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Manual Pipe Cold Bending Machine

Experiment Findings · June 2020

DOI: 10.13140/RG.2.2.23409.10089

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 Final Year Project II

Spring 2020
25-05-2020

Manual Pipe Cold

Bending Machine

Ali Faour 201503947

Kevin Gemayel 201402620
Hassan Harakeh 201501552
Mohammad Karaki 201305861

Project Advisor
Dr. Wassim Habchi
 2

Table of Contents

List of Figures _______________________________________________________ 4

List of Tables ________________________________________________________ 5

Abstract _____________________________________________________________ 6

1. Introduction _____________________________________________________ 7

1.1. Types of Bending __________________________________________________7

1.1.1. Press Bending _________________________________________________________ 7
1.1.2. Rotary Cold Draw Bending _______________________________________________ 7
1.1.3. Roll Forming __________________________________________________________ 8

1.2. Problem Statement _________________________________________________9

1.3. Literature Review__________________________________________________9

1.4. Description of the Merit Aspects of the Design _________________________10

1.5. Design Impact ____________________________________________________10

2. Pipe Cold-Bending Machine Design _________________________________ 11

2.1. Methodology _____________________________________________________11

2.2. Standards and Codes ______________________________________________12

2.3. Preliminary Machine Geometry _____________________________________13

2.3.1. List of Components ____________________________________________________ 13
2.3.2. Top Roller ___________________________________________________________ 13
2.3.3. Bottom Rollers ________________________________________________________ 14
2.3.4. Workpiece ___________________________________________________________ 14
2.3.5. Slider _______________________________________________________________ 14
2.3.6. Roller Cross-Section ___________________________________________________ 14

2.4. Rollers Relative Positions Design ____________________________________15

2.5. Dynamic Nonlinear Stress Analysis for the Workpiece __________________17

2.5.1. Workpiece Dynamic Simulation __________________________________________ 17
2.5.2. Simulation Setup ______________________________________________________ 17
2.5.3. Simulation Analysis ____________________________________________________ 18

2.6. Detailed Machine Design ___________________________________________21

2.6.1. Machine structure _____________________________________________________ 21
2.6.2. Machine dynamics _____________________________________________________ 22
2.6.3. Gearbox _____________________________________________________________ 22
 3

2.7. Machine Stress Analysis ___________________________________________24

2.7.1. Material Properties_____________________________________________________ 24
2.7.2. Top Hydraulic Plate Simulation __________________________________________ 25
2.7.3. Shaft Force Simulation _________________________________________________ 25

3. Manufacturing __________________________________________________ 27

3.1. Machining _______________________________________________________27

3.1.1. Cutting ______________________________________________________________ 27
3.1.2. Lathing ______________________________________________________________ 28
3.1.3. Drilling and threading __________________________________________________ 28
3.1.4. Plasma cutting ________________________________________________________ 28
3.1.5. Keyway cutting _______________________________________________________ 29

3.2. Assembly ________________________________________________________29

3.3. Pricing Sheet _____________________________________________________31

4. Conclusion _____________________________________________________ 32
 4

List of Figures
Figure 1 V-Shaped Press Bending [1] _________________________________________________________ 7
Figure 2, Rotary Cold Draw Bending [2] _______________________________________________________ 7
Figure 3 Roll Forming [3] ___________________________________________________________________ 8
Figure 4 Three Roller Bending Machine ________________________________________________________ 8
Figure 5 Compression and Tension [3] _________________________________________________________ 8
Figure 6 Methodology _____________________________________________________________________ 11
Figure 7 Rendered presentation of machine design ______________________________________________ 13
Figure 8 Roller Setup ______________________________________________________________________ 13
Figure 9 Roller Geometry __________________________________________________________________ 14
Figure 10 Roller Setup Geometry ____________________________________________________________ 15
Figure 11 WR vs. D [1:3000] _______________________________________________________________ 16
Figure 12 Geometry Verification SolidWorks [mm] ______________________________________________ 16
Figure 13 DEFORM-3D Final Mesh at Step 223 ________________________________________________ 17
Figure 14 Workpiece Strain Post-Simulation ___________________________________________________ 18
Figure 15 Stroke[mm] and Angular Velocity[rad/sec] vs. Time[steps] (predicted results) ________________ 20
Figure 16 Vertical Load[N] vs. Time[steps] (predicted results) _____________________________________ 20
Figure 17 Roller Torque [N.m] vs. Time[steps] (predicted results) __________________________________ 20
Figure 18 Preliminary Machine Overview _____________________________________________________ 21
Figure 19 Hydraulic Jack __________________________________________________________________ 22
Figure 20 Compound Gear Train ____________________________________________________________ 22
Figure 21 Reaction Forces due to Action force of 250 [kN] ________________________________________ 24
Figure 22 von Mises Stress [MPa] : Deformation Scale x10 _______________________________________ 24
Figure 23 Mesh Size Preview________________________________________________________________ 25
Figure 24 Stress Along Shaft ________________________________________________________________ 26
Figure 25 von Mises Stress Under Torsion [MPa] _______________________________________________ 27
Figure 26 Slider __________________________________________________________________________ 27
Figure 27 Machine Components _____________________________________________________________ 27
Figure 28 Slider Section View _______________________________________________________________ 28
Figure 29 Keyway Dimension Diagram _______________________________________________________ 29
Figure 30 Insertion of Bearing Inside Housing __________________________________________________ 29
Figure 31 Slider Alignment _________________________________________________________________ 29
Figure 32 Ball Bearing Cross-Section from SKF Catalogue [19] ___________________________________ 30
Figure 33 Sprockets for roller chains DIN 8187 - ISO 606_________________________________________ 30
 5

