FABRICATION OF PIPE BENDING MACHINE

ABSTRACT

Mechanical Engineering without production and manufacturing is

meaningless. Production and manufacturing process deals with conversion of
raw materials inputs to finished products as per required dimension, specification
and efficiently using recent technology. The new development and requirements
inspired us to think of new improvements in manufacturing field.

In our project Pipe Bending Machine various diameters of pipe is being

bend with the help of this machine and various shapes is obtained like v-shape,
circular, square, channel etc. It is widely used in various industrial operations
such as bending a tube to make coil or sheet metal to make certain shape such as
‘V’ shape.

1
 CHAPTER 1

INTRODUCTION

In modern days, all area of industries are going to like automated,

economically and accurate machinery .There is many types of pipe bending
machine are available in market like hydraulic pipe bending machine, pneumatic
pipe bending machine, manual pipe bending machine etc.

The utility model discloses a full-automatic pipe bending machine. Whole

machine is supported by a base with four supporting legs which has enough
strength to carry the weight and force of machine. Two parallel shafts are
clamped on base by clamps which carry the lower pulley. Pulleys are driven by
dc motor with chain drive mechanism. Here two guide ways are use for guide the
working pulley for up & down linear motion.

Pulley gets that motion from Lead screw is working as a nut and bolt
mechanism. The lead screw is get rotary motion from upper dc motor. Guide way
and lead screw are fitted between two horizontal supporting plates, which are
fitted on frame by the help of the two vertical parallel supporting plates.
Microcontroller Unit consist of transformer, rectifier, capacitor, display
Production efficiency is improved, the production cost is reduced, and the
application range is wide.

Bending is a manufacturing process that produces a V-shape, U-shape, or

channel shape along a straight axis in ductile materials, most commonly sheet

2
metal. Commonly used equipment includes box and pan brakes, brake presses,
and other specialized machine presses.

1.1 Overview

A bending is a process of bending a metal. The metal can be a sheet metal,

tubes, square hollow, rod, and iron angle. This type of metal has its own
thickness. In bending machine designing several considerations is taken into
including type of metal, type of the roller bender, power driven or manual and
the size of the bending machine. Usually, the difference of these types of bending
machine is only on the capacity of the bending machine that can bend a sheet
metal or tube.

Today, the bending machine that available in the market is for the sheet
metal and tube bending machine. Many machine makers vary their products
based on the capacity of the bending machine and power driven or manual.
Moreover, most of the machine uses roll bending type. This type of machine has
3 rolls which is 1 roll is fixed and the other 2 are adjustable. The sheet metal
needs to put in the roller and then rolls around it until the desire shape is
acquired. The products that can be produced with this machine are coil, truncated
cone, etc.

1.2 Need for Pipe Bending Machine

As we know that pipe bends are used in various household things therefore
it is necessary to build an economical pipe bending machine. It is also used in

3
designing of various machine components, without this bending device a
machine can’t work properly. As far as industrial application is concerned it is
used for piping purpose. The reason to design a bending machine is because there
is no proper bending machine to bend a solid or hollow pipe for small scale. The
bending machines found in the market come from variety of types. There are
bending machine such as press brake bending machine, roll bending machine and
a folding machine.

1.3 Roller for bending pipe

To give the required shape and size, roller is used. Primary function of the
roller is to achieve angular shape to the pipe. This is done through screw which
applies pressure on roller and also this roller achieved rolling action by using an
AC motor.

1.4 Functions of Bending Machine

1. To bend a pipe having thickness upto 5 mm in required angular shape.

2. To provide curvature shape to pipe.
3. Machine is convenient for portable work.
4. The machine is power operated to achive maximum accuracy in less time.

1.5 Roller requirement

1. Roller should be very accurate and easy to handle.

2. The effort required to bend pipe should be minimal.

4
 3. The rolling attachment should also provide directional stability. This
implies that the pipe should have a tendency to move to & fro.

1.6 Pipe Bending Machine

A roll bending machine uses roller to bend a metal. The roller of bending
machine can be two rollers, three rollers, or four rollers. The common product of
roll bending machine are tube bending, plate bending and a coil. All modern roll
bending machine is power driven and some of the bending machine equip with
electronic control for more. During the roll bending process the pipe extrusion,
or solid is passed through a series of roller( typically 3) that apply pressure to the
pipe gradually changing the bend radius in the pipe. The pyramided style roll
benders have one moving roll, usually the top roll. Double pinch type roll
benders have to adjustable rolls, usually the bottom rolls, and a fixed top roll this
method of bending causes very little deformation in the cross section of the pipe.
This process is suited to producing pipe which is in require shape as well as long
gentle bends like those use in making structure of pipe.

