Declaration

I declare that this written submission represents my ideas in my own words and
where others' ideas or words have been included, I have adequately cited and
referenced the original sources. I also declare that I have adhered to all principles
of academic honesty and integrity and have not misrepresented or fabricated or
falsified any idea/data/fact/source in my submission. I understand that any
violation of the above will be cause for disciplinary action by the Institute and can
also evoke penal action from the sources which have thus not been properly cited
or from whom proper permission has not been taken when needed.

Date:

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 Table Of Content

INDEX

Sr.No. Topics Page

No.

1. ABSTRACT i

2. INTRODUCTION ii

3. LITERATURE REVIEW 1

4. PROBLEM DEFINITION 4

5. OBJECTIVES 5

6. METHODOLOGY 6

7. WORKING PRINCIPLE 7

8. COMPONENTS 8

9. ADVANTAGES, DISADVANTAGES & 9

APPLICATIONS

10. FUTURE SCOPE 10

11. REFERENCES 11

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 CHAPTER 1

Abstract

Nowadays the world is focusing into automation. Each and every work of human is
reduced by a machine, but few areas like construction they use human effort to make the stirrups
which used to withstand load in beam and columns of buildings they need skilled labour to
make it.

So the aim of this project is to reduce the human effort by making pneumatic rod bending
machine which is very useful on construction site.

To make pneumatic rod bending machine it required component like pneumatic

compressor, pneumatic cylinder, hoses, directional control valve, holding attachments on steel
frame etc.

In this project it is aimed to do bending operation for stirrups using pneumatic and named
as pneumatic rod bending machine. The main objective of our project is to implement the
pneumatic rod bending machine in the construction sites with less cost compared to the existing
bending machines, and increasing the productivity of the stirrups.

Pneumatic rod bending machine consist of Pneumatic cylinder, Compressor, Hoses, Pulley,
Cutting blades, Fixture. The rod is bent by the Pneumatic cylinder piston with holding the rod
in the fixture. The main advantage of our project is the square shape of the Stirrups is bent
contain.

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 Chapter 2

Introduction

Since long time ago labour work was ver essential in constructions including mixing
coarse aggregate-sand-water- cement, ramming sand, land levelling, and digging the foundation
for base of structure, cutting rod in required length, rod bending and pouring the mixture of
concrete in columns and beams. Now days, due to development in technology it is required to
reduce the labour work and time since there are lot of available resources. As population
increasing very rapidly, demand of the construction to build the buildings for industries,
overhead bridges, human livings and population is continuously increases. Several problems
come in to the picture when we consider human work with respect to automation. By using
conventional method it is not possible to reduce construction time and building it as early as
possible.This project is to bend the rod at the specified dimensions which is used in the building
construction which called as Stirrups. Stirrup is an important reinforced element which acts as
a shear reinforcement. Presently, stirrups are made manually, which suffers from many
drawbacks like lack of accuracy, low productivity and resulting into severe fatigue in the
operator. In manual stirrup making process, operators not only subjecting their hands to hours
of repetitive motion, but also sometimes suffers internal injury to his body organ.The system
that we propose is that bending of square and rectangular stirrups. The rod is bent with the help
of pneumatic force because pneumatic system has less costly compared to hydraulic system.

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 Chapter 3

Literature Review

Have developed dedicated electro pneumatic positioned for a class of process valves. The
position uses solid-state electronics to combine the functions of both the electric to pneumatic
converter and valve positioner. Such are the savings in size and weight that have been achieved
by the use of electronics that the resulting unit is housed in an
enclosure small enough to be mounted directly on the actuator, which it is to operate. (Virvalo
et al., 1988). Showed that electro pneumatic servo systems are viable alternatives to hydraulic
systems for control of such machines as robots, but most of the research has been carried out
on them using comparatively small cylinders.

Bar-bending machine is a semi-automatic type of machine which utilizes less man-power.

This reduction in manual work results increased output. The Principle advantages are less
time consuming, production of identical stirrups, higher production rate than old traditional
method.
Our goal is to develop & design a machine to achieve high production rate with less man power
& of desired accuracy.

The bend has been made with the help of punch which exerts large force on the work clamped
on the die. The bending machine is designed in such a way that, it works automatically. The
automation strategy, when implemented is believed to result in reduced cycle time, costs and
improved product quality. Other possible advantages are repeatability, increased productivity,
reduced labor and integration of business systems. Automation is achieved with the help of
Electro pneumatic system.
Bending can be done with required dimensions and accuracy is maintained during the entire
operation. By changing the dimensions of the die required bents are made on the rods. Along
with the ease of operation use of hydraulics also makes it more precise, economical and
compact. The entire machine is easily portable and having nice aesthetics as well. Keywords:
hydraulic system, indexing mechanism, bending operation.

