PIPE BENDING MECHANISM

A Project Submitted to

GUJARAT TECHNOLOGICAL UNIVERSITY

In partial fulfilment for the award of

DIPLOMA IN MECHANICAL ENGINEERING

Submitted by

 MANAN GADHAVANA (146030319033)

 PADMANI JIGNESH (136030319564)
 BHETARIYA PRINCE (156030319014)
 YASH MATHUR (166030319537)

Under the Guidance

RAVAL SIR

DEPARTMENT OF MECHANICAL ENGINEERINGATMIYA INSTITUTE OF

TECHNOLOGY AND SCIENCE FOR DIPLOMA STUDIES-RAJKOT

1|AITSDS
 CERTIFICATE
ATMIYA INSTITUTE OF TECHNOLOGY & SCIENCE FOR
DIPLOMA STUDIES
[APPROVED BY AICTE, AFFILIATED TO GTU, GUJARAT]

DIPLOMA MECHANICAL ENGINEERING DEPT.

This is to certify that MANAN GADHAVANA

(146030319033)PADMANI JIGNESH (136030319564)BHETARIYA
PRINCE (1560303190140) YASH MATHUR(166030319537) from
AITSDS, RAJKOT has completed project on PIPE BENDING
MECHANISM, in a group consisting of FOUR students, under the
guidanceof RAVAL SIR.To the best of my knowledge & belief, this work
embodies the work of candidate himself. Presentation and language for reffered
to the examiner.

______________ ______________
Guide Sign HOD sign

2|AITSDS
 ACKNOWLEDGEMENT

This research work would not have been possible without the kind
support of many people. We take this opportunity to acknowledge that who has
been great sense of support and inspiration thought the research work
successful. There are lots of people who inspired me and helped, worked for me
in every possible way to provide the details about various related topics thus
making research and report work success.
Ourvery first gratitude goes to our Head of the Mechanical Department
ProfessorI. J. JADEJA, for his guidance, encouragement and support during
my semester. Despite his busy schedule, he is always available to give me
advice, support and guidance during the entire period of my semester. His
insight and creative ideas are always the inspiration for me during the research.
Weare also very grateful to Mr. RAVAL SIRfor providing depth
knowledge about simulation software.
We would like to express my sincere thanks to all my colleagues and the
members of the cloud computing research group. We would like to thank my
parents for their valuable support and encouragement to complete this project.
Last, but not the least my special thanks go to our institute, Atmiya
Institute of Technology and Science for Diploma Studies, for giving us this
opportunity to work in the great environment.

3|AITSDS
 ABSTRACT

Our Project is to design and construct a pipe bending machine. This

machine will be able to bend pipes or tube into curve or other curvature shape
as per the requirements with the man power. This project involves the process
of designing the pipe bending mechanism with considering forces and
ergonomic factor for the people to use. The size of the machine is very
convenient for portable work. This new concept of pipe bending machine’s
designs main purpose was for high volume production with the wrinkle free,
clean and repetitive bend pipes. Moreover, it is very easy to be carried and used
at any time and any place. This project is mainly about generating a new
concept of pipe bending that would be with maximum quality with the
minimum of cost.

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 CONTENTS
Chapter Topics Page
No.
Title Page 1

Certificate 2

Acknowledgement 3

Abstract 4

1 Introduction

1.1 Concept 8-9

1.2 Project Synopsis 9

1.3 Objective 9

1.4 Project Planning 9-10

1.5 Scope of Work 11

2 Literature Review

2.1 Design and development of stirrup Machine 12

2.2 Design and fabrication of hydraulic rod bending 13

2.3 Experimental investigation on bending methods 13

2.4 Paper review of manually operated machine 14

3 Pipe Bending Machine

3.1 Introduction 15

3.2 Types of Pipe Bending Machine 15

4 Methodology

4.1 Flow Chart 19

4.2 Time Study 20

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5 Computer Aided Design Drawing

