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DESIGN AND FABRICATION OF MULTIROD BENDING

MACHINE
C. Anbumeenakshi 1, M.R.Thansekhar2, Thanamani.M3, Santhoshkumar.R4 , Parivallal.S5,
Senthilkumar.K6
1
Assistant Professor, 2Professor, 3,4,5,6UG Student,
K.L.N College of Engineering, Pottapalayam, India

Abstract RCC column is a structural member of RCC


Nowadays for construction works bending of frame structured building. It's a vertical member
rods is necessary for constructing the pillars. which transfers loads from slab and beam
Bending of such rods is done manually by directly to subsequent soil. A whole building
setting angle plates. This wastes lot of labour stands on columns. Most of the building failure
(man) power and time. It is proposed to happens due to column failure. And most of the
replace the manual work and reduce time column failure happens not for design fault but
taken for bending by designing an alternative for the poor construction practice. So, it is very
machine to replace the manual work which important to know the construction process of
works by the principle of hydraulic system the RCC column properly .Constructing RCC
and indexing mechanism. This will reduce Column involves following four stages of works
the time taken for bending operation and are Column layout work, Column reinforcement
more than one rod can be bent at a same work , Column formwork and Pouring concrete
time. Bending can be done with required into column. In this stage of works the location
dimensions and accuracy is maintained of columns are determined practically in field. It
during the entire operation. By changing the is done by laying rope according to grids shown
dimensions of the die required bents are in the drawing and then mark the location of
made on the rods. Along with the ease of columns related to rope. In drawing, column
operation use of hydraulics also makes it locations are shown related to grid-line with
more precise, economical and compact. The dimension. Practically, in field, ropes are our
entire machine is easily portable and having grid-line. So we place columns related to rope-
nice aesthetics as well. line by measuring dimension shown in the
Keywords: hydraulic system, indexing drawing. After marking the column locations,
mechanism, bending operation we then start to place reinforcement as
instructed in the structural drawing. In building,
1.0 Introduction floor height is normally kept 10 feet. If the slab
A stirrup is a closed loop of reinforcement bar has beam then we have to pour concrete up to
that is used to hold the main reinforcement bars beam bottom level.
together in an RCC structure. In a column, the A stirrup is a closed loop of reinforcement bar
stirrups provide the lateral support to the main that is used to hold the main reinforcement bars
bars against buckling. The earliest manifestation together in an RCC structure. In a column, the
of the stirrup was a toe loop that held the big toe stirrups provide the lateral support to the main
and was used in India late in the second century bars against buckling. When used in beams, a
BC, though may have appeared as early as 500 stirrup is termed as shear or transverse
BC. This ancient foot support consisted of a reinforcement since it withstands the shear
looped rope for the big toe which was at the force. Stirrups can be of various shapes
bottom of a saddle made of fiber or leather. depending on the design and shape of the load

ISSN (PRINT): 2393-8374, (ONLINE): 2394-0697, VOLUME-5, ISSUE-1,


2018
20
INTERNATIONAL JOURNAL OF CURRENT ENGINEERING AND SCIENTIFIC RESEARCH
(IJCESR)
INTERNATIONAL JOURNAL OF CURRENT ENGINEERING AND SCIENTIFIC RESEARCH
(IJCESR)
bearing member e.g. Circular, polygonal, a U- made of iron plates welded together at the
stirrup or a crosstie. However the most joints. The frame has four supporting legs with
commonly used shape in normal construction is a side support to hold the hydraulic reservoir.
a rectangular or a square one. The frame bears the loads acting during the
bending operation which are produced by the
Traditionally, in India, the stirrups cylinder motions (forward and return stroke).
are made manually at the construction site by There are two double acting hydraulic cylinders
the bar benders using rudimentary practices. In residing on the top of the frame. One of the
most cases, such stirrups do not comply with cylinders carries a roller which helps in
the prescribed standards. Beside dimensional applying force on the rod while bending.
inaccuracies, this can lead to improper locking Another cylinder carries a lock nut by which the
of the ends thereby increasing the chances of indexing plate is rotated to allow free rotation of
failure during earthquakes. Stirrups of inferior the die during bending of the rod at different
quality act like "weak-links" in a RCC structure edges. The cylinder from which force applied
and can enhance the chances of collapse of a for bending is fixed to the frame by welded
building under adverse conditions. joints and the other cylinder is free to move
In this it is proposed a new idea of over the frame having one end pinned to frame.
manufacturing the machine with automation Followed by the cylinder the bending assembly
and sophistication as well as safety precautions. comprising the base plate, index plate and the
die are placed one over other in front of the
2.0 Construction of multi rod bending cylinders. The base plate is attached to the
machine frame through a centre shaft and welds. It
The multi rod bending machine is an electro- carries the index plate and the die. The index
hydraulic unit, where the electrical power plate is placed over the base plate and it is free
supply makes the motor to run and the hydraulic to rotate about its centre with the help of the
power pack provides the necessary force that is centre shaft. The index plate is designed with
required to bend the rods. The base of our grooved edges which make it to perfectly lock
system is formed by a strong rectangular frame the locking nut attached to the cylinder.

