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Ketema
Ketema
project reported on :
Submitted to:
this is to certify that this project report entiteld “design and manfacturing of manual
tube bendig machine” submitted to metallurgy and production departement, manufacturing
tecnology section by teshome tesfaye , ketema ayele in partial fulfilliment for the requiemnt of
award of buchular of technology in mechanical engineering with specialization in
manufacturing technology under defence university college,college of engineering.
____________________________ __________________________________
______________________________________________
1 _ ___________________________________ ________________________
(chair person)
2 _____________________________________ ________________________
(external)
3 ___________________________________ ______________________
(internal)
abstrast
in this project we will design and manufacturing simple, light weight and very cheap price
tube bending machine .this machine can be operated by any lay man with out deep knowledge of
mechanism.
the tube bender part made from steel according to the diameter of to be bended the guider
and the dies size will also be changed accordingly.
in order to change the diameter of the tube to be bended it only needs to change the tip
of the guider ,which is trade jointed with the guider and can easily be removed and fixed.
the guider tip helps to make a smooth bending curve.
the tube is going to be supported by two small sized dies which guides the guider rod
and the bigger die will bend the selected size tube.
Acknowledgement
table of contents
page no
Certificate
Acknowledgements
Abstract
Table of contents
chapter-one
introduction
1.1 Introduction…………………………………………………………………
1.6 scope………………………………………………………………………………
1.7 methodology………………………………………………………………
chapter-two
lierature survey
2.4 benging……………………………………………………………………………
A. Rigid type……………………………………………………….
2.8.4 tooling…………………………………………………………………
chapter three
chapter four
part desigen
Chapter one
today our country need high demand of equipments like house hold furniture
(beds, chair ,table, ,tv-stands and others)hospital beds, fluid pipes and other which need
tube bending machines.
this machine should be low initial cost, no need extra power without human labor
can operate by any lay man ,light in weight and portable.
this project focused on designing the manual bending machine considering to solve
above courses with the aim of initiative the investment ,through it reduce the production
time and the cost of repair.
The old type bending machines which used in private sectors have operational and
production problems ,some of them are to bend the tube using sand compact ,heat treating
,hammering and by using low melting point metals inside the bended tube and after
bending they melt and poured out ,and also need high leading time to production the
bending time.
1.6 scope
We aimed that our project target that to design and manufacturing simple ,easy
movable and maintainable tube bending machine and to introduce this machine by
prototype stage , after that any interested and who have a capital can produce and
distributed the tube bending machine.
1.7 methodology
_ from internet
_ from dec and etaf library.
Chapter 2
Literature survey
The history of pipe and tube bending process bulk to the ancient chinese civilization where they
used reeds as tube to pipe water, even in united states hollowed out trees were used earlier in
waterlines later in 1700’s cast iron was used in england to form seamless pipe and all this was
manually done as there were on specialized machine that could be used for tubing process.
However, all this changes in 1920’s when further innovation introduced the converter furnace
process which allowed companies to produce malleable law carbon steel as well as aircraft with
introduction of newer technology the tube bending industry received newer innovation which are
in helped in making tube bending process efficient and simple.
When the metal materials are bent in cold condition at first an elastic shape alteration takes place
which is replaced by a ductile shape alteration from specific degree. If the reshaping capacity
runs down, the work piece breaks. The elastic behavior is reflected in the stress-strain diagram.
See figure below, which is determined by tensile tests.
Because all material has finite modules of elasticity, plastic deformation is followed by
elastic deformation upon removal of the load .in bending, this is recovery known as spring buck.
Some spring buck occurs whenever metals are formed .spring buck is caused by the residual
stress that is a result of cold working material. For example in a simple bend, residual
compressive stress remains on the inside of the bend, while residual tensile stress is present on
the outside radius of the bend. When the bending pressure is released, metal spring buck until
residual stress force are balanced by material stiffness, which resist further strain. The most
common method used to compensate for springbuck is over bending ,in which material is bent a
sufficient amount beyond the desired angle and allowed to springbuck to the desired angle after
elastic recovery occur. Because of the uncertainty of the exact location of the neutral axis, it is
best to trial and error methods when developing close tolerance stampings. The final bend angle
after springbuck is smaller and the final radius is larger.