5.1 Introduction 21

5.2 Drawing 21

5.3 SolidWorks 21

6 Working

6.1 Steps of working 30

6.2 Calculation 30

6.3 Application 31

7 Manufacturing Process

7.1 Introduction 32

7.2 Machine used for part production 32

7.3 Lathe Machine Operations 33

7.4 Shaper Machine Operations 35

7.5 Grinding Machine Operations 36

7.6 Assemble 38

8 Costing

8.1 Material 41

Conclusion 43

Reference 44

6|AITSDS
 List of Figures
Sr. Figure Name Nos of Page
No. Figure No.
1 Press Bending 1 15
2 Rotary Draw Bending 1 16
3 Roll Bending 1 17
4 Flow Chat 1 19
5 Solid Die 1 22
6 Base Plate 1 23
7 Handle 1 24
8 Cavity Block 1 25
9 Line Diagram of Assemble 1 28
10 Rendered Assemble 1 29
11 Screen Shot of SoldWorks 1 29
12 Lathe – Handle 1 33
13 Lathe – Die 1 34
14 Shaper – Cavity Block 2 35
15 Portable Grinding 1 36
16 Assemble I. 1 38
17 Assemble II. 1 38
18 Assemble I. 1 39
19 Assemble II. 1 39
20 Final Assemble 1 40
21 Group Photo 1 40

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 List of Tables
Sr. Table Name Nos of Page
No. Table No.
1 Parts and Material 1 27
2 Part Productions 1 32
3 Costing 1 42

8|AITSDS
 CHAPTER 1
INTRODUCTION
What is Pipe Bending?
A pipe bending is a device used for the bending the pipes or tubes
in required angle for the further use.

1.1Concept
The sole purpose of this project is to understand the fundamental
knowledge of design and mechanism by using the simple mechanism property.
Prior Manual pipe benders are not only complicated in structure but also
difficult to operate. The present invention relates to a pipe bender, and more
particularly to a pipe bender capable of bending different sized pipes.
Conventional manual benders are either electrically or hydraulically driven, and
needs to be operated by two hands. One of the conventional manual pipe
benders is a T-shaped structure formed by a longitudinally extending handle and
a transversely extending fixing plate fixed on the handle. When in use, the pipe
to be bent is pressed against two support members at two ends of the fixing
plate, and then the handle is pushed to use a rack to push the pipe until it is bent.
Is this type of the mechanism, problem is that the distance between the two
support members at two ends of the fixing plate is adjusted by eye based on the
user's experience, or based on the scale on the fixing plate, so that the
adjustment is time consuming.

By the analysing the problems of older devices, we have designed

a new concept with solving the older problem. To design the machine, many
mechanical system and equipment has to be understood. By using all this, the
project is faster and easier. We also learn the proper methods of this type of
machine and mechanisms. Choosing the component material is very important
as it will affect the overall cost of the machine and the quality of the machine.
With all this consideration we had design this machine with the maximum
quality and with the minimum cost.

9|AITSDS
1.2 Project Synopsis
In this project, development of a pipe bending mechanism in a way
that it can bend the tough pipes or tubes with ease also without wrinkle in the
pipe or tube. With the use of both hand the lever rotate and will bend the pipe.

The design is as simplest as possible with the maximum output.

The design is done so that we can get the knowledge of dimension, mechanism
and forces acting on the device.

1.3 Objective
i. To develop a manual pipe bending machine.
ii. To create a device which will create no noise or vibration during
operation with more stability.

1.4 Project Planning

To start of this project, a meeting with supervisor in the first
week is done to manage the schedule of weekly meetings. The purpose is to
inform the supervisor on the progress of the project and guided by the
supervisor to solve difficulty. Briefing based on the introduction and next task
of the project is given by supervisor. Make research of literature review with the
means of the internet, books, available published articles and materials that is
related to the title.
Designing phase start of by sketching few model models using
manual sketch on A4 papers. Do it comparison for choose the best concept.
Software applications are downloaded from internet to design the
model based on the sketches. Designing Software Solid Work helps to draw the
better dimension.
The preparation of mid-presentation of the project is next. Before
presenting, the supervisor will see through the slide presentations and comment
on corrections to be made.

10 | A I T S D S
 Then, presentation on the knowledge attained and instilled in the
design phase is presented to a panel of three judges. Following up, is the
fabrication of make some method for this project. Choose the material, make
some list for the material and dimension.

