Technological University (Magway)

Department of Mechanical Engineering

SHEET METAL FORMING MACHINE
Project Report
Date-25.10.2023

Supervisor Presented by
Daw Khin Ohnmar Myo Group (I)
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 Group Members
• Mg Kaung Khant Kyaw
• Mg Pyae Oo Khant
• Mg Win Thiha Kyaw
• Mg Sitt Aung Kyaw
• Mg Yu Wine Ko
• Mg Nyi Nyi Ye Yint
• Mg Shine Wana Aung
• Mg Kyaw Nanda Htwe
• Mg Tint Naing Linn

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 Outline of Presentation

• Introduction
• Aims and Objectives
• Working Principle of Sheet Metal Forming Machine
• Main Components of Sheet Metal Forming Machine
• Types of Sheet Metal Forming Machine
• Design consideration of Sheet Metal Forming Machine
• Design calculation of Sheet Metal Forming Machine
• Results data for Sheet Metal Forming Machine
• Conclusion
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 Introduction
• Sheet Metal Forming Machine is used to bend steel into curve or other curvature shape
• Sheet Metal Forming Machine can be performed using many materials such as carbon and alloy
steels, aluminum alloys and titanium alloys
• In three roller Sheet Metal Forming Machine, using the upper roller, which is movable, the bending
process is performed by applying load (force)
• Two bottom rollers fixed which act as a support to hold the sheet of metal
• If the upper moves in the direction of the clockwise, the bottom rollers move immediately in the
direction of the anticlockwise direction
• Square threaded power screw is used to change the position of the top roller
• Frame is a fixed rigid support the assembly and also to prevent vibration from the machine
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 Aims and Objectives

• To press and bend raw metal into a specific uniform shape

• To widely use in monopoly business
• To calculate the Load on the sheet, bending stress, deflection
• To design the Sheet Metal Forming Machine

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Working Principle Of Sheet Metal Forming
Machine

Photo of Sheet Metal Forming Machine 6

Block Diagram of Sheet Metal Forming Machine

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• Driving System

• In Speed reducer, two stage reduction gear which worm gear, worm and spur gear work together

• 1.5KW motor connected with speed reducer

• The upper rollers are connected with the bracket by adjusting screw and the lower roller is connected with the
base

• Belt driving is the driving type that tighten the ring belt on the driving wheel of reducer and bottom roller’s wheel
• Movements

• Main movement refers to the motion of the upper and lower roller to rotate and bend the processed plate

• Auxiliary movement is the form of movement of the loading, unloading and lifting of the upper roller or the
upward or downward movement of the upper roller

• Processing method of bending

• The bending of the plate is achieved by the pressure generated when the upper roller moves downward
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 Main Components of Sheet Metal Forming Machine
(i) Top Roller
• mainly composed
• an important part of the ‘Sheet Metal Forming machine’
(ii) Bottom Roller
• made of the lower roll
• perfectly suitable for operating at normal temperature conditions
• uses with low-speed heavy-duty sites
(iii) Machine Frame
• composed of the machine body, the sliding plate, the shaft sleeve
• utilized to in order to assists in driving the upper roller parts to move
horizontally
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(iv) Base
• Includes a box welded structure, which is then quenched and stress
relieved
• Utilized for the installation
(v) Adjustable post plate base
• Rack upright in order to provide a connection point for the anchor bolts
between the column and concrete
• Adjusted by changing the distance between the upper and lower rollers
(vi)Ball Bearing
• Consists of a bearing insert with a spherical outer diameter in a cast
iron housing
• Fixed to the shaft by means of two set screws in the extended portion of
the inner ring
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(vii) Main Drive System
• Consist of one main motor, reducer, bearing, chain and sprocket
• provide power can rotate forward
• The torque inside the machine is transmitted to the lower rollers
through of the main reducer
• The lower rollers rotate by connecting chain with two sprockets
• The friction between the drive and the plate to feed and complete the
rolling work
(vii) Balancing Drive
• Composed of a beam, a support plate, and a rod
• Utilized for pressing facilitates the unloading of the workpiece.
• Facilitates the unloading of the workpiece .