In our project we will focus on cold working process. Cold working process is the plastic
deformation of metals below the re-crystallization temperature. This forming process is mostly
done in room temperature.
The major cold working processes or operation are basically classified under the following
1) bending
2) squeezing
3) shearing
4) drawing
2.4 bending
Bending is the uniform straining of material around the straight axis that lies in the neutral
plain and normal to the length wise direction of the strip metal. Metal flow takes place within
plastic rang of the metal, so that the bend retains permanent set after removal of the applied
stresses.
Tube bending is the term used for all metal forming processes that is used to form tube
and pipe. The pipe that are bent are used either in water ,for handles , petroleum pipe lines , in
power plant as free way signs and more .when a tube or pipe is bent, the wall which forms the
outside of the bend elongates and thins while the wall which forms the inside of the bend
compresses and thickens. A common objective in tube or pipe bending is to form a smooth round
bend. In this case, a bend can be formed with three basic tool s: the bend die, around which the
bend is formed; the clamp die, which grips the tube and holds it in position as the bend is
formed; and the pressure die, which forces the tube into the bend die groove so it can be formed.
2.4.2 bending square and rectangular tubes.
the square and rectangular tube walls are subjected to the maximum tensile and
compressive stresses at the outside and the inside of the bend when bending process takes place.
Material on the inside of the bent surface tends to expand vertically and flow horizontally along
tube face. These forces tend to draw in the vertical edges of the tube distorting the cross section
into a “key stone” shape. Square and rectangular sections do not lend themselves to good
transmission of clamping force between clamps and bend die. Tube tends to slide along the die at
the start of the bend. The basics of bending are the same for square, rectangular and round
material in that certain information is required to produce an accurate part
1. Press bending
3. Roll bender
4. Mandrel bender.
The press bender one of the most basic type of bending machines available this day. It is
used mechanical force by pressing the tube against the die to bend it.
This force could be applied pneumatically or hydraulic. The machine work on cold pipes
and only work tube with one size radius.
2.5.2 rotary draw bending.
The rotary drown bender used die sets to bend tubes. These bender can be programmed to store
multiple bending jobs each of which having a varying on bending rotary .drown degree bending
are usually used for bending pipe , tube and solid for application such as lines handles ,frames
and more .
mandrel bending of pipe and tube is used where the bent pipe and tube are
To have absolutely the least amount of deformation possible. The pipe and tube is supported
internally with a flexible mandrel support that bends with the pipe or tube, and ensures that the
interior is not deformed. The pipe or tube is drawn through a counter bending die on to fixed
radius former die, and the whole process ensures the best possible bends. Mandrel bending of
pipe and tube is used in the manufacture of exhaust pipes, custom exhaust pipes, turbocharger
exhaust and intake tubing, dairy tubing and process tubing, heat exchanger tubing, and all
stainless and aluminum tubing where a non deformed diameter finish is critical.
Fig2.5.4.1mandrel bending
bending operations will work only in two ways. The use of mandrels(filler) or
without use of mandrels(filler). Filler is used to fill the tube with loose particles mostly sands,
which is taken shaken out the tube after finishing the bending process or use of mandrels made
of hardened alloy cast iron or steel mandrel inserted in to the tube, which is then pull out after
finishing bending in order to avoid fracture and crack during bending .
mandrel is a part of the tube bending assembly that provides support to the inside of the
tube in order to prevent the tube from buckling. A mandrel may not be necessary if the wall is
thick enough. There are three general types of mandrel. Thin wall tubing can be bent to small
radii with freedom from wrinkles by use of a mandrel or filler. This wall tubing or nickel alloys
can be mandrel- bend through 180 to minimum mean radius of 2d.to minimize galling of the
inside surface of tube, mandrels should be made of hard alloy bronze rather than of steel. If the
steel mandrels are used, they should be chromium plate to reduce galling.