1.5 Scope of Work

i. Literature review on the knowledge of mechanism design.
ii. To design the mechanical parts of the pipe bending onComputer
Aided Designing (CAD) Software Solid Works.
iii. To get analytical stress-strain detail report acting on the design.

11 | A I T S D S
 CHAPTER 2
LITERATURE REVIEW

The title development of pipe bending machine requires a good

amount of understanding on the knowledge of the science. Therefore, executing
a research is necessary to obtain all the information available and related to the
topic. The information or literature reviews obtained are essentially valuable to
assist in the construction and specification of this final year project. With this
grounds established, the project can proceed with guidance and assertiveness in
achieving the target mark.

2.1 Development and design of automatic stirrup bending machine

Introduction: -

Proceeding of the first international and 16th national conference on

the machine and mechanism (iNaCoMM-2013), IIT Roorkee, India, December
18-20, 2013. Milan Virani, Jagdish Vekariya, Saurin Sheth, Ketan Tamboli UG
Student, associate professors, mechatronics engineering department, G H Patel
College of Engineering and technology.

Abstract: -

In the construction of any structure major work is done by labour.

In column or beam there are many horizontal and vertical axis rods to support
the concrete, they are required to be tied together so that they give enough
strength to the structure. Square or any trapezoid shape stirrup are used
traditional way. There is no other way to make stirrup with less human efforts,
and for this reasons automation is required which make stirrup with less human
efforts. It is possible to decrease construction lead time with increase of the
stirrup bending rate by automation only. Here an attempt is made to design and
develop an “automatic stirrup bending machine” using the principle of hydraulic
and electronic. Its uses reduce a lot of the labour cost efforts, construction lead
time, production rate of various stirrup and accuracy increases.

12 | A I T S D S
 2.2Design and Fabrication of Hydraulic Rod Bending Machine

Introduction: -

I. M. Hanoofa, S. R. Vishwanathan, P. S. Patel, N. S. Vekeriya, a

UG scholar, Mechanical engineering, kongu engineering college, erode,
tamilnadu, India.

Abstract: -

The world is focusing into automation. Each and every work of

human is reduced by the machine, but few areas like construction the usage of
machine for bending rods for stirrups which are used to withstand the load of
the beam. The main objective of the project is to implement the pipe bending
machine in any area where it can minimize the load on the labour and maximize
the performance of the work output. By the study of this paper review we got
the idea of the fabrication process. It has also described the process which will
be used for the production of the pipe bending machine.

2.3 Experimental Investigation in Pipe Bending Methods

Introduction: -

International Journal of Advance Research 2016, February 12,

2016. D. D. Panchal, A. M. Patel, P. M. Raval Graduate Student S’ad Vidhya
Mandal Institute of Technology.

Abstract: -

In current industries like oil and gas, petro-chemical and aerospace

needs very high quality bended pipes without any defects. There are several
methods of bending process where several defects occur such as ovality,
Wrinkling and the wall thinning and thickening. To overcome this all types of
the defects causing, we had the idea, how to design the parts of the pipe bending
machine. Also to study about the pipes or tubes which can be bend has all the
different properties. So different things are to be taken care of. By this study,
comparing the available methods and finding out the outcome for given
circumstances.

13 | A I T S D S
 2.4 Research Paper of Manually Operated Pipe Bending Machine

Introduction: -

The development of nation depends on the achievement in science

and technology. So, innovate a machine which is easy to use and that cannot
tolerate with accuracy. For that machine is both manually and power operated.

Abstract: -

The main purpose of the research work is to explain the design and
developed automatic pipe bending machine. It is used in automobile industrial.
Especially discussion is made on the bending project analysis of manually
operated pipe bending without any wrinkle or losing the ovality of the pipe or
tube

14 | A I T S D S
 CHAPTER 3
PIPE BENDING MACHINE
3.1 Introduction
A pipe bending is a device designed to give a required curved
shape to the pipe or tube inserted in desired angle. All over the world the
resources of energy are reduce for that we can find new sources of energy. For
that machine is both manually and power operated. The big drawback of power
operated machine is that it requires hand also. Fully power operated machine
are highly expensive. So, the manually operated is mostly preferred in Indian
market. Therefore, our objective was to get as good quality as fully power
operated machine at the minimum prize without affecting the pipe bending
productivity.