List of Tables
Table 1 Material Properties for Major Machine Components ______________________________________ 24
Table 2 Total Machine Price Including Material and Labor Cost ___________________________________ 31
 6

Abstract
Roller bending a current developing process is an available service in the present
market; however, each roller bender has a different mechanism with its pros and cons. Due to
its main advantages, the pyramidal roller bender was selected. Pipe bending machines have
passed through many enhancements, developments, and augmentations over time. Choosing a
different type of bending for a pipe plays a critical role in industries, instruments, and
transporting of fluids. The main concern is the required bend angle for which this pipe will
bend on. The following report will include a description of the usability of this machine. The
critical parameters that should be accounted for in the pipe bending are bend radius and angle,
pipe diameter, and thickness. The concept of press bending is used to carry out the operation;
thus, the required force is carried out with the assistance of a hydraulic jack. Also, other
significant parameters are accounted for, such as the bending force and torque, simulation
outcomes about the workpiece analysis, and finally the machine design. Moreover, a prototype
that satisifies the required constraints is manufactured and assembled. Being a manual cold
bending machine means no use of electricity is required, resulting in no power consumption.
In addition, this machine is convenient, accessible and affordable.
 7

1. Introduction
For centuries, humans are trying to find a way to enhance their life routine. Now, after
reaching the 21st century, discoveries are still being presented. When did all of this happen? It
all started at the beginning of the industrial revolution. The onset of the industrial revolution
took place from the 17th century until the mid-18th, this revolution was the reason for the
existence of functioning machines today. The main branch of this revolution is manufacturing
since it allowed the use of machines that significantly made human daily tasks much easier.
Cold bending has been around from 1800B.C; it slowly developed until the industrial
revolution in the 1760s’. Many types of bending are available nowadays. A pyramidal type was
chosen with a three-roller bending setup because of its various capabilities with just two
degrees of freedom. The goal is to improve this type of process using both analytical geometry
and empirical techniques to achieve an ameliorated design. There are many types of bending
techniques present now, but every type has its advantages and disadvantages.
[1] [2] [3]
1.1. Types of Bending
1.1.1. Press Bending
One of the oldest types of bending is press bending, where the
workpiece is pressed vertically to produce a V or U-shaped workpiece,
as shown in Figure 1. The workpiece will be pressed until it enters the
plastic region because if the deformation stayed in the elastic region, the
workpiece would return into its original shape, which is called spring
back. The advantages of press bending are speed and accuracy where Figure 1 V-Shaped
Press Bending [1]
each die has its angle; this provides a variety of workpiece bending.
1.1.2. Rotary Cold Draw Bending
Another type of bending is rotary cold draw bending
shown in Figure 2. The process occurs as follows, and the
workpiece is clamped to a rotating bend die and haggard
around the die. The workpiece is held tangent along with
another die, which is called the pressure die, and the
workpiece rotates until the desired geometry is formed.
Figure 2, Rotary Cold Draw
Bending [2]
 8

