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TABLE OF CONTENT
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1.0 INTRODUCTION
In three roller steel plate bending machine sheet is bend with the help of load acting
on upper roller. Three roller sheet bending machine mainly consist of following parts, 3
rollers (upper roller and 2 bottom rollers), motors, gears, power screw, and frame. Bending
operation is done by applying load (force) with the help of upper roller, which is movable.
Motor is used in steel plate bending machine for providing power transmission. Gear drives
are used for minimize the rpm transferred from motor to the machine. Spur gears are used in
3 roller sheet bending machine. Frames is a fixed rigid support used for supporting the
Figure 1.1: Three roller plate rolling sequence for fixed bottom roller gap
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The entire process of three roller plate bending machine can be divided into three:
First the flat plate is fed into the bending machine by two rotating bottom rollers. It is fed
until the plate is properly positioned. Then the centre of the roller displaced downward causes
bending of the plate. Two bottom rollers rotate continuously so that the plate also bent
continuously.
This machine can produce variety of bending size which are useful in different
Significantly this machine reduces the efforts required to bend plate to a large extent.
Bending load from the top roller required to bend the plate is the function of various
parameters:
1) Plate thickness
2) Plate width
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Figure 1.2: ROUNDO 3- Roll Plate Bending Machine
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3.0 DESIGN ANALYSIS
3.1 SHAFT ANALYSIS
When a steel plate of 1.52 m 1.22 m is bent with a bending radius, R = 0.2 m,
3
Second moment of inertia of the plate is, = where h = 0.005 m, b = 1.22 m
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According to Table A-20 inside Shigleys Mechanical Engineering Design book material
chosen is AISI 1015 HR steel is chosen and its properties as shown below
The force acting on the roller from the bending plate is, 3
=
48
9 8
4 EI 4(20510 )(1.2710 ) = (34.26k) (1.52)^3/(205109 )(1.27108 )48
W = = 34.26 KN
Rb (0.2)(1.52)
=96.28 mm
= 0 = + 34.26
34.26
RA = RB = = 17.13 kN
2
6
For calculate alternating stress, consider = 1 since no fillet occur on the shaft for midrange
For midrange stress, = 0 , it is because no torque on the upper roller shaft so no power can
be transmit to the shaft.
Therefore,
32 32(1)(17.13 x103 )
= = = 5.17107. Pa
3 (0.153 )
Sy 190 x 106
= = = 3.68
5.17107
Se = kakbkckdkekfSe
where ka = aSutb
Based on Table 6-2 which is table for surface modification factor inside Shigleys Mechanical
Engineering Design book and given the parameter of properties for AISI 1015 HR steel for
hot-rolled surface finish that needed are shown below
a = 57.7 MPa
b = -0.718
So,
1 1
nf = = 5.17107 = 2.88
( + Sut ) ( 6 +0)
149 10
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3.2 BEARING ANALYSIS
F is from force that act on the gear which can be calculate as from equation gear inside
Shigleys Mechanical Engineering Design textbook page 699 equation (13-36) which is
60000
equation transmitted load, =
60000 (7.5)
Therefore, get Wt = = = 3.37 kN
(85)(500)
RDy = 1.44 kN
RDz = 3.958 kN
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Thus, find value for C10 that can get from Shigleys Mechanical Engineering Design textbook
page 570 equation (11-9) which is
1
C10 = af FD [ 1 ]
1
( +( 0 )ln( ) )
and consider the bearing use is ball bearing with RD = 96% af = 1, a = 3, b = 1.483 , = 4.459
60 ( )( )
and0 = 0.02 while to calculate value of is = where LD = 30 kh and nD
106
= 500 rpm
60 (30000)(500)
Then, = = 900. Therefore,
106
1
900
C10 = (1) (4.21x103 ) [ 1 ]3 = 50.1 Kn
1 1.483
(900+( 4.439)ln(0.96) )
Therefore, ball bearing that can be used is any bearing that greater than specification get which
is 02-60mm ball bearing.