3.2 Types of Pipe Bending Mechanism

There are basically four types of the pipe bending mechanism. They are as
follows

A. Press Bending

15 | A I T S D S
 Fig No: - 3.1
Press
bending is the simplest and
cheapest method of bending cold pipe and tube. The pipe or tube is
restrained at two eternal points and a ram in the shape of the bend
advances on the central axis and deforms the pipe. The bent pipe or tube
is prone to deformation on both the inside and outside curvature. The pipe
or tube is often deformed into an oval shape depending on the wall
thickness of the material. This process is used where a consistent cross
section of the pipe is not required. This type of bending is suitable for
bending electrical conduit and similar light gauge product.

B. Rotary Draw Bending

16 | A I T S D S
 Fig No: - 3.2
This is the
most commonly used
style of bender for bending pipe and tubewhere maintaining a good finish
and constant diameter is important.

Rotary draw benders (RDB) are precise in that they bend using
tooling or "diesets" which have a constant center line radius (CLR). The
die set consists oftwo parts: The bend die creates the shape to which the
material will be bent.The pressure die does the work of pushing the
straight material into the benddie while traveling the length of the bend.
Often a positioning index table(IDX) is attached to the bender allowing
the operator to reproduce complexbends which can have multiple bends
and differing planes.

Rotary draw benders are the most popular machines for use in
bending tube,pipe and solids for applications like: handrails, frames,
instrument tubing andmuch more. Rotary draw benders create
aesthetically pleasing bends when theright tooling is matched to the
application.

C. Roll Bending

17 | A I T S D S
 3-roll bending is also used for producing work pieces with large
bending radii. The method is similar to the ram bending method, but the
working cylinder and the two stationary counter-rollers rotate, thus
forming the bend. Normally there are 2 fixed rollers and one moving
roller and the work piece is passed forward and backward through the
rollers while gradually moving the
working roller Fig: - 3.3 closer to the counter
rollers which changes the bend radius in
the pipe. This method of bending causes very little deformation in the
cross section of the pipe and is suited to producing coils of pipe as well as
long sweeping bends like those used in powder transfer systems where
large radii bends are required.

D. Bending Spring

These are strong but flexible springs inserted into a pipe to support
the pipewalls during manual bending. They have diameters only slightly
less than the internal diameter of the pipe to be bent. They are typically
only used for bending 15-to-25 mm soft copper pipe (used in household
plumbing). The spring is pushed into the pipe until its center is roughly
where the bend is to be. A length of flexible wire can be attached to the
end of the spring to facilitate its positioning and removal. The pipe is
generally held against the flexed knee, and the ends of the pipe are pulled
up to create the bend. To make it easier to retrieve the spring from the
pipe, it is a good idea to bend the pipe slightly more than required, and
then slacken it off a little. They are less cumbersome than rotary benders,
but are not suitable for bending short lengths of piping when it is difficult
to get the requires leverage on the pipe ends. Bending springs for smaller
diameter pipes (10 mm copper pipe) slide over the pipe instead of inside.

18 | A I T S D S
 CHAPTER 4
METHODOLOGY
In designing of pipe bending machine, a flow chart of methods had to be
used to describe it systematically. First of all, a process planning had to be
charted out. This acts as a guideline to be followed so that, the final model
meets the requirement and time could be managed. This would determine the
efficiency of the project to be done. Regulating and analyzing these steps are
very important as each of it has its own criteria to be followed.

4.1 Flow Chart

START

INTRODUCTION TO PROJECT

LITERAATURE REVIEW

CONCEPT OF PROJECT

DESIGN AND MECHANISM

PROTOTYPE OF THE DESIGN

PROBLEM SOLVING

FINAL DESIGN

END

Fig No: - 4.1

Flow Chart
19 | A I T S D S
 The flow chart starts with the introduction. Here, the introduction is first
plan to start the project. The supervisor request for understanding of the project
and make some research about the project title. Student makes project synopsis,
objective, and scope of work, problem statement and planning.Once the
introduction is done, the supervisor request for the understanding of the project.
Thus, literature review on the title is done thoroughly covering all the aspect of
the project. The medium for this research are via internet and books.

