities are calculated.
These values are usually taken as average value of stresses or strain at the centre of element.

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3.3.4 INTRODUCTION TO ANSYS
3.3.4.1 DESCRIPTION
ANSYS is a general-purpose finite-element modeling package for numerically solving
a wide variety of mechanical problems. These problems include static/ dynamic, structural
analysis (both linear and nonlinear), heat transfer, and fluid problems, as well as acoustic and
electromagnetic problems.
In general, a finite-element solution may be broken into the following three stages.
1 Preprocessing: defining the problem

The major steps in preprocessing are
(i) define key points/lines/areas/volumes,
(ii) define element type and material/geometric properties, and
(iii) mesh lines/areas/ volumes as required.
The amount of detail required will depend on the dimensionality of the analysis,
i.e.1D, 2D, axisymmetric, and 3D.
2 Solution: assigning loads, constraints, and solving

Here, it is necessary to specify the loads (point or pressure), constraints (translational
and rotational), and finally solve the resulting set of equations.
3 Post processing: further processing and viewing of the results

In this stage one may wish to see (i) lists of nodal displacements, (ii) element forces and
moments, (iii) deflection plots, and (iv) stress contour diagrams or temperature maps.
3.3.4.2 ELEMENT TYPES AND REAL CONSTANTS

The ANSYS element library contains more than 100 different element types. Each
element type has a unique number and a prefix that identifies the element category.
Real constants are properties that depend on the element type, such as cross-sectional
properties of a beam element. As with element types, each set of real constant has a reference

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number and the table of reference number versus real constant set is called the real constant
table. Not all element types require real constant, and different elements of the same type may
have different real constant values.
3.3.4.3 TYPES OF ANALYSIS

1. Linear static analysis
2. Non linear static analysis
3. Dynamic analysis
4. Thermal analysis
5. Fatigue analysis
LINEAR STATIC ANALYSIS

Linear means straight line. σ = ε E is the equation of straight line passing through
origin.
There are two conditions for static analysis
1. Force is static i.e. no variation with time.
2. Equilibrium condition
Practical applications: Most commonly used analysis. All Aerospace, Automobile,
Offshore and Civil engineering industries perform linear static analysis.
NON LINEAR STATIC ANALYSIS

This analysis for metallic non linearity problems and non metallic non linearity
problems where Stress (Force) Vs. Strain (Displacement) curve non linear.
DYNAMIC ANALYSIS
This analysis is applicable to both free and forced vibration analysis to find the
frequency at which object will vibrate and also transient response and random vibration of the
system.

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Practical Applications: Natural frequency is characteristic and basic design property

of any components while forced vibrations is applicable for components subjected to force/
displacement/velocity/acceleration varying with time/frequency.
THERMAL ANALYSIS
This analysis for finding the modes of heat transfer in all the cases i.e. conduction,
convection and radiation.
Practical Applications: Engine, radiator, exhaust system, heat exchangers, power
plants, satellite design etc.
FATIGUE ANALYSIS
This analysis for calculations for life of the structure when subjected to repetitive load.
All fatigue calculations are based on S-N curve.
Practical Applications: Applicable to all the components subjected to dynamic
loading i.e. all automobile components.
3.3.4.4 BASICS OF LINEAR STATIC ANALYSIS
A linear static structural analysis is performed to obtain the response of a

structure under applied static loads. Displacements, reaction forces, stresses, and strains are
usually items of interest that the user wants to review
The general equation of motion is as follows:
Where,
[M ]{&x&}+ [C ]{x&}+ [K ]{x} = {F (t )}
[M] is the mass matrix,
[C] is the damping matrix,
[K] is the stiffness matrix,
{x} is displacements, and
{F} is force
Because this is a static analysis, all time-dependent terms are removed, leaving the
following subset:
[K ]{x } = {F }
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For a linear static structural analysis, the displacements {x} are solved for in the matrix
equation below:
This results in certain assumptions related to the analysis:
[K ]{x } = {F }
– [K] is essentially constant
• Linear elastic material behavior is assumed
• Small deflection theory is used
• Some nonlinear boundary conditions may be included
– {F} is statically applied
• No time-varying forces are considered
• No inertial effects (mass, damping) are included
• In Design Simulation, the following elements are used:
– Solid bodies are meshed with 10-node tetrahedral element SOLID92
MATERIAL PROPERTIES
• The required structural material properties are Young’s Modulus and Poisson’s
Ratio for linear static structural analyses
– Material input is under the “Engineering Data” branch, and material assignment
is per part under the “Geometry” branch
– Mass density is required if any inertial loads are present
– Thermal expansion coefficient and are required if any thermal loads are present
– Stress Limits are needed if a Stress Tool result is present
– Fatigue Properties are needed if Fatigue Tool result is present
THERE ARE FOUR TYPES OF STRUCTURAL LOADS AVAILABLE

