1.

ABSTRACT –

The main aim of our project is to design and fabricate the hydraulic bending machine. The most
important component used in this is hydraulic Jack which is used to bend the TMT bars. This hydraulic
operated equipment is used in different fields. In Automobile industry, these hydraulic jacks are used for
greasing the job. Hydraulic bending machine consists of Vice, hydraulic jack, wiper motor. Actuation of
hydraulic jack is simple and reliable to maintain. These hydraulic bending machines are more reliable,
portable and easy to use in Industry. Hence, we are developing hydraulic bending machine.

It is a simple mechanism which can bend the TMT bars by putting very less amount of efforts. In
industry, there are many tasks in which you have to bend. There are so many mechanisms developed to
perform such functions. The main problem in all these mechanisms is they require an external power
supply. And they are also bulky and expensive. Here we are manufacturing the simplest, chipset and self-
powered bender. It can bend the same amount of load as that of a conventional bender. This bend is not
only for industrial use but it can be used anywhere like agricultural, domestic use etc.

This project is to usage of bending machine to bending rods for stirrups which are used to withstand loads
in beam and columns. Stirrups both end bend with 90 degrees right angle. 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. The design of
the bending machine will utilize subsystems which together compose the machine.

This process serves to replace the manual human operations previously used to hand manual stirrups
bending. In the past years all types of construction work are depend upon construction material, in this
material TMT bars are mostly used in construction works for column, beam, sealing etc. this TMT bar
always bent by people in past time and recent time. This process will be take more time and take more
workers for simple works. All types of bending machine available in market at high cost that small types
of construction works can’t afford this machine, and this machines are for the large diameter TMT bars,
but for the having a 8mm,10mm, and 12mm diameter TMT bars mostly used in shape of square, and
rectangular shape. This types of bends always bent by workers and takes more time. so we trying to make
a bending machine for this types of TMT rods. After this bending machine we can save time.

The machine is designed based on the principle of Hydraulic system. The hydraulic load has more power
compare to the other type of loads like pneumatic and electric. By using heavy loads we can increase the
productivity of the product. The manual stirrup making process suffers from the many drawbacks. The
construction worker is not able to bend a rod in perfect shapes and dimension .So we used a bending
machine to bend a rod and machine is better than human hands and its works perfectly and fast.

2. INTRODUCTION -

The system that we propose is for the bending of TMT steel bar. The bar is bent with the help of
hydraulic force, because the power of hydraulics is very large, so with the help of hydraulic force
we are able to bend bar. When we place a bar on the hydraulic bending machine the bar is bent by
the pressure force generated from hydraulic oil transferred by a piston cylinder assembly to the steel
bar for bending test.

Hydraulic jack is a machine used for bending the rods or work pieces manually. By using hydraulic
energy, the rod bending process can be carried out. This research is designed with hydraulic bottle

1
jack and roller. Bending is a process by which metal can be deformed by plastically deforming the
material and changing its shape. The material is stressed beyond the yield strength but below the
ultimate tensile strength. The surface area of the material does not change very much. Bending
usually refers to deformation about one axis. Bending is a flexible process by which many different
shapes can be produced. Standard die sets are used to produce a wide variety of shapes. Bending is
done using press brakes. In this study, the hydraulic power is used to bend the metal pipe because
the hydraulic system has good load capacity and good efficiency. This machine consumes no
electrical power, so it costs less compared to electrical powered hydraulic systems.

Bar bender is extensively used in the construction of buildings and fabricators. Due to heavy
prices rod bending machines did not reach to small scale construction workers. The portable rod
bender is designed for small scale constructional bending purpose which is also very portable, and
adjustable. This bender is designed for comfort to multi power source like hydraulics &
pneumatics. This portable bender can be manufactured by a mild steel (MS) for handling the
hydraulics & pneumatics power. This design gives more efficient than other benders for low
cost installation and maintenance cost. Less complicated parts. Simple bending and stress
calculation gives a support for this design.

The 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.