Essential information related to the project is gathered for referencing. In

conceptualization, few designs are done using the sketching which is then saved
to be reviewed. Sketch four concepts suitable for the project with a 3-
dimensional and understanding. The sketching is first step for designer used of
the time. The designs and concepts are than reviewed and recalculated to fit the
best dimensions and performance for pipe bending machine.

After various designs sketched, design considerations have been made

and one design have been chosen. The selected design sketched is then transfer
to solid modelling and drawing using Solidworks application. Software is used
because it gives a better dimension of Pipe bending machine compared to
manual draw and is much easier to understand and use.

Various analysis done on the design using help of the software

Solidworks. By this analysis, we can get the result where the stress is generated
the most. By getting the report of stress analysis, we can change the design of
particular part.

4.2 Time Study

For every work, there was a time taken to complete the work. The
below table will show the time taken for the work to be done. After completing
one work, next work is done and the time period is noted. As per the average of
the work done, each work required a time of one week. Each member has
equally distributed the work and completed on time as per they stated. Over all
work was completed taking time of 8 weeks (2 months).

20 | A I T S D S
 CHAPTER 5
COMPUTER AIDED DESIGN DRAWING

5.1 Introduction

After a design has been selected, the next step in designing process is 3D
model. The design is separated into part by part and the dimensioning process is
firstly sketched on the paper. The dimensioning is based on relevant dimensions
and also referring the existence pipe bending machine so that the design is fit
into other part. After dimensioning, the drawing of the design is drawn using
computer software SolidWorks. At this stage, solid modelling method is used.
Part by part solid modelling creates according to the dimension done before,
after all part create, the 3D model is assembled with each other base on the
design.

5.2 Drawing

The drawings are diving into two categories, which are:

I. Sketching: - All the ideals for tin can crusher fabrication are sketched on
the paper to ensure that ideas selection can be made after the selected
design choose.
II. SolidWorks Software: - The design or concept sketched is transfer to
solid modelling and drawing using SolidWorks Software.

5.3 SolidWorks

The drawingsSolidWorks is asolid modeler, and utilizes parametric

feature based approach to create models and assemblies.Parameters refer to
constraints whose values determine the shape or geometry of the model or
assembly.

Parameters can be either numeric parameters, such as line lengths or

circle diameters, or geometric patterns, such as tangent, parallel, concentric,
horizontal or vertical etc. Numeric parameters can be associated with each other
through the use of relations, which allows them to capture design intent.

21 | A I T S D S
 I. Solid Die

A single Die is used for this mechanism, which is being supported

and fixed by the Base Plate

The die cavity is designed in manner that it gives proper grip to

pipe or tubes that are to be bend. A hole is drilled in centre of the die to
attach the handle. The handle will rotate in the reference of solid die

Die and base plate are fixed by fasteners from the bottom of the
base plate so its won’t be obstruction during the operation.

Fig No: - 5.1

Solid Die

22 | A I T S D S
 II. BASE PLATE

The function of the base plate is to hold the pipes or tubes using the
vice in fixed position and to absorb the vibration created during the
process.

Holes are drilled in the desired positon for connecting the die, vice
and connect the base plate to the foundation support.

Connecting plate is made from MS(Mild Steel) having high

hardness also giving wear resistant properties.

Fig No: - 5.2

Base Plate
23 | A I T S D S
III. HANDLE

The handle is kept in round shapeat the end as we can extend the
handle length to get max output using minimum human efforts.

Material chosen for the handle is Mild Steel, with the specifications
of Rockwell hardness number in between 30 to 35 BHN number.

Specification is chosen 30 to 35 BHNnumber because it has

sufficient Brittleness which is required to the Lever.

Fig No: - 5.3

Handle
24 | A I T S D S
IV. CAVITY BLOCK

Small Cavity Block is used to give the proper grip to hold the Pipe
or Tube in vice without giving any moment during the operation is
carried out.

