DESIGN AND FABRICATION OF

HYDRAULIC PIPE BENDING MACHINE

A PROJECT REPORT
Submitted by
KARTHIKEYAN J 312316114318
INGARSAL S 312316114316

In partial fulfilment for the award of degree

Of
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

St. JOSEPH’S COLLEGE OF ENGINEERING

ANNA UNIVERSITY: CHENNAI 600 025

MARCH 2019

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 ANNA UNIVERSITY: CHENNAI 6000025

BONAFIDE CERTIFICATE
Certified that this project report “ DESIGN AND FABRICATION OF
HYDRAULIC PIPE BENDING MACHINE MACHINE” is the bonafide
work of “KARTHIKEYAN J (312316114318) , INGARSAL S
(312316114316) ” who carried out the project work under my supervision.

SIGNATURE SIGNATURE
Dr VADDI SESHAGIRI RAO M.E.,M.B.A.,Ph.D.,F.I.E Mr .J. MARIYAPPAN M.E.,

Principal & Head Of Department Assistant professor

Dept .of Mechanical Engineering Dept. of Mechanical Engineering

St. Joseph’s College Of Engineering St. Joseph’s College of Engineering

Chennai-6000119 Chennai-6000119

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 CERTIFICATION OF EVALUATION

COLLEGE : St. JOSEPH’S COLLEGE OF ENGINEERING

BRANCH : MECHANICAL ENGINEERING
SEMESTER : VI
S.NO NAME OF THE TITLE OF NAME OF THE GUIDE
STUDENTS PROJECT

1. KARTHIKEYAN J DESIGN AND Mr .J .MARIYAPPAN M.E.,

FABRICATION
(312316114318) OF ASSISTANT PROFESSOR
HYDRAULIC
PIPE BENDING
DEPARTMENT OF
MACHINE
MECHANICAL
ENGINEERING
2. INGARSAL S

(312316114316)
The report of the Design and Fabrication project work submitted by the
above students in the partial fulfilment for the award of the degree of bachelor
of Mechanical Engineering in Anna University was evaluated and confirmed to
be the work done by the above students.

Submitted for UNIVERSITY VIVA EXAMINATION held on

______________

(INTERNAL EXAMINAR) (EXTERNAL EXAMINAR)

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 ACKNOWLEDGMENT

We express our sincere thanks to our Chairman Dr . B . BABU

MANOHARAN M.A.,M.B.A.,Ph.D., and Managing director Mrs.B.
JESSIE PRIYA M.Com., and our director Mr. B. SHASHI SEKAR
M.Sc., INTL.Business of St. Joseph’s College Of Engineering for their kind
attention and valuable suggestions given to us throughout the course.

We are indebted to our Principal and Head of the Department of

Mechanical Engineering Dr. VADDI SESHAGIRI RAO M.E., Ph.D., F.I.E
for being a source of inspiration throughout our study in this college.

We thank our Vice Principle and HOD-Lab Affairs, Department of

Mechanical Engineering Dr.S.ARIVAZHAGAN M.E.,Ph.D., and our staff for
their guidance and encouragement at each and every stage of our project work.

We also thank our Professor and HOD- student Affairs, Department of

Mechanical Engineering, Dr. N.ARUN KUMAR M.E.,Ph.D., for his guidance
and encouragement at each and every stage of our project work.

With profound respect, we express our deep sense of gratitude and our
sincere thanks to our internal guide, Mr J. MARIYAPPAN M.E., for his
valuable guidance and suggestions.

We express our thanks to all the staff members for their assistance and
guidance in making this project a success.

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ABSRACT
The hydraulic pipe bending machine is planned to do bending by utilizing
a hydraulic power pressure. This bending machine bends a small piece of sheet
metal, plates, pipes, bars, rods with respect to shape of rollers. Normally the
bending machine used in workshops are large in size and high in cost they are
difficult to accommodate by smaller workshops .The motto of this project is to
develop a portable low cost bending machine. This project comprises of a
hydraulic jack, basic casing, ram pulley, 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.

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CHAPTER TITLE PAGE
NO. NO
ABSTRACT 5
TABLE OF CONTENT 6
LIST OF FIGURES 7
1. INTRODUCTION 8
1.1. HYDRAULIC PIPE BENDING MACHINE 8
1.2. NEED 9
1.3. WORKING PRINCIPLE 10
2. DESIGN CALCULATION 12
3. FABRICATION OF
HYDRAULIC PIPE BENDING MACHINE 14

3.1. COMPONENTS USED IN THE PROJECT 14

3.2 DIADRAMMATIC VIEW OF COMPONENTS 15
4. WORKING 19
5. `ADVANTAGES 20
6. APPLICATIONS 21
7. BILL OF MATERIALS AND
COST ESTIMATION 22
8. CONCLUSIONS 24
9. REFERENCE 25

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LIST OF FIGURES

DESCRIPTION PAGE NO

1) CATIA MODEL 10

2) HYDRAULIC JACK 15

3) FRAME 16

4) RAM 17

5) ROLLERS 17

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 CHAPTER 1

INTRODUCTION

In modern days, all area of industries are going to like automated,

economically and accurate machinery .There is many types of pipe bending
machine are available in market like hydraulic pipe bending machine,
pneumatic pipe bending machine, manual pipe bending machine etc.

