LAGUNA STATE POLYTECHNIC UNIVERSITY

COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT

DESIGN AND FABRICATION OF MANUAL ROLLER BENDING

MACHINE
FME6 - WORKSHOP THEORY AND PRACTICES

PROJECT LEADER:
VALE, MYNARD

MEMBERS:
CALIM, JULIO III
DE VILLA, MARVIN
NAZ, JAMAICA
ODO, GIOVANNI KOJI
RAZON, RALF RENS
VITERBO, JAN FREDERICK
 ABSTRACT

This study aims to create a roller-bending machine that can be used in the
workplace to bend pipes and metal strips. This project is in style and builds a movable
roller bending machine. This equipment bends steel pipes and meta strips into the desired
curvature shapes. The machine's size makes it ideal for mobile work. It is totally made of
steel. Furthermore, it is portable and convenient to use at any time and location. It reduces
human labor and requires less expertise to figure out this machine. We are inclined to
tackle live arising with a hand roller bending machine powered by block, motors, gears,
and support frame. Power is the pipe-bending machine, and everything is done manually.
As a result, our goal is to increase precision at a cheap cost while maintaining pipe bending
efficiency. Instead of delicate vogue, this machine operates on a straightforward kinematic
system. Because of its mobility, it is commonly used in workshop or fabrication searches.
A bending machine is another common instrument in the workshop for bending metal.

OBJECTIVES

This project will help learners in enhancing their skills in the use of various machine
tools and equipment, as well as achieve the following:

1. Table Top Manual Roller Bending Machine Design and Construction

2. Bend pipes/rods up to 1 inch in diameter using chain and sprocket, bending and
moving rollers, bearings, and spindle wheel as key components.

3. The employment of a screw-based mechanism in conjunction with spindle-powered

rollers enables the operator to accomplish the desired bending.

4. Housing and supporting frame installation.

 INTRODUCTION

The massive problem that those who work on various metallic works and general
constructions encounter is indeed the bending of metallic strips. This issue arises
throughout these tasks because the metallic pieces require a great deal of pressure,
strength, and accuracy to bend. Several machines can be utilized to accomplish this, but
the cost is enormous. This construction is more user-friendly for everyone, relatively
inexpensive, incredibly beneficial, and will fill those who wish to spend their time
constructively with feelings of delight and satisfaction.

The rationale for developing a Manual Roller Bending Machine for pipe bending is
that there is no suitable roller bender for bending metal pipes on a small scale. There are
various varieties of Manual Roller Bending Machine available on the market. Roller
benders include press brake bending machines, roll roller benders, and folding machines.
Furthermore, the roller bender for pipe bending is designed to bend a metal pipe. Another
argument for the roller bender design is that the roller benders on the market are large and
expensive. The present roller bender on the market is designed for large capacity metal
pipe bending. Given the capacity of roller benders on the market, the existing roller bender
does not meet the usage requirements.

The operation of a roller bender is straightforward. As a result, purchasing

an existing roller bender to be used for simple roller bending operations is not feasible.
Also, the machine is large and takes up a lot of space. Also, due to the roller bender's
weight and limited area, an issue will occur when moving and storing it.
 BACKGROUND

A roll bender is a mechanical tool with three rollers that is used to bend a metal
object into a circular path. The rollers flexibly rotate about three parallel dimensions with
uniform horizontal distance. Two immovable outer rollers cradle the bottom of the material,
while an adjustable inner roller pushes on the topside.

Roller bending machines are widely used in industries across the world to
perform various operations on metal sheets. When compared to other machines, the size
of these machines is quite large. These devices contain numerous components that aid in
the bending of metal sheets. Bending metal sheets is required by several industries to
produce various parts in accordance with the specifications. Metal structures are made up
of various metal sheets and strips. These strips are formed by bending them over a roller.
The metal sheet is placed between the rollers, and it bends forward due to the rolling force
of the rollers.

This machine also reduces the thickness of the sheet. Bending the metal strips
using these devices took a lot of work. Several bending metal strips are utilized in building
and metals projects. Also, these machines use a lot of energy and effort to bend the
sheets, such as fuel or electricity.