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Three Stirrups are prepared at a time, which makes the machine more productive. The use of
Scotch yoke Mechanism is used to convert the reciprocating motion of pneumatic cylinder
into rotary motion. Main purpose of use of pneumatic System is to save cost of overall
machine. Main purpose of automation is fast and continuous production without much
attention on machine. Need of automation was felt and so the machine is made automatic

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 Chapter 4

Problem Definition
Presently, stirrups are made manually, which suffers from many drawbacks like lack of
accuracy, low productivity and resulting into severe fatigue in the operator. In manual stirrup
making process, operators not only subjecting their hands to hours of repetitive motion, but
also sometimes suffers internal injury to his body organ.The system that we propose is that
bending of square and rectangular stirrups. The rod is bent with the help of pneumatic force
because pneumatic system has less costly compared to hydraulic system.

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 Chapter 5

Objective

Rod and pipe bending is widely used for various industrial purposes. Most of the rod bending
machines are hydraulic or screw based that require a lot of time and energy for bending rods.
So here we propose a compact and pneumatic based rod and pipe bending machine that bends
pipes and rods as per angle set by user. Our system uses pneumatic piston, pipes, valves,
hinges, supporting frame and electronics mechanism to achieve accurate bending. We use
pneumatic piston attached to a movable bed that is attached to the supporting frame using
hinges for vertical movement. This bed is used to support the materials to be bent. We then
use the supporting frame to mount the rod support and holders. We now use electronic sensors
to get reading of the bending angle. User is allowed to select the angle at which bending is
needed. As per users settings made the system operates the pneumatic system once user starts
bending process. The system now operates the pneumatic cylinder automatically until desired
bending has been achieved. This machine demonstrates the concept of fully automatic
pneumatic bending system.

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 Chapter 6

Methodology

Pneumatic cylinder is used to provide the force required for bending rod to make stirrups. As
we are bending three rods at a time we required more force.

Assuming TATA TISCON 500D material rod which is generally used at construction side.
This are available in diameter of 6, 8, 10, 16, 20 and 25 mm generally to make stirrups 8 or
10mm rod are taken.

Mechanical properties of TATA TISCON 500D

Yield stress = 500 N/mm2

Ultimate stress = 545 N/mm2

Assuming Factor of safety (FOS) = 1.5

Therefore, allowable bending stress = Yield stress / F.O.S

σb = 500 / 1.5

σb = 340 N/mm2

Force required to bend one rod of 8mm by flexural formula

M / I = σb / Y

Bending moment (M) = Force * Perpendicular distance

M = F * L (N-mm)

Moment of inertia (I) = π / 64 * d4

= π / 64 * 84

= 201.06 mm4

Y = d / 2 = 8 / 2 = 4 mm

M / I = σb / Y

M / 201.06 = 340 / 4

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M = 17136 N-mm

Assuming eccentricity 25 mm

M=F*L

17136 = F * 25

Force required to bend one rod of 8 mm

F = 690 N

Force required to bend 3 rods of 8 mm

F = 3 * 690

F = 2070 N

Pneumatic cylinder design

We know pressure given by

P=F/A

Assuming pressure in cylinder 5 bar = 5 * 105 N/mm2

5 * 105 = 2070 / π/4 (d)2

d = 0.0726 m

d = 72.6 mm

Cylinder diameter = 72.6 mm

Selecting Diameter = 80 mm.

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 Chapter 7

Working

We will be using compressor of pressure of 10 bar as per availaible

We will be regulating this pressure using pressure regulator and reducing the pressure up
to approximate 5 bar.

Therefore, this pressurized air will pass through pressure regulator.

Then 2/2 direction control valve is used to control the direction of the air.

Then it will pass through the flow control valve to control the flow of air.

Then it is sent to spring control double acting cylinder to create the force to bend the rod.

Then it is passed to further mechanism to carry the process.

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4
 Chapter 8

Components

1.PNEUMATICS ACTUATORS
Pneumatic actuators are the devices used for converting pressure energy of compressed air
into the mechanical energy to perform useful work. In other words, Actuators are used to
perform the task of exerting the required force at the end of the stroke or used to create
displacement by the movement of the piston. The pressurised air from the compressor is
supplied to reservoir. The pressurised air from storage is supplied to pneumatic actuator to do
work. The air cylinder is a simple and efficient device for providing linear thrust or straight-
line motions with a rapid speed of response.
There are three types of pneumatic actuator: they are
Linear Actuator or Pneumatic cylinders ii) Rotary Actuator or Air motors iii) Limited
angle Actuators

A compressed air system transfers power in the form of air pressure. A device somewhere
else in a workshop can use the energy the compressor creates. The basics of compressed air
pipework are simple. You just need to attach a compressor to an end-use device via a pipe.