 The system that we propose is for the bending of TMT steel bar.

 The bar is bent with the help of hydraulic force, because the power of hydraulics is very large, so with the
help of hydraulic force we are able to bend bar.

 When we place a bar on the hydraulic bending machine the bar is bent by the pressure force generated
from hydraulic oil transferred by a piston cylinder assembly to the steel bar for bending test.

Objectives -

1. To make a bending machine to bend a metal bar.

2. Analytical design of “hydraulic bar bending machine.

3. Modelling and simulation of “hydraulic bar bending machine.

4. Preparation of prototype sample of “hydraulic bar bending machine.

5. Experimental workout of “hydraulic bar bending machine.

6. Study of comparative result of “hydraulic bar bending machine.

History -

2
In the past years all types of construction work are depend upon construction material, in this material
TMT bars are mostly used in construction works for column, beam, sealing etc. this TMT bar always bent
by people in past time and recent time. This process will be take more time and take more workers for
simple works. All types of bending machine available in market at high cost that small types of
construction works can’t afford this machine, and this machines are for the large diameter TMT bars, but
for the having a 8mm,10mm, and 12mm diameter TMT bars mostly used in shape of square, and
rectangular shape. This types of bends always bent by workers as shown as following Images. in this
images bends TMT bars by hands, so we trying to make a bending machine for this types of TMT rods.
after this bending machine we can’t save time.

TMT - TMT means Thermo Mechanical Treatment, which is a thermo mechanical process; These TMT
steel bars are generally used material in construction for enhanced protection against earthquake and
another type of natural disasters. To ensure safety for your structure TMT steel bars should be resistant to
corrosion which helps to obtain a longer life to your structure.

TMT Rod : Thermo-mechanical processing, also known as thermo mechanical treated bars ' ( TMT ), is a
metallurgical process that integrates forging , rolling and/or work hardening with heat - treatment into a
single process.

Specific Application of TMT Bars -

1) 8mm diameter TMT bars -

this types of bar mostly used to connect the vertical rods of columns, and horizontal rods of beam. This
rods used in different types of shape like circular, square, rectangular, triangle etc. it is commonly used in
making houses, walls, complexes.

2)10mm diameter TMT bars -

this types of bars used in making of stairs and different construction shape working for connecting the
column and beam rods. It is use in making of tall building, colleges etc.

3) 12mm diameter TMT bars -

12mm diameter rods use for heavy construction, bridges and also for special types of stairs and sealing.

3
Using the mechanical bending process some problems as listed below -

1. Leverage required for bending heavy sections is large; hence a tremendous amount of human effort is
necessary.

2. Labor cost is more.

3. Time-consuming, in terms of setting time ad operation time.

4. Space occupied is more.

5. Quality is not good.

6. Defects in the form of angular deformation and wrinkles are seen.

Using Hydraulic Jack as TMT bar bender -

Conventional mechanical process is replaced by the hydraulic system which offers many benefits
Hydraulic automatic bending is a perfect solution to the above problem wherein bending force is
generated is quite large about (0.5 ton) with a minimal human effort.

The hydraulic automatic bending uses a hydraulic pump mechanism to apply a gradual force up to
5000kg. Loading is done by operating handle of the jack which carries the cutting action, resulting in a
safe and damage free operation.

In order to increase the speed of operation, the pneumatic circuit is used to operate the hydraulic pump
and the relief valve and return spring set will help the quick return of hydraulic ram, thereby reducing the
idle time of the machine

Advantages -

1. Safety device for emergency power off. When the electricity is failure, the hydraulic bending and
bend removing machine can using by manual .
2. It is a portable and simple construction.
3. The length of stroke can be varied even within small ranges.
4. It is not occur in noise and vibration.
5. Inertia losses are not more.
6. Skilled personnel are not require.
7. Maintenance cost is law.

Disadvantages -

1. It is require more time.

2. Initial cost is more.
3. Intensive care should be taken while working

4
Application -

1. It is use in workshop
2. It is very useful in all small scale industries.
3. It is used in automobile industry.
4. It is used where build building.