Mandrel must be lubricant before use chlorinated oil with extreme pressure additive are
recommended for sever bending or for ease of removal water soluble lubricant are used. Any
conventional filler material such as sand, resins, and low melting alloy can be used. Sand is the
least desirable because it is difficult to pack tightly and thus can lead to the formation of wrinkles
or kinks during bending. Low melting alloy filler produce the best bends .the expansion
characteristic of this filler ensure that voids are eliminated and a sound carries is created . Alloy
filler are removed by heating the bent tube in steam or hot water. Metallic filler must not be
removed by direct torch heating .because they contain elements such as lead, tin, and bismuth
that will embitter nickel alloy at elevated temperatures.
A . Rigid type: it fits the interior of the tube, and shaped to conform to the start of the
bend .however, because they are rigid, they support the entire circumference of the tube
only as far as the point of bending not beyond the tangency of the bend .
B .flexible type mandrel they are generally of shims .this type of mandrel is sometimes
used with square tube and box section .where only few bend are needed .inserting and
removing flexible mandrel is usually difficult .most of the time they are made of rubber .
When bending without internal support, the dies should be slightly smaller than those
used for bending with a mandrel or filler .this way is suitable for and pipes that have a
wall thickness greater than 7% of the outside diameter or for large radius bends.
According need of investment there are different types of bending machine those are:
1. Manual bending machine
The original method of manual bending begin with human power .although bending a
tube by hand is very economical, it is not conductive to higher productive to higher
production rate, quality repeatability . Operation of this machine requires that the
operator place the tube in the tooling area at the proper bend position ,actuate the tooling
in to position, and physically ,”pull” the machine mechanism to produce the bend. Basic
machines have a single dial, gage or adjustable stop which serves as guide line to
produce a desired angle of bend. When more than one bend per part is to be produced,
the operator must index the part to the next bend point and repeat the process to the
desired second bend angle .
B. Short runs.
C. Small diameter
a. Increased capacity
b. Less physical interface
c. Suited for higher volume
d. Standard machines are more accurate
e. Capable of more difficult applications
mostly automatic tube bending machines are called cnc bending, which are compute
numerical controlled tube benders. Modern computer technology is linked with servo-
mechanical control offers an excellent method for controlling the three bending axis. Cnc bender
mechanics operate very similar to the other draw bending methods the difference is that servo
derives control the distance between bend and plane of bend. A carriage/collecting system is
standard equipment .tooling movement and sequencing, part storage data, and other items are
controlled by the computer automatically.
a. Capital expenditure
b. Requires computer skill
c. May need water, air or electrical
d. Need high maintainability
there are many factors that influence bending process. Some of the problems are
buckling or folding. Buckling is the a deformation that happens to a tube surface suppose to be
straight after being bent, the tube undergoes a non uniform deformation, fracture or cracking is
the major concern in any bending which are directly related with ultimate stress of the material.
Some of the factors which affects which affect the bending process are:
1. Wall thickness
2. Method of bending
3. Size of the material
4. Tooling
5. Internal and external lubricants
2.8.1 wall thickness
the thickness of the tube is one of the important factors in the bending process. Large
thickness can be bent without the fear of fracture or cracking on the other side tube which
have small thickness must be felled with sand or loose particles such as mandrel to avoid
buckling or cracks. As shown bellow in the table. If thin-walled pipes are bent to small
radii, the material on the inside of the bend is pressed back behind the line of tangent, where
it is no longer supported by the bend die and therefore susceptible to wrinkling this problem
is wiper die. As shown in the fig. Below
the wiper die is a form part, which is mounted inside the bend behind die and has a
sharpen edged end, which is placed in positive fit into the pipe groove of the bend die and
pushed to the line of tangent is avoided, this minimizing wrinkling. However, if wrinkles
have already been formed, they cannot be eliminate after bending .bending is impossible
below the bending limit determined by stretching and it comes to work piece failure as a
result .the bending limit due to wrinkling separate the range, where the bending with
mandrel (and wiper die ) is possible .and within the range pipe can be bent without mandrel
.the large ratio of outside diameter to the wall thickness of the pipe and the smaller ratio of
bending radius to the outside diameter shows wrinkles while bending .bending round
,square or rectangular material involves stretching the outside diameter of the bend and
compressing its inside diameter .consequently ,a big wall thickness allows a tighter bend
radius and more material stretch ability with less distortion
0 12.7 60 20
0 15.88 45 31.75
0 19 45 47.5
0 22.2 60 45
0 25.4 60 50 63.5 62
0 28.6 50 89
0 31.8 75 101
0 38.1 95 95
0 25.4x25.4 60 87
*minimum distance between bends depends on bend orientation ,clamp size and degree of bend