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Corrosion in a piping system can break off and accumulate into obstructions. Plastic pipes
over many benefits over metal.

They do not corrode, so you don’t have to worry about rust dropping into your air flow. This,
in turn, reduces the risk of obstructions.
The interior surface is smooth and never deteriorates, which encourages laminar flow.
The pipes are lightweight and easy to transport and fit.
Cutting through plastic pipes is quick and simple and requires basic tools.
Plastic pipes can be glued together, which is less costly and quicker than welding metal.

2. Pressure regulator
It is a control valve that reduces the input pressure of a fluid to a desired value at its output.
Regulators are used for gases and liquids, and can be an integral device with an output
pressure setting, a restrictor and a sensor all in the one body, or consist of a separate pressure
sensor, controller and flow valve. In pneumatic systems, during high velocity compressed air
flow, there is flow-dependent pressure drop between the receiver and load (application).
Therefore the pressure in the receiver is always kept higher than the system pressure. At the
application site, the pressure is regulated to keep it constant.

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3. FLOW-CONTROL VALVES
Flow-control valves, as the name suggests, control the rate of flow of a fluid through a
hydraulic circuit. Flow-control valves accurately limit the fluid volume rate from fixed
displacement pump to or from branch circuits. Their function is to provide velocity control of
linear actuators, or speed control of rotary actuators.
Velocity of piston (Vp) (m/s) = Flow rate in the actuator / Piston area
Pressure-compensated flow-control valve
A pressure-compensating spool built into a flow control valve maintains a constant pressure
drop across the metering orifice independent of changes in supply and load pressure.

Two-port pressure-compensated flow-control valve (with symbols), see text for explanation.
It shows diagrammatically a two-port pressure-compensated flow-control valve together with
its symbols. Flow rate is set by an adjustable metering orifice (1) which also be viscosity-
compensated. In the unoperated condition, the compensating spool (2) is biassed fully open
by the compensator spring (3). As soon as flows occurs, there will be a pressure drop across
the valve and pressure upstream of the metering orifice tends to close the valve, but this is
opposed by the spring assisted by pressure from downstream of the metering orifice. The
compensator spool adopts a balanced position with a consequen-tial pressure drop over the
compensating orifice (4) formed by the partially closed spool. A rise in supply pressure tends
to close the spool and the. increased pressure drop across the compensating orifice balances
the increase in supply pressure. If the load pressure rises, the compensating orifice opens,
again maintaining the pressure drop over the metering orifice at a set value. This pressure
drop is usually 3-6 bar, dependent upon the size of the metering orifice

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 Chapter 9
Advantages & Applications

9.1 Advantages-

o High durability and reliability

o Simple design
o Pneumatic systems are safer than electromotive systems
o Environmental friendly
o Economical low cost

9.2 Applications-

 Angle bending
 Metal bending
 In construction fields
 In production

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 Chapter 10

Future Scope

Operation for making stirrup is tedious and required continuous manual work to perform the
bending operation. This will minimize human efforts for less physical exertion of the operator.
Adverse effect of repetitive work on human health is minimising. Reduce the wastage of stirrup
and this will reduce the cost of stirrup making activity. There is a scope to design the stirrup
with safety standards and with ergonomic considerations which will help to avoid the incidents
during manually stirrup making. There is a scope to improve the stirrup making efficiency and
production capacity of stirrup by using human powered flywheel motor of stirrup making. The
currently available machines are motor power (electrical supply) operation machines and
hydraulic type machine which cannot work where non-availability of electricity. This research
presents a new urge as method to bend the given rod of 6,8 mm diameter with the help of human
power as a energy source for performing the job. This area is having a large scope because of
construction in MIHAN & CARGO project, at the same time fast development in rural area.

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 Chapter 11

References

 www.sciencedirect.com
 Dr.R.K.Bansal (2010) “Fluid Mechanics and Hydraulic Machines” Laxmi
Publications, ISBN 978-81-318-0815-3
 International Journal of Recent Research in Civil and Mechanical Engineering
(IJRRCME)

 Vol. 2, Issue 1, pp: (9-18), Month: April 2015 – September 2015.

(Singh et al., 1985). [1]

 International Research Journal of Engineering and Technology (IRJET) e-ISSN:

2395-0056 Volume: 05 Issue: 04 | Apr-2018[2]
 International Journal of Recent Research in Civil and Mechanical Engineering
(IJRRCME) Vol. 2, Issue 1, pp: (9-18), Month: April 2015 – September 2015,
Available at: www.paperpublications.org [3]
 ISSN (PRINT): 2393-8374, (ONLINE): 2394-0697, VOLUME-5, ISSUE-1, 2018
DESIGN AND FABRICATION OF MULTIROD BENDING[4]
 International Journal of Advance Engineering and Research Development Volume
4, Issue 3, March -2017[5]