1.6.1 Reason to Design a Pipe Bending Machine

The reason to design a bending machine for pipe bending is because there
is no proper bending machine to bend a metal pipe for small scale. The bending
machines found in the market come from variety of types. There are bending
machine such as press brake bending machine, roll bending machine and a
folding machine. Moreover, the design for the bending machine for pipe bending
is to bend a metal pipe. It produces sheet metal bending with desire degree of

5
bending except 90°. Other reason regarding to the bending machine design, the
bending machine in the market come with big size and the bending machine is
expensive.

The existing bending machine in the market is created for huge capacity
for bending a metal pipe. With the capacity of bending machine that exists in the
market, the existing bending machine is not fulfilling the requirement of the
usage. The requirement of operation of bending machine is simple. Thus it is not
suitable to purchase existing bending machine to be used for simple bending
machine operation. Moreover, the machine is heavy and use up a lot of space. In
addition, the problem will arise when to move and put the bending machine due
to heavy and space.

1.7 Scope of Project

In order to define the scope of a project, it is necessary to first establish the

project objectives. The objective of a project may be to produce a new product,
create a new service to provide within the organization. Automatic pipe bending
machine is less costly comparing to hydraulic and pneumatic pipe bending
machines and more accurate than manual pipe bending machine so Small
industries as well as big manufacturer of various pipes. Bent pipe used as a
structural member in vehicles and also used as a passageways in condenser,
evaporator, water & gas line, drainage lines etc

6
 In nowadays, this type of automatic pipe bending machine is used in many
different industries like automobile, aerospace, power plants and all mfg.
industries etc

Bent pipe used as a structural member in vehicles and also used as a

passageways in condenser, evaporator, water & gas line, drainage lines etc.

7
 CHAPTER 2

LITERATURE SURVEY

In april,2013 Prof. Nilesh Nirwan and Prof. A.K.Mahalle, Department of

Mechanical Engineering, G.H. Raisoni college of engineering Nagpur has found
a PORTABLE ROLLING PIPE BENDING MACHINE is used for reliability,
easy convey and good quality purpose. But there is some difficulties like not
used for mass production and slow process due to hand operated device.

In Nov, 2015 Prof. A. Pandiyan of Department of Mechanical

Engineering, Of Saveetha School of engineering Chennai has found a ZIGZAG
PIPE BENDING MACHINE is used for making zigzag profile pipe. It is
operated by hydraulic bottle jack. This bending machine is only used for zigzag
profile so, not used for other bending operations.

In Sep, 2011 Prof. N.N. Jadeja of Department of Mechanical Engineering,

Of GEC Bhvnagar has found MANUALLY OPERATED PIPE BENDING
MACHINE is used in small industries. This machine generally used for low cost
purchasing purpose. It has low accuracy of bending and force is not uniformly
distributed over a whole length of pipe so, this bending machine is not
preferable.

H.A. Husain, M. Sohil Pervez of Department of Mechanical Engineering,

Of Anjuman college of engineering and Technology, Chennai Nagpur, has found
a BICYCLE INTEGRATED PIPE DESIGN BENDING MACHINE. It is unlike

8
other electric motor operating pipe bending machine. It is used for ECONOMIC
& ACCURATE DIMENSION. It will help to maintain environment green. Here
is one Disadvantage is process taking more time.

In May, 2014 Basil Okafor & Danial Obiora of Department of Mechanical

Engineering, of Fedral University Owerri Nigeria has found MOTORIZED PIPE
BENDING MACHINE WHICH IS OPERATED by 2HP MOTOR. This
machine can run in both upward and downward direction. Here worm and wheel
gear mechanism is used. Mandrel used for less thickness pipes.

Ahmed Ktari:-In his paper he has done Modeling and computation of the
three-roller bending process of steel sheets. This experiment consists of two-
dimensional finite element model of this process was built under the Abaqus
/Explicit environment based on the solution of several key techniques, such as
contact boundary condition treatment, material property definition, meshing
technique, and so on.