5
3. LITERATURE REVIEW -
Investigation methods for analysis of transient phenomena concerning design and operation of hydraulic-
machine systems—A review Deyou Lia, Xiaolong Fua , Zhigang Zuob, Hongjie Wanga, Zhenggui Lic ,
Shuhong Liub , Xianzhu WeiOver the past decade, the use of conventional one-dimensional numerical-
simulation methods has been demonstrated to be inadequate in terms of their usefulness in investigations
concerning transient processes in hydraulic machines systems—their theoretical analyses and engineering
applications. Consequently, numerous three-dimensional numerical methods capable of accurately
simulating transient processes in hydraulic-machine systems have been proposed and improved upon in
recent years. Through use of these novel methods and strategies, many researchers have investigated
transient characteristics of processes occurring within hydraulic machine systems along with
corresponding formation mechanisms. This study presents a comprehensive review of related
experimental studies, novel numerical methods and strategies along with transient characteristics and
formation mechanisms in hydraulic-machine systems. Based on this study, suggestions have been made
concerning the selection of simulation methods to be used and directions for future research have been
proposed.

The paper deals with manufacturing of pipes which use power operated sheet bending machine and
manually operated sheet bending machine. It also includes limitations of manually operated bending
machine. From the results of the paper the productivity of power operated bending machine is higher.P.
S. Thakare[1].

Author told in recent year’s pipe bending machine is used in both industry and domestic purpose for
bending the pipe under the required angles and dimensions. Sometimes Heat treatment is used for pipe
bending but the heat treatment technique is not safe and have problems are produced in the pipes, such as
wrinkling, curve forming, reduced thickness, whole forming, reduced strength, easy breakable. In the
hydraulic pipe bending machine having an good advantage compared to heat treatment methods. V.
Senthil Raja[2].

In this paper, a bicycle integrated pipe bending mechanism has been designed and developed. The
applications of bent pipes are in frames, barricades, handle of bicycle. Most of industries uses bent pipes
as air conditioning, boiler, power generation, ship building, furniture, railroad, automotive, off-road and
farm equipment, aircraft etc. Due to adequate human power in countries like India, the human powered
machine will result in improvement of the economy and employment of nation. In Asian countries people
are facing electricity cut-off during most of the days so such system plays an important role in rural areas.
H. A. Hussain[3].

Hydraulic equipment has wide use in various automobile fields. These hydraulic instruments are used for
lowering and raising chair in Barber shops and in dental clinics. Hydraulic bending machine is the
suitable equipment to bend pipes, rods and bars. The pipe or rod to be bending is kept between the rollers.
With use of hydraulic jack we implement force on the pipe and bend it to the required angle depending on
the dies used. Hydraulic bending machine is less expensive, flexible and portable compared to those
which are discussed earlier. Hence it is better to replace current standard machines by hydraulic pipe
bending machine. Mohan Krishna S. A.[4].

The aim of this paper is to develop a pipe bending machine which is useful to bend a pipe in workshop.
This project is to design and construct a portable pipe bending machine. This machine is used to bend
steel pipes into curve and the other curvature shapes. The size of machine is very convenient for portable

6
work. It is fully made by steel. Moreover it is easy to be carry and use at any time and any place. It
decreases human effort and requires low skill labors for operating the machine. In this paper they
designed manually operated pipe bending machine with use of gears, motors, pulley, and frame. This
bending machine is both manually and power operated .Prashant P. Khandare[5].

Metal forming is a process in which the desired shape and size are obtained through plastic deformation
of a material without any loss of material. Bending is a metal forming process in which straight length is
transformed into a curved length. Roller forming process is a continuous bending operation in which a
long strip of metal is passed through typical roller adjustments, until the desired curvature shape is
obtained. The bending changes according to material and according to the loading condition and
thickness of sheet. Mahesh Gadekar [6].