• Inertial loads
These loads act on the entire system

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Density is required for mass calculations

• Structural Loads
These are forces or moments acting on parts of the system

• Structural Supports
These are constraints that prevent movement on certain regions

• Thermal Loads
Structurally speaking, the thermal loads result in a temperature field, which

causes thermal expansion on the model.
ROTATIONAL VELOCITY
• Rotational velocity is another inertial load available
– Entire model spins about an axis at a given rate
– Can be defined as a vector, using geometry for axis and magnitude of rotational
velocity
– Can be defined by components, supplying origin and components in World

Coordinate System
– Note that location of axis is very important since model spins around that axis.
– Default is to input rotational velocity in radians per second. Can be changed in

“Tools > Control Panel > Miscellaneous > Angular Velocity” to revolutions per minute (RPM)
instead.
FORCE LOADING
• Forces can be applied on vertices, edges, or surfaces.
• The force will be distributed on all entities. This means that if a force is applied
to two identical surfaces,each surface will have half of the force applied.
• A force is defined via vector and magnitude or by components.

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FIXED SUPPORT
– Constraints all degrees of freedom on vertex, edge, or surface
– For solid bodies, prevents translations in x, y, and z
– For surface and line bodies, prevents translations and rotations in x, y, and z
EQUIVALENT STRESS
• Equivalent Stress:
– The von Mises or equivalent stress se is defined as:
1
σe =
2
[ ]
(σ 1 − σ 2 )2 + (σ 2 − σ 3 )2 + (σ 3 − σ 1 )2
– This criterion is commonly used for ductile metals.
– When uniaxial tensile tests of specimens are performed to determine the yield
strength and stress-strain relationships, the engineer needs a way to relate the uniaxial data to
the stress state (tensor). Hence, the equivalent stress is a commonly used scalar invariant for
this purpose.
MAXIMUM EQUIVALENT STRESS THEORY
– The Maximum Equivalent Stress Theory can be used for the “Stress Tool”. It
compares the equivalent stress with the yield (or ultimate) strength and is suitable for ductile
materials.
– The criterion is as follows
σ y
F safety =
σ e
– Where σy is the tensile yield (or ultimate) strength.
– The maximum equivalent stress criterion is also known as the distortion energy
criterion.
MAXIMUM SHEAR STRESS
– The maximum shear stress tmax is defined as

2010
σ1 −σ 3
τ max =
2
Which results in the largest principal shear stress
– This value can be compared to the yield strength to predict yielding for ductile
materials
Stress Intensity
– The stress intensity is twice the value of the maximum shear stress.
– The stress intensity provides the value of the largest difference between
principal stresses
Maximum Shear Stress Theory

– The Maximum Shear Stress Theory or the Tresca criterion can be used for the
“Stress Tool”. It is suitable for ductile materials.
fσ y
Fsafety =
τ max
– The criterion is as follows where sy is the tensile yield strength and factor is a
factor (default =0.5)
– The failure surface is plotted in two-dimensional principal stress space below
with the von Mises criterion superimposed on in with a thin line.
BASICS OF MODAL ANALYSIS

A modal analysis, or a free vibration analysis, is performed to obtain the natural
frequencies and mode shapes of a structure
– Modal analysis does not consider the response of the structure under dynamic
loads but rather the natural frequencies. A modal analysis is usually the first step before
solving more complicated dynamic problems.

