ProjectDESIGN AND FABRICATION OF SHEET ROLLING MACHINE Report
ProjectDESIGN AND FABRICATION OF SHEET ROLLING MACHINE Report
ProjectDESIGN AND FABRICATION OF SHEET ROLLING MACHINE Report
OF SHEET ROLLING
MACHINE
A PROJECT REPORT
Submitted by
K.FEROZE ALI
950612114030
S.ABDUL RHAMAN
950612114301
V.BALA SANKAR
950612114305
A.GURUVARAN
950612114306
BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING
EINSTEIN COLLEGE OF ENGINEERING
TIRUNELVELI
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
SUPERVISOR
Professor,
Assistant Professor,
INTERNAL EXAMINER
EXTERNAL EXAMINER
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 students 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.
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.
ABSTRACT
PROJECT OBJECTIVE
To implement the skills acquired in previous semester to practical
problems
PROJECT,MECHANICAL
curriculum
to
fulfil
the
ENGINEERING
above,
we
are
ANNA
focused
UNIVERSITY
in
the
area
of
LIST OF FIGURE
PAGE NO
1.1 Stress in bending
12
14
15
16
17
19
21
22
LIST OF CONTENT
Page No
1. Introduction
11
2. Bending
12
13
3. Process of rolling
13
15
5. Steps in rolling
16
17
7. Working principle
18
8. Design
19
20
21
22
9. Synopsis
28
10. Application
29
11. Advantages
30
12. Disadvantage
31
32
10
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.
Punching
Roll forming
Rolling
Spinning
Stamping
Bending
Deep drawing
Expanding
Curling
Press brake forming
11
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
U-Die bending
V-Die bending
Roll bending
Bending in the four slide machine
Curling
Dimpling
Flanging
U-Die bending with spring pad
12
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.
13
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.
14
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,
5.STEPS IN ROLLING
15
17
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
18
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;=frictionalforce;ho,hf=thicknessof thesheet before and
after timet.
Atleast two rollers were involved in flatrolling dependingonthe thicknessand
properties
ofmaterial
whilethreeormultiplerollersystem
isrequiredinshape
19
20
21
2
Elastic limit (yield stress) y =515MN/ m
Poissons ratio=0.34
Given data from the specification of the machine
22
K= (R i+ r l)2 f 2
23
f 2 t rl
K ru
Ri
2 ru rl t K
=0.0863m
sin =
f
(R i+ r l+ t)
=sin
0.06
(0.863+ 0.025+0.001)
48.7 o
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
=0.017m
24
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=
=594.67 106
N
m2
I=
b t3
12
0.4 0.0013
12
1
66.89
=
9
e 207 10 3.333 1011
Ri +
t
2
=66.89 Nm
=3.333
1011
=9.704m
=0.863+0.0005=0.8635m
1
1
1
=
=
r 0.08635 0.103
r =
b t 2
4
1.872m
0.534m
25
1 0.017
66.89= Pv 4 + 2 tan 48.7
PV =
257.59N
Pl=
257.59
2 cos 48.7
=195.14N
Ps
=195.14
48.7=
sin
146.60N
MpV
r
( )=(
66.89 0.0215
0.534
=2.69kw
M p rl
r
( )=(
66.89 25
=
0.534
Shaft diameter:
For greater strength 45c8 (steel) is common for shafts
26
3131.55N-mm
Syt = 580
Sut = 770
N
2
mm
N
mm2
Mt
=
=
16
d 3
kb M b 2 K t M t
(60 10 6 ) P
2n
0.092 60
=
2 0.025
35rpm
( 60 106 ) 2.69
Mt
Kb
=1.5,
max
2 35
Kt
) =7.33
105
N-mm
=1
27
16
( 138.6
) ( 1.5 1942300 ) +( 1 733931.65 )
2
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.
28
10.APPLICATIONS
29
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
30
12.DISADVANTAGES
This machine has a hand operated one
Production time is high.
31
NAME OF MATERIALS
QUANTITY
3
2
1
6
6
TOTAL
32
AMOUNT
1500
500
500
100
400
500
500
4000/-
33
34
35
36