2.8.4. Tooling.
After the parts have been designed ,the method of bending has been chosen ,and procedure
to bend within proper tolerance should be established .the machine must be setup with a
proper tool ,which is based on design condition, tooling that includes bend die ,clamp block,
follower or slide block ,mandrel and wiper die .
Irmco Gel
(847)864-0255
Water soluble gel type paste,used
for steel, aluminum ,&non
ferrous.part#460-80a
Houghton international Heavy oil Non water soluble oil used for
(610)395-8440 stainless steel .part# how-to-
draw3005
The quality is characteristic that a product or service must have. For example, product must be
reliable and useable .the most important qualities are the ones that customer want .the product
quality can be judged either by material or attributive quality characteristic. If you look at bent
pipe shape, you can judge the product as “good” if neither collapses on the cross section, cracks,
wrinkles, bulges nor any similar faults can be detected. Metric quality properties are being angle,
straight lengths, wall thickness, oval shape or roughness of the surface. Given tolerance ranges as
a precondition allow separation of the pipes in good products or rejects according to these
properties.
1 Lead 1 1 80 1 80
labor
1
2 Labor 1 50 1 50
total 2 130
As it has seen from the above table the air force pays an average of 46,800 birr per year to the
labor and this figure does not include over time bonus .fro the above table there is one machine
of pipe bending and in one shift there are two labors : one is the operator and the other one
which are helping the operator .in this shop the work hours are 8 .the tube or pipe has different
long and is cut in the required length by using hand saw .the processes of grinding takes place
for making smooth end of the pipes therefore the tube is ready to be bent at any specific degree
of angle. This bending machine can bend 60 pieces per day . The shop bent the pipes for fitting
hydraulic ,air, fuel ,and oil lines and they work with big concentration and because of the above
cases they bent small amount of tubes per day.
chapter three
d=40mm
𝜋(44.454 −404 )
Z= = 2967.98mm3
32×44.45
𝜋×𝐷
A= ×40.6, where d=44.45
2
𝜋×44.45
A= ×40.6 = 2835mm2
2
In order to protect collapsing a pipe during clamping process use car man’s formula,
collapsing pressure pcl, is given as follows:
For maximum diameter pipe
Pcl=658.6(t/d)-14.5
When t/d>0.03
2.4/44.45=0.054>0.03
Then pcl =658.6(0.054)-14.5
Pcl =21.06n/mm2
The hand force(q1) in hand operated clamping shouled not exced 150n.
Clamping force calculated from formula (with out formula)
Working done in turning the arm=lifting the weight,q
fx(2𝝅l)=qx pitch
fx(2𝝅d)=qx𝝅d tan𝜶
= 𝑭∗(𝟐𝝅𝑫)
Q 𝝅𝒅𝒕𝒂𝒏𝜶
100 800-950
120 900-1100
140 1000-1300
chapter four
part design
.
---------------------selection of thread guider
𝜋(40)
A= 𝜋d2 /4= = 1257𝑚𝑚2
4
p=50kn/1257mm2
chapter four
part design
4.1 components of mechanism