We consider the force react on upper roller is the reaction force because the shaft does not get
force from bending plate. The used reaction force get from the shaft analysis which is
34.26
RA = RB = = 17.13 kN and consider it equal to FD.
2
Then the equation C10 get to use inside from Shigleys Mechanical Engineering Design
textbook page 567 equation (11-3)
60 ( )( ) 1
C10 = FD [ ]
106
and consider the bearing use is Cylindrical roller bearing with a = 10/3, b = 1.5, = 4.48,
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Then,
1
60 (60000)(500) (10)
C10 =(17.13 x 103 ) [ ] 3 = 162 kN
106
Therefore, cylindrical roller bearing that can be used is any bearing that greater than
specification get which is 02-90mm cylindrical roller bearing.
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3.3 GEAR ANALYSIS
Wt
The material used is AISI 1020 Steel-Rolled. According to Table A-20 inside Shigleys
Mechanical Engineering Design textbook,the properties of material is shown below
Pitch diameter of the gear, d = 280mm with 36 teeth. Therefore from equation (13-2) inside
Shigleys Mechanical Engineering Design textbook page 668 the module, m=d/N
For diametral pitch, P it can get from equation (13-1) same page with equation (13-2) above:
For the speed of gear rotation, used n = 500 rev/min which is equal to 8.333 rev.
Therefore, the pitch-line velocity is from equation (13-34) inside Shigleys Mechanical
Engineering Design textbook page 699. As shown below,
V =
11
The velocity factor from equation (14-6b) inside Shigleys Mechanical Engineering Design
textbook page 731:
6.1+ 6.1+7.33
KV = = = 2.202
6.1 6.1
Transmitted load, on the gear can be calculate from equation inside Shigleys Mechanical
Engineering Design textbook page 699 equation (13-36) which is transmitted load,
60000
=
60000 (7.5)
Therefore, get Wt = = = 3.37 kN
(85)(500)
The gear having 36 teeth and face,F=0.02m. Based on Table 14-2 inside Shigleys Mechanical
Engineering Design textbook page 730, the Lewis form factor Y for gear with 36 teeth is 0.384.
Then substitute in equation (14-8) page 731 as follows:
(2.202)(3.37 103 )
= = = 124
(0.02)(7.77x103 )(0.384)
The next step is to estimate the size factor kb. From Table 13.1 inside Shigleys Mechanical
Engineering Design textbook page 688, the sum of the addendum and dedendum is
1 1.25 1 1.25
l= + = + = 17.44
0.129 0.129
The tooth thickness t is given in Figure 14-1(b) inside Shigleys Mechanical Engineering
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Design textbook page 729 as t = (4) when x = from equation (14-3). Therefore,
2
3(0.384)
x= = 4.465m t = (4(17.44)(4.465)) = 17.65mm
2(0.129)
We have recognized the tooth as a cantilever beam of rectangular cross section, so the
equivalent rotating beam diameter must be obtained from equation (6.25) inside Shigleys
Mechanical Engineering Design textbook page 297:
1 1 1
de =0.808()2 = (0.808)( )2 = 0.808[(20)(17.65)]2 = 15.18mm
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The load factor kc from equation (6-26) page 298 is unity. With no information given
concerning temperature and realibility we will set kd = ke = 1 and ka = 0.935
In general, a gear tooth is subjected only to one way bending. Exceptions include idlers gears
and gears used in reversing mechanisms. We will account for one way bending by establishing
a miscellaneous-effects Marin factor kf.
Since a Gerber locus runs in and among fatique data and Goodman does not, we will use kf =
1.66. The Marin equation for the fully corrected endurance strength is
Se = kakbkckdkekfSe
For stress, start with determine the fatique stress concentration factor kf. For a 20 degree full
depth tooth the radius of the root filler is denoted rf where ,
0.300 0.300
rf = = = 2.33
0.129
From figure A-15-6 at the appendix of Shigleys Mechanical Engineering Design textbook.