Experimental investigation of energy saving -

opportunities in tube bending machines Paolo Albertellia, Matteo Stranoa, Michele MonnoIn the scenario
of containing the global warming, devising energy savings strategies in industry has become a proper and
urgent matter. Since manufacturing is one of the most energy demanding sectors, research and the linked
industries started tackling this issue proposing new eco solutions. In this paper, an experimental
investigation of the energy saving opportunities in tube bending machines is performed and critically
discussed. The analysis is carried out comparing an electrical tube bender and a hydraulic machine of
comparable size. The experimental measured are also used to fit energy models that are used to extend
the comparison considering different working conditions of the tube bending machines. The results show
that relevant energy savings can be achieved introducing the electrical drives.

Tube bending machine modelling for assessing the energy savings of electric drives technology Paolo
Albertelli, Matteo Strano The aim of the work is to carry out a comprehensive analysis of the energy
saving opportunities offered by the introduction of electric drives in the rotary-draw tube bending
technology. Although there is a clear industrial trend towards the replacement, especially for low tonnage
forming machines, of the traditionally adopted hydraulic drives, there is a lack of scientific research that
has studied its implications on energy consumption. For this purpose, an energy model for tube bending
machines was developed. The parameters of the model were identified exploiting experimental power
measurements performed on both a hybrid hydraulic-electric and a fully electric machine. The energy
saving analysis was carried out through the updated energy models. For sake of generality, the analysis
was extended considering various tube material-diameter combinations and different machine working
conditions. The results showed that relevant energy savings can be obtained and that the improvements
are affected by the machine throughput. It was also observed that the minimum achievable energy saving
is significantly higher (at least three times) than the energy share for processing the tube. An efficiency
analysis of both types of machines was also reported. The introduction of the electric drives allows
increasing the machine efficiency up to 50 percentage points. This achievement slightly decreases with
the increment of the rotary-draw bending machine throughput.

Design and fabrication of Hydraulic -

7
Pankaj Kumar Pandey, Arjun Kumar Nishad, Alok Mishra, Dinesh Kumar Gupta, Faisal Ali Ansari The
hydraulic metal bending machine is planned to do bending activity for utilizing a hydraulic power
pressure. This bending machine bends a small piece of sheet metal, plates, pipes, bars, rods. The motto of
this project is to develop a portable low-cost bending machine. This project comprises of a hydraulic jack,
pedestal bearings, basic casing, driving and driven rollers, metal shaft, nut and bolts. The fundamental
favourable position of our venture is Metal bar are twist fit as a fiddle (U-shape, circle twist) constantly
and less human exertion in task.

Mr. Harshad Khairkar, Mr. Dhananjay Kopre, Mr. Saurabh Kalkar, Ms. Dipali Kambe, Prof. Sarang
Gulhane The foremost aim of our project is to fabricate a hydraulic operated jack for the purpose of pipe
bending and bend removing machine. Hydraulic operated equipment’s are used in different fields. In an
Automobile hydraulic jack is raised for greasing job. Stepping on the brake pedal creates the hydraulic
power, which stops the rotation of the four wheelers or two wheelers to stop. In order to remove the bend
of pipes, rods and bars hydraulic bend removing machine is the most suitable equipment. To remove
bends from pipe or rod to be supported between the die holders and jack is actuated on pipe. It exerts
force on the pipe and bends it to the suitable angle depending on the dies used. Hydraulic bending
machine is consisting of hydraulic jack, die holder, pulley, slider, wiper motor, and spring. Actuation of
hydraulic jack is simple and reliable to maintain. In industries, Hydraulic bending and bend removing
machine is portable, it is a flexible and less expensive. Hence it is better to replace conventional machines
by hydraulic pipe bending and bend remove machine automatic operated bending machine requires no
maintenance and power utilization. During mass production it can be converted into automated or
electrically operated jack so that the rate of production can be increased. Applications of bending
machines are found to be in production industries, workshop automobile etc. now a day focusing into
automation. this project is aimed to bending pipe operation of by using automatically with help of wiper
motor.