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 Types of Sheet Metal Forming Machine

There are four types of Sheet Metal Forming Machines.

a. Ring rolling
b. Roll bending
c. Roll forming
d. Profile rolling

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 Types of Sheet Metal Forming Machine
(a) Ring rolling
• A forming process for the production of rings
• A headed and pierced ring
• Two or more rotating dies (rollers) are used

(b) Roll Bending

• a device for the radial forming of flat
• a type of machine tool used for making continuous
point metal sheet bending
• machine can be used to make cylindrical parts, conical
parts, and various arc-shaped parts
• works similarly to a profile bending machine
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(c) Roll Forming
• designed to make sheet metal into straight formed shapes
• The roll forming process takes a continuous flat sheet of metal
• by station shape the metal into a finished shape

(d) Profile Rolling

• an element is adapted to a desired radius or diameter
• an adapted pressure in a roller
• used for curved buildings, profiles for wind turbines

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The advantages and disadvantage of ‘Sheet Metal Forming Machine’
Advantages
• Good Efficient
• Small size
• Light weight
• Simple structure
• Easy to manufacture and install
• Potable
• Reducing time
• The labor required is minimum
Disadvantages
• Limitation of thickness
• Can form only sheet metal
• Remove the belt when manual run 15
 Applications of Sheet Metal Forming Machine
(a) Construction and Architecture
• a crucial technique for adding intricate architectural features to
buildings
• to create captivating and unique designs
• the realization of imaginative concepts by shaping metal plates into
intricate and unconventional forms for sculptural-installation
(b) Energy and Power Generation
• for the fabrication of cylindrical or spherical vessels
• vessels play a crucial role in various applications, including steam
generation
• is integral to the fabrication of boilers and heat exchangers
• used to create precision components for turbine casings, rotor
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blades, and other critical parts
(c) Aerospace
• used to create various structural components for aircraft, including fuselage sections,
wing spars, and tail assemblies
• employed to craft curved and contoured panels that optimize lift, stability, and control
during flight
• utilized to manufacture engine casings that encase and protect aircraft engines

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 DESIGN CONSIDERATION OF ‘SHEET METAL FORMING MACHINE’

Power

In an electric motor , the mechanical power is defined as the speed times the torque.

Where,
(rad/s)
N = Speed of the motor(rpm)
T = torque (N-m)
P = Power of the motor(KW)

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 Torque

A force that produces or tends to produce rotation or torsion. an automobile engine

delivers torque to the drive shaft.

Where,
T= torque of the motor(N-m)
P= power of the motor(KW)

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 Moment of Inertia

The moment of inertia is defined as the product of mass of section and the square of the
distance between the reference axis and the centroid of the section.

For rectangular section,

Figure 3.1

Where ,
I = Moment of Inertia(mm4)
b = width (mm) 20
Bending Stress

Bending stress is the arising when external forces or movements cause an object to bend
or deform.

Bending Stress,

Where,
= stress(N/mm2)

M= Bending moment(N-mm)

I = Moment of Inertia(mm4) Figure 3.2

y= perpendicular distance of the natural axis(mm)

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Deflection

Deflection is the degree to which an element of structure changes shape when a load is
applied.