2.33
Get , = = 17.65 = 0.132
And since D/d is infinity , we approximate with D/d = 3 giving Kt = 1.7. From figure 6-20 page
303 inside Shigleys Mechanical Engineering Design textbook get q = 0.70. Therefore, from
equation (6-32) same page as above parameter used.
For a design factor, = = Kf , therefore
338.85
FS = = 1.83
(1.49 124)
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3.4 BOLT ANALYSIS
RC RB
RD RA
Reference
point
Consider the net weight of the machine is 3500 kg and use a bolt from grade 4.6 with safety
factor 3. So, from Table 8.11 page 427 inside Shigleys Mechanical Engineering Design
textbook for properties bolt with grade 4.6 are the size range inclusive is between M5-M36.
And the minimum proof strength of this bolts grade is 225 MPa.
Fc
C B
FD
FC
FB
FB
D
A
FD FA
FA
The shear reaction that passes through the center of the body is
The distance from centroid to the center of each bolts is equal which is
1
RA = RB = RC = RD = (0.492 + 0.992 )2 = 1.1 m
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1) Bolt in shear
34335
F = = 8583.75 N
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Since the Rn are equal, the secondary shear forces are equal and based on equation (8.57) page
448 inside Shigleys Mechanical Engineering Design textbook
34335(990)
F = = = 7725.38 N
4 4(1100)
The primary and secondary shear forces are plotted to scale and the resultant obtained by using
the parallelogram rule. The magnitudes are found by analysis to be
FA = FB = 15.07 kN
FC = FD = 6.29 Kn
15.07
The maximum forces are on FA and FB, therefore = ( )
2) Bolt in tensile
lA = lD = 10mm lB = lC = 990mm
33992(10 ) 3
U=
1 1+2 2 +
= 2(10)+2(990) = 17.34 N/mm
FA = FD = 17.34 X 10 = 173 N
Maximum bending stress occurs on the bolt which is far from the axis of rotation.
17.17
= ( )
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Based on distortion energy theory, DET
1
= ( 2 + 3 2 )2
17.17 2 15.07 2 1
= (( ) + 3( ) )2
31.24
=( )( )
Factor safety is 3.
n=
31.24 225
So, =
3
At = 416mm
From Table 8-1, get the nominal major diameter for the bolt in mm which is M30 X 3.5
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3.5 WELDING ANALYSIS
1
2
RA = RB = RC = RD = (0.5 + 12 ) 2 = 1.12 m
Find the value of J using case 2 in Table 9-1 in Shigleys Mechanical Engineering Design
textbook.
(32+ 2)
J=
6
(1)(3(2)2+ (1)2)
J=
6
17
= 2.167 4
= M=FL= (45K) (0.75) = 33750 N.m
(33750)(1.12)
= = = = = 17.4
2.167
=(318017.426.57)2 +(17.426.57)2
=3172.25MPa
=(3180+17.426.57)2 +(17.426.57)2
=3642.35MPa
=
=
= =
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4.0 RESULT AND DISCUSSION
In designing a three roller bending machine it is required to calculate the force for bending.
From this force the machine parameters and motors power are decided. There are factors that
should be considered while calculating this force. Some of the factor are:
1) Material properties
3) Bending radius
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Table 4.3: Material Specification
In designing a bearing it is required to calculate the transmitted load,. From this force the
forces acting on the bearing decided. There are factors that should be considered while
1) Desired life
2) Desired speed
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In designing a gearing it is required to calculate the transmitted load,. From this force the
forces acting on the gear decided. There are factors that should be considered while calculating
1) Desired life
2) Desired speed
All the structural members have been sized to support the specified load with a safety factor
ranging from2.0 and 4.0.
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5.0 CONCLUSION
Instead of using the high cost software to analyse the force and power of motor to design
bending machine we can design our own bending machine by referring the theories regarding
bending machine. All the parameters related to the bending theories like bending force, bend
radius, material thickness and etcetera are calculated and analyse in our project. The analysis
6.0 REFERENCES
1. Mr. Nitin, Mr Prafulla Force Analysis of Metal Sheet in Bending Operation on Sheet
Bending Machine
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APPENDICES
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