Figure 1: Multirod bending machine

The rotation of the index plate is arrested end is connected to the springs. The springs are
during bending with the help of a locking attached to cylindrical pins that projects into the
system fitted to the bottom of the frame. The die die through the holes drilled inside the die
is placed over the index plate and hold firmly to surface. By pressing the long plate that acts as a
it by centre shaft and locking pins. The die is handle the pins are retracted and lifted
not allowed to rotate independently; it rotates respectively. In order to actuate the cylinders a
along with the index plate. The locking system hydraulic reservoir is placed along the side
is simple spring actuated mechanism having a support of the frame. The rectangular sump
long rectangular plate one end placed over a rod contains the oil necessary for hydraulic
welded to the reservoir top surface; the other operation. The reservoir along with the motor,
pump, filter and direction control valve is operation the rods are prevented from back
collectively known as the hydraulic power pack. track by using a key. The key is a three plate
The oil flow from the tank to the actuators is welded closing lid type structure which locks
through the hydraulic hoses and regulated by the rod in between the gap provided.
the direction control valve. During the bending
5.2 WORKING PRINCIPLE

FIGURE 2 Piston and Die arrangement

The rod to be bent is cut to proper dimensions of the right side piston. The piston motion is
and then placed along the outer surface of the arrested when the die has turned completely to
die with its projecting side perpendicular to the its next edge and the retraction of the piston
left side cylinder. The rods are locked using the happens. Now we have the same setup as it is in
locking key before start of the operation. The the starting stage of bending, by doing the same
power supply is on and the motor starts to run, procedure the rod is bent along the outer surface
there after the motor is allowed to run for of the die and by indexing the die again and
sometime which is to allow proper circulation again the required shape (square) of the stirrups
of hydraulic oil inside the oil reservoir, pump is obtained. Finally the completed stirrups are
and the direction control valve respectively. taken out form the die for use.
While ensuring proper working of the hydraulic
power pack the cylinders are also checked by
moving the piston (forward and retraction).
After completing the preliminary checkups the
left side lever of the DCV is pushed front which
moves the left side cylinder’s piston forward,
there by applying some force to the rod in front
of it. The rod is bent along the outer surface of
the die by the guidance of the grooved roller
attached to the front end of the left side piston.
After reaching the full forward position the
piston is stopped and then retracted slowly
along the same path as it is travelled before.
Now the die is indexed to its next edge by
actuating the right side piston. The right side
piston carries a locking plate along with a pin.
The locking pin engages with the curved profile
of the indexing plate making the die and the
index plate to rotate during the forward motion
Figure 3: 2 D view of multirod bending machine
Table 1. List of components

SI.No. Component Quantity


name
1 Bending cylinder 1
2 U bend lock 2
3 Given rod(6mm) 3
4 Required die 1
5 Indexing plate 1
6 Base plate 1
7 Electric motor 1
8 Hydraulic tank 1
9 Frame 1
10 cylinder (Index) 1
5.3 5
ADVANTAGES .
AND 4
APPLICATIONS
•Reduction of man C
power employed. O
•Improved output. N
•Increased safety. C
•Easy handling & L
movement of U
machine. S
•Easy access to all I
areas. O
N
With the
implementation
multirod bending
machine the manual
usage and cycle time
is reduced. This
hydraulic and
controlling system
is totally
environmentally
friendly and
contains no
hazardous. They
are compact in
size and
reliable. For making r t.com/uplo 2.
20 stirrups without r ad/2014/sp Isites.harvard.
using multirod u ecial/ta edu/Bending
bending machine p psa/41_TA Pneumatic
the time consumed s PSAMEC Rubber
was about 1 hr ) H003.pdf
and by utilizing 1Hrs. Actuation
multirod bending 15 Min. ieee
machine the time Thus multi rod journal
consumed was about bending machine is conference on
15 minutes and used for making 2010//
hence the time stirrups(automatic) 3.
consumption was with improved www.mdpi.com/20
reduced of about 45 output and 76-0825/5/1/3/pdf
minutes and the increased safety. 4.
productivity was A www.axerwa
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