The goal of this project is to lower the roller bending machine's operating and
maintenance costs. Also, this manual machine requires less maintenance and is simple
to operate. Also, the manual roller bending devices did not require any energy to work. As
a result, the design of these projects helps industry reduce the cost of a certain project.
DESIGN/ METHODOLOGY
 TABLE OF SPECIFICATION
COMPONENTS FUNCTION

1. Bending Rollers This component is a flexible forming tool that can be

used to roll or bend metal tubes into cylinders,
cones, curves, and other shapes.
The three-point forming circle principle is how this
machine operates. The working rolls' relative
position changes and rotating motions continuously
deform the metal tube in a flexible manner until the
appropriate shape is achieved for the workpiece.

2. Spindle Wheel A spindle wheel is a revolving shaft that has a fixture

to retain the tube. The tool is supported by the
spindle shaft, which also acts as a positioner and
rotational drive. And it's for this reason that the pipe
is manually moved by the bending roller.

A power transmission method known as a "chain

3. Chain Sprockets
and sprocket drive" is used in engines to transmit
power from the crankshaft to the camshaft by
engaging a roller chain with two or more toothed
wheels or sprockets. Chain sprockets' primary
function is to maintain a constant speed between
the spindle and rollers.

The bearing stabilizes the shaft's position, limits

4. Bearings axial and radial motion, and ensures precision in
● Housing rotation. In bending machines, it also serves to
lessen friction and enable smoother rotation of the
moving elements. Your bearings are supported by
bearing housings, which can also house monitoring
devices. They are
shielded from foreign objects and kept lubricated. In
essence, they offer adaptable mounted bearing
solutions and support the included bearing's
optimum performance, service life, and cost-
effective maintenance.
 5. Screw A screw's two main uses are to raise or keep things
● Moving Roller together. All portions of the bending machine,
including the bearing case and the up and down of
the adjustable bending rollers, are made up of
screws, making them

the most essential of all the components. Without

it, it is impossible to bend steel with good quality.
Roller screws are also significantly more durable
than rival technologies, allowing them to tolerate
extremely high-duty cycles and attain lengthy
lives. Planetary roller screws provide high
precision and reproducibility.

6. Supporting Frame In order to prevent precise bending, the

supporting frame is attached to the
machine's main frame.

7. Mounts The mounts are the machine's foundation,

dividing the table and the bending machine
itself.

8. Joints and Screws A screw joint is a kinematic pair with one degree of
freedom that is utilized in mechanisms. Screw joints
offer single-axis translation by leveraging the
threads of a lead screw to do so. Screwed joints are
commonly utilized where machine parts must be
easily attached or removed without causing harm to
the machine or the fastening. Screwed joints are
extremely dependable in operation.
 BILL OF MATERIALS
TOOLS/ MATERIALS

DESCRIPTION UNIT QUANTITY UNIT PRICE TOTAL

1. Tubular Kg 5.5 Php. 30.00 Php. 165.00

pc 1 Php. 380.00 Php. 380.00

2. Metal Sheet kg 22.5 Php. 40.00 Php. 900.00

3. Angle Bar kg 9 Php. 58.00 Php. 530.00

4. Welding Rod Pcs 7 Php. 7.00 Php. 49.00

kl 1 Php. 200.00 Php. 200.00

5. Cutting disc Pcs 2 Php. 30.00 Php. 60.00

pc 1 Php. 115.00 Php. 115.00

6. Solid Bar kg 1.5 Php. 47.00 Php. 70.00

7. Roller pcs 3 Php. 310.00 Php. 930.00

8. Ehe pcs 2 Php. 90.00 Php. 180.00

9. Polishing steel pc 1 Php. 100.00 Php. 100.00

wire wheel

10 Pillow block pcs 4 Php. 65.25 Php. 261.00

11 Turning wheel pc 1 Php. 140.00 Php. 140.00

12 Screw kl 1/2 Php. 270.00 Php. 135.00

13 Spacer pc 1 Php. 95.00 Php. 95.00

 14 Chain pc 1 Php. 150.00 Php. 150.00

15 Paint pc 2 Php. 150.00 Php. 300.00

PICTURES/ CURRENT PROJECT STATUS

As of May 24, 2023, we already finished our manual roller bending machine. Over
the past few months of construction, we experienced the difficulties of putting the machine
together. Everyone poured their efforts into the project. We utilized all the listed materials, each
of which played a crucial role in the machine. We also purchased numerous tools and
equipment throughout the construction period. In total, we spent 4,760 pesos, and on average,
each person contributed 600 – 700 pesos. Our hard work has paid off, resulting in the
successful completion of the project.