Another Cavity Block is used to hold the Pipe or Tube between the
die and the roller. Main function of this component is to give uniform
load on the Pipe or Tube when the force is applied to the handle during
the operation

Small taper is given to the lengthy cavity block so it can easily fix
between the pipe or tube and the roller.

OHNS (Oil Hardening Non Shrinking) Material is used for both of

the cavity block

Fig No: - 5.4

Cavity Block
25 | A I T S D S
V. ROLLER

Roller is used to reduce the surface tension created on the pipe due
to the presence of the cavity block.

Main function of the roller is to transfer the force uniformly from

the handle to the cavity block. Also to transform the sliding friction to
rolling friction.

Stud is used to join the handle and the roller with the ground
clearance. Mild Steel of grade EN31 is used for the roller due to its stress
relieving property.

VI. FASTENERS AND STUD

To make a tight but temporary joint, fasteners are used. To join the
base plate to the foundation, solid die to the base plate and the vice to the
base plate fasteners are used.

Stud is used on the handle of the machine as it is connected to the

rotating parts like roller of the handle. Where on the one side it is fixed
with the handle and on other side with the roller.

In total 2 Studs and 6 fasteners are used in the mechanism.

26 | A I T S D S
Sr. Component Material Quantity
No.
1. Base Plate Mild Steel 1

2. Die Mild Steel (EN31) 1

3. Handle Mild Steel 1

4. Roller Mild Steel (EN31) 1

5. Cavity Block OHNS 1

6. Fastener - 6

7. Stud - 2

Table No: - 5.1

Parts and Material

27 | A I T S D S
 8

7 1

6 3

Fig No: - 5.5

Line Assemble

1. Solid Die
2. Stud
3. Handle/Lever
4. Roller
5. Base Plate
6. Vice/Clamping device
7. Tapered Cavity Block
8. Cavity Block

28 | A I T S D S
 Fig No: - 5.6
Rendered Assemble

29 | A I T S D S
 CHAPTER 6
WORKING

Design is kept in such a manner that most output is gained from the
input. Also, the design is kept simple so that any operator can understand the
mechanism and work with ease.

6.1 Steps of Working: -

1. Pipe Bending as a process starts with loading a tube or pipe on the vice of
the solid block. Cavity Block is used to hold the pipe firmly.
2. The handle is moved to the position so the pipe and die can be aligned.
3. Another cavity block is placed between the roller and the pipe. Taper part
is to be inserted so less force is to be used.
4. Now the handle is rotated with the reference of the die. Two markings are
made on the die at 90 degrees and at 180 degrees respectively to handle.

5. When the desired angle is achieved the handle is rotated clockwise so the
final product can be released.

6. The pipe is pulled out of the die and the desired angle is achieved.

6.2 Calculation: -
Bending stress equation

𝑀 𝛿 𝐸
= =
𝐼 𝑌 𝑅

30 | A I T S D S
Where,
M = Torque or Moment generated by Man Force
I = Moment of Inertia
E = Modula's of Elasticity
R = Radius of Die

6.3 Application: -
• Angle Bending
• Metal Folding
• U hook
• Marine Tube
• Scroll Bending

31 | A I T S D S
 CHAPTER 7
MANUFACTURING PROCESS
7.1 Introduction
Before the manufacturing process of the project starts, we have
reviewed and visited industry for the basics knowledge of the machines and the
operation to be carried out. Also, the knowledge of the material selection for a
specific job has been understand with the help of the institute professor and the
seniors of the department.

After designing phase, fabrication processes take place. These

processes are about using material selection and make the product base on the
design and by followed the design dimension. Many methods can be used to
fabricate a product, like welding, cutting, bending, grinding, drilling and many
more methods. Fabrication process is a process to make only one product rather
the manufacturing process was used at the whole system production. This way
include part by fabrication until assembly to others component.

7.2 Machine used for the Parts Productions

Sr. Machine Operations Place

No.
1. Lathe Turning, Finishing, Facing Workshop

2. Shaper Cutting Workshop

3. Drilling Drilling Mira Industries

4. Welding Arc Welding Mira Industries

5. Lathe Threading Mira Industries

6. Shaper Shaping Mira Industries

Table No: -7.1

Part Production 32 | A I T S D S
Operation Carried: - Turning and Finishing

Overview: -

Finishing operation is carried out using the sand paper fixed on the tool
post. Apron is pulled back and the finishing operation gets started. Digital
Vernier caliper is used to know the dimension of the Handle.