1.1.3. Roll Forming

Roll forming is another type of bending machine which is
very similar to Draw Bending [4]. It is this specific type of bending
that was chosen to satisfy the given constraints for this project. Its
process was invented by Leonhard Euler as shown in Figure 3, and it
had the same mechanism as the draw bending, except that roll
Figure 3 Roll Forming
forming is a continuous bending process in which opposing rolls are [3]
used to produce long sections of formed shapes from coil or strip
stock. Several pairs of rolls are usually required to progressively accomplish the bending of the
stock into the desired shape. Moreover, roll forming
can yield more fragments with uniformity and
reliability during the making of the workpiece [5]. A
disadvantage of roll forming is the excess scrap
generated at the tips of the workpiece
The 3-roller bending is considered a flexible
type of bending. A roll bender is a mechanical
machine having three rollers used to twist a metal bar
into a round bend. The two rollers on the bottom are
used to fix the workpiece in a horizontal direction and Figure 4 Three Roller Bending Machine
the upper roller will apply a downward force. The upper roller is adjusted using a hydraulic
jack; thus, the roller only moves in the vertical direction. When defining the current bend angle,
this clamp is locked and the bottom rollers start to rotate, thus making a bending force Figure
5 on the workpiece which will result in deforming the workpiece hence achieving plastic
deformation. On the right side we can observe the machine referring to Figure 4 . The main
advantages of this process are that this mechanism is straight forward and simple, it can remedy
the workpiece that has been deformed in a wrong way such as skew (Bending Error), accurate,
consistent, and convenient. However, the disadvantages of such a process are unusable scrap
parts. This occurs especially in vertical 3 roller bending [6], which means if the pipe is long,
due to its weight (workpiece weight) while being rolled, it will bend to a side and cause torsion,
this is a type of manufacturing inaccuracy of
unwanted deformation or deflection. Furthermore,
the extremities of the workpiece will become scrap.
Likewise, excessive deformation on the pipe in the
Figure 5 Compression and Tension [3]
beginning and end of the rollers due to direct contact
 9

from the vast force, resulting in a slight bump on the workpiece, and on the thin-walled profiles,
wrinkling may occur which means it’s hard to account for the spring back.
1.2. Problem Statement
The objective of this machine is to bend steel or copper pipes with a diameter up to 5 cm and
a thickness up to 5mm. Moreover, it should include a bending angle ranging from 0 to 180
degrees and a bending radius of curvature up to 10cm. Moreover, the key feature of this
machine is that cold-bending can be applied manually with a force not exceeding 100N.
1.3. Literature Review
The Curling Force is the force that will be subjected to the pipe [7]. Besides, the results
were centered around a specific equation (1). This formula is used to achieve permanent
deformation in the outer and inner fibers of the material. The following relation should be
applied [8]
D E
< (( ) + 1)
T YS
(1)

Nomenclature
D : Pipe diameter [mm]
T : Thickness [mm]
E : Modulus of elasticity [GPa]
YS : Yield stress. [MPa]
The main objective is the accuracy of the bending machine at an economical cost.
Moreover, manual bending tends to minimize wrinkles and can reduce spring back. Reducing
the deformation of the tubes should be noted as per [9]. The relevant reduction was that the
manual bending is an upright design to minimize workpiece deflection and was able to maintain
the shape of the tube and reduce the problems such as spring backs and wrinkles.
Each bending machine had its design, an adjustment in the design had to be made to acquire
the project requirements. Two of the requirements were the static and dynamic bending forces.
A comparative study of static and dynamic bending forces during the three-roller cone frustum
was done in [10]. The results were that the static bending force decreases as the bottom roller
inclination increases, while the dynamic bending force increases as the bottom roller inclination
increases. Moreover, the bending force during static bending is quite larger compared to the
bending force required during the dynamic bending [11].
 10

1.4. Description of the Merit Aspects of the Design

Automated bending machines usage results in several issues, including high energy
consumption for motors that run on electricity [12]. Also, the material used in the machine is
steel, which is fully recyclable [13] resulting in a limited impact on the environment.
Economically, the project is a manual bending machine that is less expensive than automated
projects that require electricity resulting in additional costs.
To build an acceptable design, the question of workability, durability, and reliability of
the components constituting the bending machine must be taken into
consideration.

1.5. Design Impact

The three-roller bending machine is used for producing workpieces with small bending radii.

Usually, there are two fixed and a single moving roller. The workpiece passes forward and

backward through the rollers while gradually moving the upper roller downwards. Hence, the

upper roller position dictates the workpiece bend angle. This bending method causes minor

deformation to the cross-section of the pipe and is suited to produce coils of the pipe, as well

as long sweeping bends. With the guidance of a stationary roller, the pipe enters through one

side of the machine. The pipe is held at the initial point of the second roller, after entering the

required distance in the display. One of the main advantages of the three-roller pyramidal

setup is its ability to produce multi-radius pipes (radius of curvature), this can be obtained by

changing the upper roller position while rolling the pipe.

