DESIGN AND

FABRICATION OF
BENDING MACHINE

ABSTRACT

My project is to design and

construct a bending machine. This
machine is used to bend steel into
curve or other curvature shape. The
size of the machine is very convenient
for portable work. It is fully made by
steel. Moreover it is easy to be carried
and used at any time and any place.

INTRODUCTION

To build this machine many equipment

or machine is used. By using all this
equipment, process for making the project is
faster and easier. I had also learned a proper
method for operating all this machine and
equipment. Choosing component material is
very important, because it will affect the
overall cost of the machine and the product
quality. With this consideration, I had design
this machine with the maximum quality and
low in cost.

TYPE OF BENDING
MACHINES

TUBE BENDING
CIRCLE BENDING
BAR BENDING
CHENNEL BENDING
SQUARE BENDING

TUBE BENDING:
The Forming Roller method of tube bending is recommended
for all large bends. where the centerline radius is at least 4
times the outside diameter of the tube. It can also be
successfully employed for bending pipe or heavy wall tubing
to smaller radii and is the most practical method of bending
very small diameter tubing. The Forming Roller and Radius
Collar must be grooved to exactly fit the tube and the tube
must not be allowed to slip during the bending operation as
even a slight amount of slippage will cause distortion.

CIRCLE BENDING:
This operation is somewhat involved by
the fact that most materials spring
back after they have been formed. To
compensate for this, it is often
necessary to use a Radius Collar having
a smaller diameter than that of the
circle required. Actual size can best be
determined by experiment, as the
spring back varies in different
materials. Material should be precut to
exact length before forming.

CHANNEL BENDING:
The same general bending rules which cover the forming of channel with
flanges out also apply when it is formed with flanges in. Since it is necessary to
compress the flanges as they are bent inward, the operation shown below requires
considerably more bending pressure than when forming with the flanges out, and it
is recommended that the largest possible radius be used to allow for compression of
the material. if a sharp 90 bend is desired, it can be obtained by cutting a notch out of
the channel flanges before forming around a special Zero
Radius Block as illustrated . It is sometimes possible to make a circle in channel by
using a segment of a Radius Collar similar . By following the procedure outlined on,
the circle can be formed in three operations. To form channel with the flanges facing
upward it is necessary to first fill it with Cerro bend or some other commercial filler as
it is not possible to support the flanges in this position with a radius Collar.

SQUARE BENDING:
Forming zero radius bends around square, rectangular, or
other multisided blocks employs the same principle used in
scroll bending. Forming Nose leads material between
corners of the block. Any number of zero radius bends can be
obtained in one operation by this method in all types of solid
materials. Both centered and off-center square eye can also
be formed by following the same procedure outlined on. This
method of bending is limited by the size of the square block
and the ductility of the material. In general, when squares
larger than 1 are needed, they should be formed in
progressive operations using the zero radius block.

WORKING

WORKING
The rod to be bent is placed in
between the two Jigs mounted on the
circular plate. The motor is attached with
the circular plate. The power from the
motor is transfered which rotates the
circular
plate
in
anticlockwise
direction.one Jig is connected to the
motor and the other Jig is rotated due to
the rotation of circular plate. The rod will
be fixed since the fixed rod lies on the

CALCULATION
motor speed is 40 rpm and power is equal to 0.5 hp.
Given

Speed (N) = 40rpm

Power =0.5hp=0.37285kw
=0.3728*103 w

Power is transmitted by the motor is known as

P =2
0.3728*10^3 = 2
T = 89*103 Nm

WKT,T = (16)
89103 = (16)d3
Here
d = 10mm (where diameter of rod to be bend
= 458 N/mm2

calculated shear stress = 458 N/mm2

wkt ,
(by) = (MtI)
y = (d2) = (102) = 5mm

moment of inertia I = (64)d4

I = (64)104 = 490.87 mm4

b= 891035/490.87
bending stress b = 906.66 N/mm2
substitute all the values in the above relation.

906.66/10 = M/490.87
M
= 44500 N mm

WL/4= 44500
W
= 445004/100
L
= length of the rod = 200 mm
W = 1780 N =182 kg
Polar moment of Twist
J
= (32)d4
= (32) 104
J
= 981.74 mm4
Common angle of Twist
= (TLCsJ)
Cs = modulus of rigidity
= 8.4104 N/mm2

= (90103100/8.4104981.74)

= 0.109 rad
= 0.109(180)
= 6.25

APPLICATIONS

ANGLE BENDING
METAL FOLDING
U HOOK
MARINE TUBE
HEAT EXCHANGER
SCROLL BENDING

ADVANTAGES
Easily operated.
Simple construction.
Low cost.

SPECIFICATION
MOTOR
MOTOR POWER-0.5hp
SPEED-40rpm
CIRCULAR DISC
DIAMETER -20mm
THICKNESS -2.5mm
jigs -2 no
BATTERY -12v