33 | A I T S D S
Operation Carried: - Facing

Overview: -

Facing operation is carried out using the single point cutting tool fixed on
the tool post. Desired diameter is turned and checked using the digital Vernier
Caliper. Die is faced, turned and finished using the lathe machin

Shaper – Cavity Block

Operation Carried: - Shaping

Overview: -

Cavity Block is prepared using the shaper machine. Both, small cavity
block and the tapered cavity block is done using shaper machine. The round
cavity is made using the form tool and the cutting operation is done using the
single point cutting tool

Operation Carried: - Grinding

Overview: -
Portable Grinding machine is used for the operation of uneven part like
cavity block, base plate – vice etc. Surface finishing tolerance is kept below
0.05mm.

7.6 Assemble

All the parts have been manufactured and finished with the desired
dimensions so, assemble is carried out. After the parts has been achieved the
corrosion resistance paint, the fastening of the parts is done with proper tools
like Wrench and screwdrivers. The assemble is done in the industry of the
project member for the availability of the proper tools used for assemble.

34 | A I T S D S
Above Assemble

I. Starting from the base plate, the vice/clamping device is assembled

using the fasteners at the drilled hole.
II. Then the die is assembled to the base plate from the bottom of the
plate.

Above Assemble

I. Handle/lever is fixed with the roller using the stud.

II. Handle/lever is now assembled with the die.

35 | A I T S D S
7.7 Final Assemble

Fig No: - 7.10

Final Assemble

36 | A I T S D S
 CHAPTER 8
COSTING
Costing is done on the basis of the money paid to market rate by
the dimension and the approx. weight of the part. The estimation is done by
surveying many store and most common rate is taken into the considerations.

8.1 Material
A. MS EN31
Due to its stress reveling properties, it is best used for Supporting
𝑘𝑔
Frame.It has the density of 7.8 and having tensile strength of
𝑚3
𝑁
750
𝑚𝑚2

B. Mild Steel
𝑁
As it can handle high stress up to 850 to 1000 it best suitable
𝑚𝑚2
for the connecting plate.

C. OHNS
The OHNS stands for the name Oil Hardening and Non-Shrinking
material. This material is chosen because of the property to add
hardness without losing the shape of material given.

37 | A I T S D S
 Table No: - 8.1
Costing

Sr. Component Material Weight Rate

No. (Kg.) (Rs.)

1. Base Plate Mild Steel 2.5 405

2. Die Mild Steel 1.8 265

(EN31)

3. Handle Mild Steel 1.65 280

4. Roller Mild Steel 0.5 250

(EN31)

5. Cavity Block OHNS 1.45 125

Total 7.9 38 | A I T S1325

DS
 CONCLUSION

 To eradicate the common issue of wrinkling instability at Inner surface,

Wall thinning at Outer Surface and cross-section deformations.
 As it is manually operated, design has been fully concentrated on factor
of safety.
 Due to low cost this can be marketed to any of the nation.
 Removing the complicated Design of the system, simple mechanism is
used.
 This mechanism can be easily handled by any operator with ease.

39 | A I T S D S
 REFERENCES
Literature
1. M. N. Virani, J. P. Vekariya, S. K. Seth UG Students of G H Patel
College of Engineering and Technology. “Design and Development of
Automatic Stirrup Bending Machine”,iNaCoMM December 18, 2013.
2. D. D. Panchal, A. M. Patel, P. M. Raval Graduate Student S’ad Vidhya
Mandal Institute of Technology.“Experimental Investigation in Pipe
Bending Methods”,February 12, 2016.
3. “Design and Fabrication of Hydraulic Rod Bending Machine”
4. V. B. Bhandari, Mc Graw Hill, “Design of machine Elements”, ISBN
978-0-07-068179-8 March 18, 2012
5. R. K. Rajput, S. K. Chand “Strength of Material”, ISBN 81-219-2594-0

Websites
1. www.ScienceDirect.com
2. www.Quora.com

40 | A I T S D S