2010
A modal analysis is a subset of the general equation of motion:
[M ]{&x&}+ [C ]{x&}+ [K ]{x} = {F (t )}
[M ]{&x&}+ [K ]{x } = 0
In modal analysis, the structure is assumed to be linear, so the response is assumed to
be harmonic.
Where,
φi is the mode shape (eigenvector) and
ωi is the natural circular frequency for mode i.
By substituting this value in the earlier equation, the following is obtained:
−ω [M]{φi }cos(ωit) +[K]{φi }cos(ωit) = 0

2
i
(−ω [M]+[K]){φ }cos(ωt) = 0

2
i i i
Noting that the solution fi =0 is trivial (very small), wi is solved for:
([K ] − ω i
2
[M ]){φ i } = 0
For a modal analysis, the natural circular frequencies wi and mode shapes fi are
obtained from the matrix equation:
This results in certain assumptions related to the analysis:
• [K] and [M] are constant:
• Linear elastic material behavior is assumed
• Small deflection theory is used, and no nonlinearities included

2010
• [C] is not present, so damping is not included

• {F} is not present, so no excitation of the structure is assumed
• The structure can be unconstrained (rigid-body modes present) or partially/fully
constrained, depending on the physical structure
• It is important to remember these assumptions related to performing modal analyses
in Design Simulation.
MODAL ANALYSIS PROCEDURE

The modal analysis procedure is very similar to performing a linear static analysis, so
not all steps will be covered in detail. The steps in yellow italics are specific to modal
analyses.
– Attach Geometry
– Assign Material Properties
– Define Contact Regions (if applicable)
– Define Mesh Controls (optional)
– Include Supports (if applicable)
– Request Frequency Finder Results
– Set Frequency Finder options
– Solve the Model
– Review Results
GEOMETRY AND MATERIAL PROPERTIES

Similar to linear static analyses, any type of geometry supported by Design Simulation
may be used.
– Solid bodies
– Surface bodies (with appropriate thickness defined)

2010
– Line bodies (with appropriate cross-sections defined)
• For line bodies, only mode shapes and displacement results are available.
• For material properties, Young’s Modulus, Poisson’s Ratio, and Mass Density
are required
– Since no loading is assumed, no other material properties will be used, if

defined.
LOADS AND SUPPORTS

Structural and thermal loads not used in a modal analysis. Supports can be used in
modal analyses:
– If no or partial supports are present, rigid-body modes can be detected and
evaluated. These modes will be at 0 or near 0 Hz. Unlike static structural
analyses, modal analyses do not require that rigid-body motion be prevented.
– The boundary conditions are important, as they affect the mode shapes and
frequencies of the part. Carefully consider how the model is constrained.
– The compression only support is a nonlinear support and should not be used in
the analysis.
– If present, the compression only support will generally behave similar to a

frictionless support.
SOLVING THE MODEL

• After setting up the model, one can solve the modal analysis just like any other
analysis by selecting the Solve button.

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4.1 ANALYSIS RESULTS:
MESHED VIEW OF PIPE BENDING MACHINE

2010
LOAD APPLICATION

2010
PIPE DEFORMATION

2010
BODY DEFORMATION

2010
SHEAR FORCE DIAGRAM FOR L=300

2010
BENDING MOMENT DIAGRAM FOR L=300

2010
DEFLECTION DIAGRAM FOR L=300

2010

2010

2010
DEFLECTION DIAGRAM FOR L=300 AT DIFFERENT LOAD POSITION

2010
4.2 APPLAUSEMENT:
MANUAL PIPE BENDING MOTORIZED PIPE BENDING

MACHINE MACHINE
Middle Roller is used for the pipe Supported Rollers are used for the
movement and which is driven by movement of pipe and which are
man driven by motor
Bending rate is low Bending rate is high
Takes more time to adjust the Easily adjustable compared to

distance between rollers manual pipe banding machine
More fatigue for an operator Less fatigue for an operator
Minimum two operators required to Only one operator is sufficient to

operate the machine operate the machine

2010
CONCLUSION
The purpose of this project was to analyze and redesign the structure of a currently
modeled pipe bender with the ultimate goal of offering redesign suggestions that would make
the machine more efficient. As outlined in the discussion above, the pipe bender redesign is
improved the ease of use with less fatigue to operators. Furthermore, this was able to be
accomplished at no loss of functionality. This demonstrates the importance of proper
engineering technique and analysis when designing a product.