 11

2. Pipe Cold-Bending Machine Design

2.1. Methodology

Figure 6 Methodology
 12

The flow chart, as shown in Figure 6, represents a thorough review of the history of this
type of manufacturing process and what is being practiced.
Each design should meet the constraints of the objective, which is included in the usability
analysis. Once everything is approved the machine can be analyzed and evaluated.
2.2. Standards and Codes
The following standards and codes were referred to, to ensure the safety of every part
of the machine. They serve as a guide for decisions related to component geometry, workpiece,
and machine materials to ensure that the machine respects international standards. This will
help keep the design on track for entering the market in the future.
I. AISI [1030 Cold; 4340 steel, annealed] [14] were selected as materials for the
machine and the workpiece.
II. LEED requirements were met by using sustainable and recyclable material, and
since the machine is fully manual. It is also applied to the coating used.
III. HSE [Safe use of work equipment Provision and Use of Work Equipment
Regulations 1998. Approved Code of Practice and guidance L22 (Fourth
edition) [15] standards were followed to ensure the safety of operations,
responsible for decreasing the risk of injuries.
IV. BS EN ISO 13857:2008 Safety of machinery. [16]Safety distances to prevent
hazard zones being reached by upper and lower limbs - British Standards
Institution.
V. DIN 1026-1: 2000 [17]Commercial Steel UPN beams were selected following
the metric standards, available at the Lebanese local market.
VI. DIN 471, Circlips (retaining rings) for shafts.
VII. ASTM [A 500; A 181; A 105; A 898] [18] were used so that the bending
limitations of the workpiece does not exceed maximum deflection to avoid
rupture.
VIII. ISO 15 for SKF [19] ball bearing selected from a catalogue.
IX. DIN 8187 – ISO 606 [20] is used for sprockets for the roller chain.
X. ISO 1580; 4017; 7045 [21]The International Standard for metric screws and
ANSI B18.6.3 [22] for hex head screws
 13

2.3. Preliminary Machine Geometry

Figure 7 Rendered presentation of machine design

2.3.1. List of Components
Part labeling (Refer to Figure 7):
1: Top Roller 2: Bottom Rollers 3: Workpiece 4: Top Plate
5: Tower Support 6: Base Support 7: Rail Support 8: Bottom Shaft
9: Top Shaft 10: Slider 11: Compounded Gear Train 12: Top Bearing
13: Lower Bearings 14: Plate Bolts 15: Gear Chassis 16: Chain/Gear
Many aspects of the geometry of the machine were tackled. First, the design of the
roller cross-section was sketched in a drawing shown in figure 9 below. Then, the analysis of
the relative positions of the three rollers was done using a mathematical model to achieve the
radius of curvature required. Finally, a detailed design of the chassis and all complimentary
components was made to house the rollers in an efficient way to minimize stresses, distribute
them uniformly, and keep the machine at the optimum weight, size, and cost.
2.3.2. Top Roller
The major force applied vertically
downward on the top roller is used to bend
the 50mm diameter pipe locally. The force
applied on this roller comes from two parallel
hydraulic jacks located at the two sides of the
shaft holding the roller. It is also important to
note that this roller is free to rotate and that is
held by bearings. Figure 8 Roller Setup
 14

2.3.3. Bottom Rollers

The top roller exerts a downward force on the workpiece which will transmit to the two
bottom rollers. The latter will create a reaction force that will act upwardly on the workpiece.
These bottom rollers are manually driven by a torque reduction mechanism. A manual spur
gearbox is designed. The torque applied on the roller coming from the gearbox is calculated in
a way to overcome the local bend created by the top roller and to continuously roll the profile
creating a homogenous radius along the pipe. These rollers are placed in a pyramid setup having
the top roller above the two bottom rollers as shown in Figure 8 above.
2.3.4. Workpiece
As shown in Figure 7, the workpiece has a circular cross-section with a diameter up to
50mm and a thickness up to 5mm. These types of pipes are either extruded or rolled then
welded. The workpiece fits perfectly in the roller to avoid distortion. It should reach a radius
of curvature of 100mm after being roller reaching a U-shape or a full circle.
2.3.5. Slider
The slider shown in Figure 7 fits with a clearance of 2mm on all sides between two
vertical UPN beams [Part Number 5]. A bottle hydraulic jack is located between the slider [part
number 10] and the top plate [part number 4] with a conical steel fitting to eliminate excessive
stress.
2.3.6. Roller Cross-Section
Accounting for direct forces is very
important. It is transmitted from the roller
to the pipe, thus the roller cross-section, as
shown in Figure 9, must be precisely
Figure 9 Roller Geometry
mating half of the workpiece, to be able to
distribute the force equally on the outer skin of the pipe, to avoid rough or damaged surface.
 15