4. WORKING PRINCIPLE -
The system that we propose is that bending of rectangular strips . The strip is bent with the help of
hydraulic force , because the power of hydraulics is very large the main aim of our project is to increase
the productivity so with the help of hydraulic force we can able to bend 3-6 strip depending upon the
diameter.

The bending machine equipment can be in the full-length bend Rod controlled within 90°. According to
shape requirements, we can also complete work-piece without repositioning on the device equipped with
914.4mm long stirrups. Machine work to bend stirrups into L-shape and Square shape also can band into
a circular shape. The rod is bent with the help of hydraulic force, because the power of hydraulics is very
large the main aim of our project is to increase the productivity so with the help of hydraulic force we can
able to bend 2-4 rods depending upon the diameter. In the older machines are rectified in that case we
8
place a rod for bending in the existing system we have to reposition the rod for every bend, but in our
Machine once the rod is placed we need not reposition the rod for all bends. This is done by a special
attachment of coupling the pinion wheel of a rack and pinion set to a freewheel, the function of the
freewheel is to change the position of the table to90 degrees. When the hydraulic cylinder in the forward
stroke the freewheel slips and hold the fixture table at the time the rod is bent. In return stroke of the
cylinder the rack rotates the pinion which is connected to the freewheel turns the table to 90 degrees.

5.METHODOLOGY -

Machine Description:-

The machine is designed based on the principle of Hydraulic system. The hydraulic load has more power
compare to the other type of loads like pneumatic and electric. By using heavy loads we can increase the
productivity of the product. The manual stirrup making process suffers from the many drawbacks. The
construction worker is not able to bend a rod in perfect shapes and dimension .So we used a bending
machine to bend a rod and machine is better than human hands and its works perfectly and fast.

In this machine used subsystems are:

1. Free length and 12mm dia. bent a rod subsystem

2. bending subsystem

3. Rotate wise as 360 degree subsystem

Main Components and Functions:-

A. Hydraulic Jack -

The design of a hydraulic jack A jack is a mechanical device used as a lifting device to lift heavy loads or
to apply great forces. Hydraulic jack get their power from pressurized hydraulic fluid which is typically
oil. Hydraulic jack is placed on slider and for better operation the base of the hydraulic jack is welded.
Hydraulic bottle jack can be operated with everything in the packaging. It does not need any additional
fluid, or an electrical source. The six-pound jack can lift vehicles weighing up to 3 tons simply by moving
a handle up and down.

9
B. Bearing -

A bearing is a machine element that constrains relative motion to only the desired motion, and reduces
friction between moving parts. A wide variety of bearing designs exists to allow the demands of the
application to be correctly met for maximum efficiency, reliability, durability and performance.

C.Shaft -

10
A shaft is a rotating machine element, usually circular in cross section, which is used to transmit power

from one part to another, or from a machine which produces power to a machine which absorbs power.
The various members such as pulleys and gears are mounted on it. The material used for ordinary shafts
is mild steel.

D. Frame - frame is base or foundation of TMT bar bender machine. That is support all the components
of TMT bar bender machine. Frame Our frame consist square cross sectioned tubes that is connected
using welds , entire apparatus is placed over the frame work it act as base for our project . Material of the
tubes is mild steel . Using the arc welding the frame work will finish.

E. Hinge - A hinge is a type of the bearing that connects two solids objects, typical allowing only a
limited angle of rotation between them. Two objects connected by an idle rotate relative to each other
about a fixed axis of rotation. Hinges may be made of flexible or of moving components in biology many
joints function as hinges.

11
Step 1: - We started the work of this project with literature survey. We gathered many research papers
which are relevant to this topic. After going through these papers, we learnt about Hydraulic Bending
machine.

Step2: - After that the components which are required for my project will be decided.

Step 3: - After deciding the components.

Step 4: - The components will be manufactured and then assembled together.

Step 5: - The Experimental Testing will be carried out.