2010
REFERENCES
Machine Design – R.S Khurmi.

Strength of Materials-R.K.Bansal.
Design Data Hand Book – Balaveera Reddy And Mahadevan-2003 Edition.
Design Data Hand Book-Dr.K.Linghaiah.
Production Technology-R.K.Jain.
Material Science & Metallurgy – O.P.Khanna.
WEB:
www.wikipedia.com
www.howstuffworks.com
www.scribd.com

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Design, Modeling And Analysis Of Motorized Pipe Bending Machine

1.1 INTRODUCTION TO BENDING MACHINE:

1.2 SCOPE OF WORK:

Dept. of Mechanical Engg. PESCE , Mandya Page 1

2.2 LITERATURE SURVEY AND CASE STUDY

Dept. of Mechanical Engg. PESCE , Mandya Page 2

2.2.1 Pipe Bending Process:

2.2.1.1 Rotary Draw Pipe Bending:

Dept. of Mechanical Engg. PESCE , Mandya Page 3

2.2.1.2 Compression Pipe Bending

Dept. of Mechanical Engg. PESCE , Mandya Page 4

2.2.1.3 Stretch Bending

Fig.a.Initial configuration of stretch bending

Fig.b.Final configuration of stretch bending

Dept. of Mechanical Engg. PESCE , Mandya Page 5

2.2.1.4 Roll Bending

Dept. of Mechanical Engg. PESCE , Mandya Page 6

Manual Pipe bending machine

Problems faced by users:

Dept. of Mechanical Engg. PESCE , Mandya Page 7

3.1.1 POWER REQUIRED TO DRIVE ROLLERS:

Dept. of Mechanical Engg. PESCE , Mandya Page 8

Moment of inertia, I = Π (D4-d4) ...............................Table 1.4(page no.9)

For deflection, y = 1.25mm

Mmax = WL ……………………………………………..Table 1.4(page no.10)

Z = I …………………………………………………Table 1.3(page no-8)

Dept. of Mechanical Engg. PESCE , Mandya Page 9

Torque = FD’ where,

Dept. of Mechanical Engg. PESCE , Mandya Page 10

3.1.2 DESIGN OF LEAD SCREW:

Pitch diameter, d’ = Do+Di

Dept. of Mechanical Engg. PESCE , Mandya Page 11

Dept. of Mechanical Engg. PESCE , Mandya Page 12

3.1.3 DESIGN OF NUT:

Sheer stress due to axial load τscrew = W .

Allowable sheer stress, τat = σat = 31 = 15.5N/mm2

Allowable stress in compression, σac = σyc = 278.5 = 139.25N/mm2

Dept. of Mechanical Engg. PESCE , Mandya Page 13

3.1.4 DESIGN OF HANDLE:

Dept. of Mechanical Engg. PESCE , Mandya Page 14

3.1.5 DESIGN OF SHAFT:

Fig shows shaft supported by bearings

3.1.6 KEY DESIGN :

Key material is same as that of shaft material

Dept. of Mechanical Engg. PESCE , Mandya Page 15

Width of key, b = ds/4 = 25/4 = 6.25 mm

From DDHB for diameter of shaft,

Shearing strength of key,

Dept. of Mechanical Engg. PESCE , Mandya Page 16

σb < σt material is safe

Torque, Ts = W x d’ x tan (Φ + α)……………………………..page no-107…9.24a

3.1.7 V-BELT AND PULLEY DESIGN:

Dimension of Standard V-grooved pulley

Dept. of Mechanical Engg. PESCE , Mandya Page 17

3.2.2 FEATURE BASED MODELING

3.2.3 PARAMETRIC MODELING

Dept. of Mechanical Engg. PESCE , Mandya Page 18

2D VIEW OF LEAD SCREW

Dept. of Mechanical Engg. PESCE , Mandya Page 19

2D VIEW OF NUT PLATE

Dept. of Mechanical Engg. PESCE , Mandya Page 20

ALL DIMENSIONS ARE IN MM

Fig : 2D View of Assembled Pipe Bending Machine