SUPERVISOR MEMBER

UNIVERSITY OFDAW KHAING TINZAR TUN

U MYINT SAN TECHNOLOGY
(YATANARPON CYBER CITY)
FACULTY OF PRECISION ENGINEERING

DESIGN AND CALCULATION OF SHEET METAL ROLLER BENDING MACHINE

PRESENTED BY
MG HAN LIN HTUN
5PrE-74
FIRST SEMINAR 1
 Outlines of Presentation

 Abstract
 Introduction
 Aims and objectives
 Literature reviews
 Pyramid type roller bending machine
 Components of roller bending machine
 Working Principle
 Methodology
 Future plan
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 References
 Abstract

 Roll bending is a continuous form of three point bending where plates and
sheets are bent to a desired curvature using forming rolls.

 Roll bending machine have three rolls in the form of a triangle.

 The two lower rolls are driven and the position of the upper roll is adjustable to
control the degree of curvature in the product.

 The roller bending process usually produces larger parts of cylinder or conical
cross sections in large quantity.

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 Introduction

 Roller bending process can be used to deform a sheet or plate to hollow shapes.

 The process can be performed using many materials such as mild, carbon and
alloy steels, aluminium alloys and titanium alloys.

 Rolling machines with both three and four rolls are indispensable to the
production of cylinders with various curvatures.

Figure1- Roller bending machine

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 Aims and Objectives

The following are the objectives of the work.

 To make a bending machine to bend sheet metal plate with 5mm thickness ,
Length=2500mm and diameter=240mm.
 To make on simple working principle.
 To make in minimum cost.
 To be easy maintenance.

The aims of the thesis are

 To study the design of rollers , the design of spur gears and the design of worm
gear sets.
 To study fundamental factors of roller bending machine.
 To study the main knowledge of design and mechanism.
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 Literature Reviews

 In 1877 Herkules started with the manufacture of bending machine, the

production of the most diverse parts and with foundry technology.

 In 1883 Henry Cort started modern rolling practice and Iron Mills.

 Ahmed Ktari has done Modeling and computation of the three-roller bending
process of steel sheets.

 M K Chudasama has done the experiment on Analytical Model for Prediction

of Force during 3-RollerMulti-pass Conical Bending.

 In 1890, M. B. Bassett, and W. Johnson found the bending of plate using a

three roller pyramid type plate bending machine.

 In 1886 P.G. Mehar studied the manually operated and power operated sheet
bending machine.
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 Pyramid Type Roller Bending Machine

 Pyramid type bending roller machine is used for bending sheet metal
covers.
 The most common applications of this pyramid type roll bending machine
lie in fields like cone making, aluminum and steel fabrication, marine and
ship building.
 There are two rolls, top and bottom rolls in the machine between which
the sheet metal is placed for bending.

Figure2- Pyramid Type Roller Bending Machine

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 Components of Roller Bending Machine

Sheet metal plate

Roller

Gear

Base

motor

Figure3- Three Roller Bending Machine

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CONT’D
 Base- The base on the sheet metal rolling machine is formed by used standard
channel on which the entire weight of the metal rolling machine is acted.

 Roller:-The metal rolling machine has two lower roller and one upper roller
between which the sheet metal is fed.

 Gears :-A gear is a rotating machine part having cut teeth which mesh with
another toothed part to transmit torque. Geared devices can change the speed,
torque, and direction of a power source.

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CONT’D

Figure4-Structure of worm , worm wheel and motor

Figure5-Structure of spur gears and motor

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CONT’D

Figure6-Spur Gear

Figure7-Worm Gear Sets

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CONT’D
Advantages of Spur Gear

 Spur gears have high power transmission efficiency.

 They are compact and easy to install.

 They offer constant velocity ratio.

 Unlike belt drives, spur gear drives have no slip.

 Spur gears are highly reliable.

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CONT’D
Disadvantages of Spur Gear

 Spur gear drives are costly when compared to belt drives.

 They have a limited center distance.

 Spur gears produce a lot of noise when operating at high speeds.

 They cannot be used for long distance power transmission.

 Gear teeth experience a large amount of stress.

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CONT’D
Applications of Spur Gear

 Metal cutting machine

 Marine engines

 Mechanical clocks and watches

 Fuel pumps

 Washing machines

 Gear motors and gear pumps

 Rack and pinion mechanisms

 Automobile gear boxes

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CONT’D
Advantages of Worm Gear

 Worm gears drives operate silently and smoothly.

 They are self-locking.

 They occupy less space.

 They have good meshing effectiveness.

 They can be used for reducing speed and increasing torque.

 High velocity ratio of the order of 100 can be obtained in a single step.

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CONT’D
Disadvantages of Worm Gear

 Worm gear materials are expensive.

 Worm drives have high power looses and low transmission efficiency.

 They produces a lot of heat.

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CONT’D
Application of Worm Gear

 Gate control mechanisms

 Hoisting machines

 Automobile steering mechanisms

 Lifts

 Conveyors

 Presses

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 Working Principle

 The machine consists of three rolls (two bottom roller ,upper roller).They are
arranged in a pyramid type formation.

 The sheet metal is placed between the two bottom rollers and upper roller for
bending.

 The upper roller can be adjusted up and down position by manually.

 The upper roller exists in a fixed position to feed and grip the sheet metal.

 Two bottom roller are driven by gears.

 Then , the motor is started in clockwise direction till one end of the plate
comes over first bottom roll reverse the motors and get second end on second
bottom.

 By repeating this process continuously the sheet metal can be bent to the
desired shapes precisely.
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 Methodology
Calculating the
Choosing the
Choosing dimensions Choosing the motor design of worm ,
materials of rollers ,
of sheet metal plate power worm wheel and
gears and shaft
shaft

Calculating the
Calculating the Calculating the
center distance Calculating the spur
bending force and diameters of three
between two bottom gear design
friction force rollers
rollers

Calculating the
Calculating
power required for
minimum distance
the rollers to bend
between upper and
5mm sheet metal
lower rollers
plate
 Future Plan
 To calculate the material tensile strength

 To calculate the velocity ratio

 To calculate the pitch circle diameter of worm

 To calculate worm and worm gear design

 To calculate the design of worm shaft

 To calculate the design of spur gear

 To calculate the bending force on two bottom rollers

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 References

 Steven R. Schmid, “Manufacturing Engineering and Technology”

Fourth Edition (2005)
 R.S. Khurmi, J.K. Gupta , “A Text Book of Machine Design” First
Edition (1996)
 Ryder G.H., “Strength of Materials” , Third Edition. (1977)
 Jonathan Landeros, “Sheet Metal Design”
 http://www.bhavymachinetools.com/
 http://www.bhavyamachinetools.com/sheet-metal-
machine/shearing-machine.html

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THANKS YOU

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