Jong GyeShin:-In their paper he has done the experiment on Mechanics-

Based Determination of the Center Roller Displacement in Three-Roll Bending
for Smoothly Curved Rectangular Plates. The objective of this paper is to
develop a logical procedure to determine the center roller displacement, in the
three-roll bending process, which is required in the fabrication of curved
rectangular plates with a desired curvature.

M K Chudasama:-In their paper he has done the experiment on Analytical

Model for Prediction of Force during 3-RollerMulti-pass Conica Bending. In this

9
paper, the total deflection of the top roller required is divided in steps to get the
multi pass bending.

M. B. Bassett, and W. Johnson :-In their paper, The bending of plate using
a three roll pyramid type plate bending machine, J. strain Analysis Process
manual, maintenance manual, machine capacity chart and technical specification
of rolling machine, M/s Larsen& Toubro ltd, Hazira, Surat, India.

Dr. C. C. Handaet. al :-This paper gives a review and Discussed about the
productivity analysis of manually and power operated sheet bending machine
considering time required to complete one pipe, total expenditure required to
manufacture one pipe, number of operators and labors required during both
operations, etc. Limitations of the manually operated sheet bending process over
power operated sheet bending machine is also discussed.

P.G. Mehar:- In his M. Tech Thesis studied the manually operated and
power operated sheet bending machine. Experimentations were conducted on
sheet in order to measure actual no. of passes, time required to complete bending
process etc. Also, productivity of sheet bending process is analyzed in depth.
Design of various components of power operated sheet bending machine
considering various theories of failure in elastic region and values for bending
force, power required, spring back radius etc. for different diameters, thicknesses
and width of sheet metal has been determined.

I Muhammed, S.Ravivishwnath, P Sureshkumar , N. Sarvanan Design and

fabrication of hydraulic rod bending machine, April 2014. Worked on design and

10
fabrication of rod bending machine and they concluded that Each and every work
of human is reduced by a machine, but few areas like construction the usage of
machines for bending rods for stirrups which are used to withstand loads in
beams and columns are not done by machine because the cost of machine is high
and need skilled labours to operate it. So this project is aimed to do bending
operation for stirrups using hydraulics and named as hydraulic rod bending
machine. The main objective of our project is to implement the hydraulic rod
bending machine in the construction sites with less cost compared to the existing
bending machines, and increasing the productivity of the stirrups.

Vilas Shinde, Darshan Adhav, Suraj Jadhav, Afsar Attar, Sandip Gorde.
Design and fabrication of hydraulic stirrup making machine, May 2016.They
worked on Design and Fabrication of Hydraulic Stirrups Making Machine and
they concluded that Since testing the stirrup making machine it is observed that
how much time is required to make single piece of stirrup by effective working.
The detail description is given as below: Loading and unloading combining
clamping the bar to fixture it almost takes only 5 to 6 seconds. Time required to
forward and backward stroke is about 10 to 11 seconds during which stirrup is
made. Considering machine ergonomics that is interaction of human operator
with machine, it is very easy to operate it because operating switch is provided at
suitable place of machine. Again loading and unloading is not complicated since
not very specialized tooling is used it is very simple structure.

11
 CHAPTER 3

TYPES OF BENDING MACHINE

3.1 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.

Fig: 3.1 Tube Bending

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.

12
 Fig: 3.2 Tube bending operation

3.2 Circle Bending:

Fig: 3.3 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

13
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.

3.3 Channel Bending

Fig: 3.4 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

14
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.

3.4 Square Bending

Fig: 3.5 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

15
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 blocks.

16
 CHAPTER 4

THREE ROLLER BENDING

Three roller bending is also used for producing work pieces with large
bending radii. The method is similar to the ram bending method, but the working
cylinder and the two stationary counter-rollers rotate, thus forming the bend.
Normally there are 2 fixed rollers and one moving roller and the work piece is
passed forward and backward through the rollers while gradually moving the
working roller closer to the counter rollers which changes the bend radius in the
pipe.

Fig 4.1-roll bending

4.1 Working Principle of 3 Roll Pipe Bending Machine

3-roll bending is used for producing work pieces with large bending radii.
The method is similar to the ram bending method, but the working pulley and the

17
two stationary counter-pulley rotate, thus forming the bend. Normally there are 2
fixed pulley and one moving pulley and the work piece is passed forward and
backward through the pulley while gradually moving the working pulley closer
to the counter pulley which changes the bend radius in the pipe.