The pneumatic which uses the highly compressed gas ans manual pipe
bending uses the lever or screw gauge type and hydraulic pipe bending uses the
fluid pressure to manipulate the lower force to large amount of force

1.1 HYDRAULIC PIPE BENDING

The hydraulic bending press is one of the most flexible machines on the
market, allowing the fabricator or iron worker to shear, punch, bend, scroll, and
press thousands of different parts. When considering industrial machinery, the
hydraulic bending press is the perfect machine shop tool for the metal
fabricator. The hydraulic pipe bending press fits any small to medium-sized
industry when machinery for large-scale production must necessarily make way
for machinery with distinctly lower production costs.The operating procedure
of hydraulic pipe bending machine is simple when compared to other pipe
bending machine. Biggest improvements were placing the hydraulic cylinder
near the die holder. The hydraulic pipe bending press is most bend accuracy due
to less deflection in the table. The die holder is used to hold the die in the proper
position. We have to change the die to produce different shape of pipe such as
‘V’ type, ‘L’ type etc
The cross section of pipe which can be bended has been vary according to
the shape of the rollers if the rollers are straight cylinders then we have been

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able to bend an rectangular section bar if it is arc shaped then we able to bend
cicular pipes.

1.2 NEED
Generally the bending ,achine used in workshops are large in size and
high in cost they are difficult to accommodate by smaller work shops.The motto
of this project is to develop a portable low cost bending machine. This type
bending machine made for the small size workshops to use. They are made for
mini workshops to do small size bendings at low cost.

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1.3 WORKING PRINCIPLE OF HYDRAULUC PIPE
BENDING MACHINE

The operating procedure of hydraulic pipe bending machine is simple

when compared to other pipe bending machine. The hydraulic pipe bending
press is most bend accuracy due to less deflection in the table. The rollers are
used to hold the die in the proper position. We have to change the roller to
produce different shape of pipe such as ‘V’ type, ‘L’ type etC
Hydraulic pump consists of piston, piston rod and oil. The hydraulic pump
reciprocating handle is move upward and downward continuously, so that the

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compressed oil goes to the hydraulic cylinder. The hydraulic cylinder consists
of piston and piston rod. The end of the piston rod the ram is fixed. The
compressed oil pushes the hydraulic cylinder piston forward. Already the pipe
to be bended is fixed in between rollers and ram.
By changing the die in the hydraulic pipe bending machine, we have to produce
different shape of bended pipe such as “V” type, “L” type etc. The ram is strike
the pipe forcely, so that the pipe is bended with respect to ram movement and
roller position.

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 CHAPTER 2
DESIGN CALCULATION
SPECIFICATIONS

Roller length =60mm

Bolt diameter=14mm

Load ( W) = 5 ton(60kN)

Operating pressure (p) = 10 M Pa

Lift range (L) = 150mm

Man effort put on the handle (e) = 20 Kg

Permissible tensile stress of mild steel (σt) = 120 N/mm2

Factor of safety = 5

Permissible shear stress of mild steel (τ) = 20 N/mm2

Permissible compressive stress of mild steel(σC)= 20 N/mm2

Permissible compressive stress of cast iron (σCI)= 120 N/mm2

Permissible shear stress of cast iron (τCI) = 35 N/mm2

Permissible shear stress of bolt ( τb) =200 N/mm2

BOLT STRESS CALCULATION

Permissible shear stress of bolt ( τb) =200 N/mm2

Shear stress in bolt = load/area

Area of bolt =( π/4)*142 =155 mm2

Shear stress induced =60000/(4*155) =96.7 N/mm2

Thus the induced stress is less than the permissible shear stress,

So the bolt is safe in shear.

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BENDING CALCULATIONS

supported beam so the deflection of pipe is compared to the deflection

of beam The bending of pipe is considered as a bending in the simply supported
beam.

W = Load applied through jack

k A = Area

Syt = Yield strength of material

δ = Deflection

L = Length between two bobbins

E = Modulus of elasticity

I = Moment of inertia

W = Syt * Area

δ =WL3/48

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 CHAPTER 3
FABRICATION OF HYDRAULIC PIPE BENDING MACHINE

3.1 LIST OF COMPONENTS USED

 HYDRAULIC JACK
 FRAME
 RAM
 ROLLERS
 NUTS AND BOLTS

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3.2 DIAGRAMMATIC VIEW OF COMPONENTS
HYDRAULIC JACK

Hydraulic jack works on the principle of ―Pascal‘s law‖. When the handle is
operated, the plunger reciprocates then the oil from the reservoir is sucked into
the plunger cylinder during upward stroke of the plunger through the suction
valve. The oil in the plunger cylinder is delivered into the ram cylinder during
the downward stroke of the plunger through the delivery valve. This pressurized
oil lifts the load up, which is placed on top plate of the ram. After the work is
completed the pressure in the ram cylinder is released by unscrewing the
lowering screw thus the pressure releases and the ram is lowered, then the oil is
rushed into the reservoir.It consists of plunger cylinder on one side and ram
cylinder on the other side. These two cylinders are mounted on base which is
made of mild steel. Plunger cylinder consists of plunger which is used to build
up the pressure by operating the handle. Plunger cylinder consists of two non-
return valves i.e. one for suction and other for delivery. Ram cylinder consists
of ram which lifts the load. The ram cylinder connected to delivery valve of
plunger cylinder. It is also consists of lowering screw this is nothing but a hand
operated valve used for releasing the pressure in the ram cylinder for get down
the load.
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FRAME