Where,
=Deflection(N/mm)

W= Load of the Beam(N)

L = Length of the beam(mm)

E= Young’s Modulus of the beam(N/mm2)

I= Moment of Inertia(mm4)

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Load Acting On The Sheet

Where,
E = Modulus of elasticity of compression(N/mm 2)

I = Moment of inertia of sheet. (mm4)

R = Radius of curvature(mm)

L = Length of Sheet(mm)

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’
DESIGN CALCULATION OF SHEET MRTAL FORMING MACHINE

Design Specification of Sheet Metal Forming Machine

Table 4.1 Specification of Sheet Metal Forming Machine

Sir Name Symbol Value Unit

1 Power of Motor P 1500 W

2 Speed of Motor N 1440 rpm

3 Voltage V 220 V

4 Ampere A 9.6 A

5 Width of Sheet Metal B 762 mm

6 Length of Sheet Metal L 914.4 mm

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Required Torque of motor and reducer for ‘Sheet Metal Forming Machine’

Power of the motor = 15KW= 1500W

Speed of the motor , N = 1440 rpm

Angular speed of the motor,

=150.79 rad/s

Power of the motor,

P = Tm × ω

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 Continued

Torque of the motor = 9.947 Nm

Power output= motor power =1500W

Power input = voltage × ampere

= 220V × 9.6A

= 2112 W

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Mechanical efficiency,

= 0.710

= 71%

Speed Ratio of the Motor to Reducer = 1:50

So, Speed of the Reducer, N = speed of the motor ×

= =28.8rpm

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 Continued

Motor power = speed reducer power

Speed reducer power = 1500W
Torque of the speed Reducer,

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=180.96N-m=180.96×10 N-mm

Calculation of load & stress acting on the sheet

W = 4EI/ RL

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 FOR STAINLESS STEEL
b =762 mm
L=914.4mm

r=291.06, dmax=2x291.06=582.12
R=(582.12+1.5)/2=291.82mm
(a) For t1=1.5mm,

(i) = 4EI / RL

E = 196 x MPa or N.

=629.97 N 29
 (ii)
Bending stress

=1007.5
(iii)
Deflection of sheet at mid span to obtain required radius of curvature

=238.88mm

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 Fig(4.1) Schematic Illustration of Bending Stress

(b) For = 2.5mm,

(i) = 4EI / RL

= 2915.14N

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(ii) Bending stress,

=1679.12

(iii)

=238.768mm

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[c] For =3.5mm,

= 4EI / RL

=7999.24N

= 5037.42

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(iii)

= 238.567 mm

(d) For = 5mm,

(i) = 4EI / RL

= 23321.07 N

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=3358.2

= 238.768mm

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Table(4.2) Result Data of ‘Sheet Metal Forming Machine ’

No Thickness of Material(mm) Load (W) Bending Stress() Deflection ()

(N) () (mm)

1 1.5 629.97 1007.5 238.886

2 2.5 2915.14 1679.12 238.768

3 3.5 7999.24 5037.42 238.567

4 5 23321.07 3358.2 238.768

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Table(4.3) Result Data of ‘Sheet Metal Forming Machine
Sir Name Value Unit

1 Angular speed of the motor 150.79 rad/s

2 Speed of the reducer 28.8 r.p.m

3 Mechanical efficiency 71%

4 Torque of the motor 9.947× N-mm

5 Torque of the speed reducer 497.35× N-mm

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 Conclusion
• ‘Sheet Metal Forming Machine’ to bend a metal plate up to 6 mm thick mild steel plates has been
carried
• The major components of the machine designed were: the rolls shaft diameters; the chain drive;
the spur gears drive and holding keys and the framework
• Constant radius of curvature (R), constant dimensions by changing the material, load(W) increases
as the value of modulus of elasticity(E) increases
• Load is directly proportional to the modulus of elasticity
• Same radius of curvature (R) and material if thickness varies from1.5 mm to 5mm, it directly
affects the value of load(W)
• Load increases as the thickness changes in increasing
• Skilled labor as they lowered the top roller with the help of power screw in some extent
• Required deflection of the Sheet Metal Forming Machine are 238.886mm, 238.768mm,
238.567mm and238.768mm.
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Top roller and bottom roller Chain and sprockets
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Driving System Painting of Sheet Metal Forming Machine

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 Installation of Sheet Metal Forming Machine

Sheet Metal Forming Machine

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Thanks For
Your Time
&
Attention
Today

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