Fig 4.2 Initial Condition

This method of bending causes very little deformation in the cross section
of the pipe and is suited to producing coils of pipe as well as long sweeping
bends like those used in powder transfer systems where large radii bends are
required.
Pipe enters through one side of machine with guidance of stationary
pulley. Also the continuous radius of curvature can achieved of pipe.

18
 Fig 4.3 Running Condition

4.2 PROCESS OF ROLLING

In the first stage the pipe is kept between top roller and bottom
rollers as shown in Figure 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 in reverse 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 roll contact. They had considered varying radius of curvature for the pipe
between the rollers and proposed mathematical model to simulate the mechanics.

19
 CHAPTER 5

FABRICATION AND SPECIFICATION OF BENDING MACHINE

5.1 FABRICATION

It consists of several parts namely:-

a. FRAME- The frame provides support to the entire machine components.

b. DIE- A bending die consists of a vice which is welded to it and which is
used to hold a pipe firmly.
c. STAND- It is used to support the rod or pipe at other side.
d. VICE- It is located on the stand which provides strength to the rod.

5.2 COMPONENTS OF MACHINE

Lead Screw

Here lead screw used for convert the rotary motion into linear motion.

Fig 5.1 Lead Screw

20
Bearing

Bearings used are radial bearing as a supporting part for shaft which allow
the rotary motion and reduce the friction of shaft.

Fig 5.2 Bearings

Shaft

Shaft is used for transmit power from motor to pulley.

Fig 5.3 Shaft

21
Base

Base is the supporting member for all parts of machine.

Fig 5.4 Base

Supporting Plates

Supporting plates are used for giving support to the lead screw and guide
ways.

Fig 5.5 Supporting Plates

22
Pulley

Pulley is generally used as a DIE which allows to bent the pipe.

Fig 5.6 Pulley

Clamps

Clamps are used for holding the shaft of stationary pulley on base table.

Fig 5.7 Clamps

23
5.3 Specification

Sl. No Components Specification

1. FRAME 2m x 1m

2. STAND .5m x 5m

3. DIE Radius=8cm and thickness=3cm

24
 CHAPTER 6

DESIGNING

Pipe bending as a process starts with loading a tube into a pipe bender and
clamping it into place between two dies, the clamping block and the forming die.
The tube is also loosely held by two other dies, the wiper die and the pressure
die.

A pipe bending machine is a simple bending machine which is operated by

an ac or dc motor. The motor is attached to the frame of the machine and also
consist of a circular die on which a vice to hold the rod is welded.

Fig: 6.1 Pipe bending machine

First of all the rod to be bend is set in the vice of the machine and then
power supply is put on, then the motor begins to produce torque and depending
upon the dimension of the rod it is bend.

25
 The power from the motor is transferred which rotates the circular plate in
anticlockwise direction and bend the rod for given radius. Various die can be
used as per requirements namely v-die, wiping die, roller die, etc.

Fig: 6.2 Pipe bending Assembly

26
 Fig: 6.3 Base (frame)

Fig: 6.4 Upper Supporting Plate

27
 Fig: 6.5 Vertical Supporting Plate

Fig: 6.6 Working Pulley Holding Plate

28
Fig: 6.7 Pulley

Fig: 6.8 Shaft

29
 Fig: 6.9 Clamp

Fig: 6.10 Working Pulley Shaft

30
 CHAPTER 7

MATERIALS AND CONSTRUCTION

Basic components

The basic construction and main components of portable 3 roller pipe

bending machine is given below,

7.1 Basic Frame

The hollow square pipes of material of mild steel are selected for the
frame. The pipes are cut into required size by cutting machine. The end of the
pipes cut into 45 degree (angle) to form rectangular frame. After cutting, the end
of the square pipes is grinded so that it became smooth and convenient for
welding. The square pipes are welded together to form a rectangular basic frame.

7.2 Roller

In this project the roller is used to bend a pipe in angular shape. There are
3 rollers are used to bend a pipe in curvature shape. Roller is a cylinder that
rotates about a central axis and is used in various machines and devices to move,
flatten or spread something. A roller always consist a bearing.