The frame is the main body of the machine which holds the load of a
every component
The frame has been made by joining the square tubes and plates. The
tubes are 40mm in size and 2mm in thickness . they are made by hot drawing
process so it can hold large weight and light in weight.
The plate which is joined to the tubes are hot rolled they can also
withstand more loads. They attached to the pipes by means of arc welding

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RAM

The ram is fixed to the hydraulic press or jack vertically if the hydraulic
jack moves up with each stroke the ram goes up.

ROLLERS

The rollers are fixed at both ends of the frame but the rollers are not
allowed to move horizontally or vertically it can only rotate through its axis.

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NUTS AND BOLTS

Here the nuts and bolts are not used for fastening purpose here bolt used as
axle rod for rollers

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 CHAPTER 4
WORKING
The operating procedure of hydraulic pipe bending machine is simple
when compared to other pipe bending machine. The hydraulic pipe bending
press is most bend accuracy due to less deflection in the table. The rollers are
used to hold the die in the proper position. We have to change the roller to
produce different shape of pipe such as ‘V’ type, ‘L’ type etC
Hydraulic pump consists of piston, piston rod and oil. The hydraulic pump
reciprocating handle is move upward and downward continuously, so that the
compressed oil goes to the hydraulic cylinder. The hydraulic cylinder consists
of piston and piston rod. The end of the piston rod the ram is fixed. The
compressed oil pushes the hydraulic cylinder piston forward. Already the pipe
to be bended is fixed in between rollers and ram.
By changing the die in the hydraulic pipe bending machine, we have to produce
different shape of bended pipe such as “V” type, “L” type etc. The ram is strike
the pipe forcely, so that the pipe is bended with respect to ram movement and
roller position
The bending of pipe is based stroke of ram and the position of rollers. If
the stroke is more the bending curvature is more if the distance between the
rollers are less we have curvature with small size.
The distance between rollers are adjustable. It can be change by
changing the position of the rollers by just connecting bolt and nut at various
positions
The circular tubes are able to bend by this machine at any size we want it
to bend.
The cross section of the tube can be varied by varying the cross section of
rollers By using different rollers the different cross section of the pipe being
bended.

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 CHAPTER 5
ADVANTAGES
 Hydraulic pipe bending machine develops greater forces than mechanical
pressure and hence it is for forming, bending, and drawing and extrusion
operations.
 The hydraulic pipe bending machine can exert its full forces at any
position of the ram stroke whereas the force is maximum at the end of
stroke in mechanical press.
 The sliding action of the punch slide is uniform.
 The length of stroke can be varied even within small ranges.
 No noise, no vibrations and hence smooth operation.
 Stroke length and position of stroke can be varied easily.
 Wide speed ranges.
 Inertia losses are less

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 CHAPTER 6
APPLICATION
 The hydraulic pipe bending machine brakes can be fitted with hundreds
of tooling options for acting as a press brake (using the table as the level
for accuracy),

 Ram bender (for pipe or solids),

 Rotary draw tubing bender

 Shear, punch, ornamental iron twisting machine, straightener, etc.

 This machine tool is great for any welding shop, fabricator, or general job
shop

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 CHAPTER 7
BILL OF MATERIALS

S.NO MATERIAL QUANTITY

1 SQUARE 5m
TUBES
40*40mm

2 Hydraulic jack 1

3 PLATE 2

4 ROLLERS 2

5 RAM 1

6 FASTNERS AS REQUIRED

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COST ESTIMATION

S.NO MATERIAL AMOUNT IN

RUPPES

1 SQUARE 600
TUBES
40*40mm

2 Hydraulic jack 2000

3 PLATE 200

4 ROLLERS 150

5 RAM 200

6 FASTNERS 100

7 WORKING 500
COST

TOTAL 3750

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 CHAPTER 8
CONCLUTION
The motto of this project is to make pipe bending machine at low cost and
small size and with long life of working. The bending machine is mainly made
for make it to afford by the small workshops ,welding shops ,or any other small
machine shop. The project is successfully finished and tested and the expected
result has come .so it is very useful for bending a tubes in workshops .

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 CHAPTER 9
REFERENCE

1) PSG DESIGN DATA BOOK

2) RS .KHURMI, “THEORY OF MACHINES”
3) JK. GUPTA, “THEORY OF MACHINES”
4) RK.RAJPUT “MANUFACTURING TECHNOLOGY”

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