12
Implementation - This machine effectively increases the production capacity of your steel yard,
minimizing the use of manual labor. TMT bending machine, also known as, Bar Bending Machine are
boisterously designed for life long operation making them uncomplicated to use and extremely user
friendly. Our TMT bar Bending Machines are sternly designed to reduce the role of manpower as well as
maintain low cost of production for our clients. Bar benders are manufactured in large batches, under
tight quality controlled environment and are thoroughly tested before shipping them across the globe. Set
on a wide body with a heavy duty gearbox, Bar Bending Machines boast of a rigid design which helps
maintain the performance of the machine year after year. Oil bathed gearboxes with hardened forged
alloy gears provide maximum strength and innovative features such as push button bending give operator
comfort. The automatic angle selection permits precise bend at a preset angle making it one step bending
process for various forms of bends and stirrups. Bar Bending Machine is easy to use, the machine can be
operated by a layman with minimal experience. TMT Bar Bending machine is highly appreciated by our
clients for its high strength, outstanding performance and for being cost effective. Our Research and
Development department is highly modified with the employment of the latest technology. Therefore, we
incline to make changes in the machine to prepare it for easier usage keeping cost under the bindings.
Available in different models, for rebars with maximum diameter up to 28mm (Single phase/ 3 phase),
36mm, 42mm, 52mm and 55mm and can be customized as per to our customer's requirement.

13
6.SCOPE OF WORK -

Machine can be handled by any operator very easily. In this system have a low cost and a design is
simple so it can be used in any type of construction site. In this system bending of stirrup rod can
extended to its length against workstation is possible. By changing the fixture in the table we can obtain
various shapes and sizes of the stirrups. A successful solution for the manual hand making stirrups.
Increase the production rate. Machine cost is less compare to existing bending machines. In future we try
to bend TMT bars of large diameter, it can used in every construction sites. Process of single bars
bending is taking less time compare to manual hand bending.

14
7.CONCLUSION -

The concepts behind the design of the whole machine system, which together as a whole function as the
rod cutting and bending automatic machine, are to produce a product which would require minimum
setup time for different shapes and rod lengths, hands free operation, and minimum maintenance. In the
original rack and pinion concepts there is bend rod of any shapes. These ideas were not implemented due
to the thought that it would result in machine setup and programming, greater cost, and possibly greater
maintenance requirements. the components designed and selected for the automatic bending machine are
sufficient for performing the motions of the machine without failure. This work has provided an excellent
opportunity and experience to use limited knowledge. The Hydraulic Bar Bending Machine is working
with adequate condition. This Hydraulic Bar Bending Machine is used for Bending and also Bend is
removed by satisfactory condition. Therefore in the Future, we can design and manufacture a large scale
Hydraulic Bending Machine.

15
8.REFERENCES -
[1] Investigation methods for analysis of transient phenomena concerning design and operation of
hydraulic-machine systems—A review Deyou Lia, Xiaolong Fua , Zhigang Zuob, Hongjie Wanga,
Zhenggui Lic , Shuhong Liub , Xianzhu Wei.

[2] Experimental investigation of energy saving opportunities in tube bending machines Paolo Albertellia,
Matteo Stranoa, Michele Monno.

[3] Tube bending machine modelling for assessing the energy savings of electric drives technology Paolo
Albertelli, Matteo Strano.

[4] DESIGN AND FABRICATION OF HYDRAULIC BENDING MACHINE Pankaj Kumar Pandey,
Arjun Kumar Nishad, Alok Mishra, Dinesh Kumar Gupta, Faisal Ali Ansari.

[5] FABRICATION OF AUTOMATIC HYDRAULIC BENDING AND BEND REMOVING

MACHINE Mr. Harshad Khairkar, Mr. Dhananjay Kopre, Mr. Saurabh Kalkar, Ms. Dipali Kambe, Prof.
Sarang Gulhane.

[6] Design and Fabrication of Hydraulic Rod Bending Machine I.Muhammed Hanoofa , S.Ravi
Vishwantha , P.Sureshkumara , N.Saravanan.

16