7.3 Sprocket & chain

In this project sprocket & chain are used to give rolling motion to the
roller and due to it, pipe moves over the roller. One sprocket is connected at

31
motor end and other is connected at middle roller end to give the rolling motion
to middle roller. A Chain drive is useful for effective power transmission
choices.

7.4 Screw rods

This attachment is used for apply a pressure on pipe which is used for
bending purpose. The screws have achme threads which can sustain high
torsional stresses against high load. The diameter of screw rod is designed by
using formules of “Power screw”.

7.5 Pedestal bearings

Pedestal bearing are used to give easy& convenient motion to roller by

using shafts which is attach to roller.

32
 CHAPTER 8

CALCULATIONS

Load acting on pipe (P)

P=Mass of Upper Pulley

= Density of material × Volume of upper pulley (V)
V= area × thickness = π/4 × D2 × t - (πd/2)

where

D= Diameter of pulley
t= Thickness of pulley
d= diameter of pipe

33
 CHAPTER 9

ADVANTAGES

Advantages

1. Easily operated

2. Simple construction

3. Low cost

4. Rigid construction

34
 CHAPTER 10

APPLICATIONS

Applications

1. Angle Bending

2. Metal Folding

3. U Hook

4. Marine Tube

5. Heat Exchanger

6. Scroll Bending

35
 CHAPTER 11

CONCLUSION

In this project , a iron rod is efficiently bend for a given power of motor,
whose diameter is 2.8 cm. the various pipe bending machines consisting of
various dies used for production in Industries are known in this project This
bending tool is very useful in household application as it runs at very low cost
and very efficient.

In this project various pipe shape that is square, v-shape, channel bend;
circular shapes are bending the rod at any angle.

FUTURE SCOPE

In the next stage we are trying to make a pipe bending machine which will
be helpful in easy bending of pipes. Although there is higher initial cost involved
we have tried to make the system cost effective and also add different
enhancements to make the system more efficient so that it may work around the
year.

36
REFERENCES

[1] Wikipedia - Bending Machine (tube bending)

[2] Clifford M.J., Eastwood D. (2006). Design of hydraulic pipe bending
machine No. 77 pp.269-280.
[3] Strength of Material – Er. Rk Rajput, for calculating minimum diameter of
rod.
[4] V.B.Bhandari (2012) “Design of Machine Elements” Mc Graw Hill,
ISBN.
[5] Hiroyuki goto,Ken ichiru, Hidenobu saitro, Yuu ishikura and Yutaka
tanaka ,"Applications with a new 6- dof bending machine in tube forming
processes".
[6] Jose VitorSouze, International Journal of Machine Tools &Manufacture,
2002.
[7] Z. Hu, R.Kovacevic, M.Labudovic, “Experimental and numerical
modelling of buckling instability of laser sheet forming”, International
Journal of Machine Tools & Manufacture, 2002..
[8] Nayyar, P.E., Mohinder L. (2000). "A1". In Mohinder L. Nayyar,
P.E...Piping Handbook (7th Ed.). New York: McGraw-Hill. ISBN,
[9] Effect of internal pressure and shape imperfections on plastic loads of pipe
bends under in-plane closing moment,T. Christo Michael,A.R.Veerappan,
S. Shanmugan, Engineering Fracture Mechanics 105(2013)1 – 15.
[10] Cherniy.V.P. 2001. Effect of Curved Bar Properties on Bending of Curved
Pipes. Journal of Applied Mechanics, Vol. 68, pp.650 – 655. Cherniy. V.

37
 P. 2003. The Bending of Curved Pipes with Variable Wall Thickness.
Journal of Applied Mechanics, Vol. 70, pp. 253 – 259.
[11] Final Working of Rolling Pipe Bending Machine ISSN : 2249-5770
[12] EXPERIMENTAL DESIGN AND FABRICATION OF A PORTABLE
HYDRAULIC PIPE BENDING MACHINE ISSN: 2230-9926
[13] Design of a Hydraulic Pipe Bending Machine FPL−GTR−148
[14] Research Paper of Manually Operated Pipe Bending Machine ISSN -
2250- 1991
[15] Fabrication of zigzag Bending Machine ISSN No 2277 – 8179
[16] Design And Analysis Of Portable Rolling And Bending Machine Using
CAD And FEA Tool ISSN: 2278-0181

38