2.4. Rollers Relative Positions Design

The roller positioning played a major
role in reducing the force required by the top
roller, and the torque required for rolling. The
bottom rollers were placed 400mm apart, and
their inner radius was 75mm, compensating
the pipe radius of 50mm. The major constraint
is to reach a bend radius of 100mm, so the
change in radius with respect to the
displacement of the top roller has to be
calculated as shown in equation (2) using
trigonometric sine formula for angle ∠ ABI
included in triangle ABI. Point B is the Figure 10 Roller Setup Geometry

center of the radius of the workpiece. Combining equations (2) and (3) gives the following
equation (4) which is later on compiled using MATLAB to obtain the plot in Figure 11. The
plot allows a visual inspection of the effect of linear vertical downward displacement on the
radius of the workpiece.

𝐵𝐷𝑅
2
∠ ABI = 𝛼 = arcsin ( 𝐴𝐵 )

(2)

𝐴𝐵𝑐𝑜𝑠𝛼𝐸𝐵 = 𝐷𝐵 − 𝐼𝐵 + 𝐴𝐺
(3)

𝐵𝐷𝑅 1
𝑊𝑅 = (𝐷 − (𝐷 + 𝑅𝑅) ∗ cos (asin (( ) . 𝐷+𝑅𝑅 )) + 𝑅𝑅)
2

(4)

Nomenclature:
WR : Workpiece outer radius [mm]
D : Upper roller vertical displacement downward [mm]
RR : Roller Radius [mm]
BDR : Bottom Distance Between Rollers (fixed = 400mm) [mm]
 16

Referring to Figure 11, the

change in radius exponentially
decreases, the further the roller is
displaced. Thus, the relationship is
not linear; therefore, a measuring
device must be included after
finishing the manufacturing to
indicate the radius reached at each Figure 11 WR vs. D [1:3000]
position for more accurate rolls. The point [X:125mm; Y:200mm] displayed in Figure 11 shows
the maximum downward displacement of the upper roller, in other words, the minimum radius
that can be reached geometrically (shown in Figure 12) is at the point where the three rollers
get aligned. This significantly shows that in this roller setup, there cannot be a smaller radius
forged.
Hence, choosing the 400mm spacing
between the bottom rollers is tied to multiple
constraints. On one hand, increasing the
distance between them leads to the increase of
the roller radius, leading to higher
manufacturing and material cost. On the other
hand, a smaller distance can lead to failure
Figure 12 Geometry Verification SolidWorks
due to undersized parts undertaking large [mm]
stresses. Therefore, Value Engineering was
done to balance the costs and the stresses in each component. This simulation is shown in
section 2.7. The minimum inner radius of curvature to be reached is equal to the roller diameter
75mm. The inner radius of curvature required is 100mm, hence a geometric safety factor of
1.33 is accounted for which allows more flexibility of the machine design.
 17

2.5. Dynamic Nonlinear Stress Analysis for the Workpiece

2.5.1. Workpiece Dynamic Simulation
STL files modeled on SolidWorks are exported to Deform-3D to simulate a nonlinear,
plastic deformation on the workpiece. This simulation is used to estimate the forces required
to forge the pipe, meeting the required constraints mentioned in section 1.2. The software
differentiates between the workpiece
(Master) and the die (Slave). The die is
considered as rigid and is not meshed.
The simulation was divided into 223
steps whereas, in every step, the model
is re-meshed, as shown in Figure 13.
The mesh is made of triangular elements
of 0.1 mm size which leads to non-
distorted results. There are 25406 nodes
and 87496 elements [23]. Figure 13 DEFORM-3D Final Mesh at Step 223

2.5.2. Simulation Setup

2.5.2.1. Workpiece Material Properties
The material is set as steel and not copper since steel has a higher yield strength. AISI-
1035 standard is chosen since it is available in the local market. The plastic and elastic
properties are set according to [24], with an elastic Young modulus of 206GPa, Poisson Ratio
of 0.3, and a yield function type of Von Misses, with Normalized Cockcroft & Latham fracture
types [22].
2.5.2.2. Geometry Setup
The workpiece geometry is set to the upper bounds of the constraint. The pipe has an
outer diameter of 50mm and a thickness of 5mm. The selection is chosen according to the worst
case that is stated in the problem statement in section 1.2.
The die geometry is cylindrical having an extruded cut of the shape of the pipe to
maintain the shape and to distribute the forces all over the surface area avoiding an oval cross-
section. The inner radius and the spacing are calculated in section 2.3, and the inner radius is
chosen to account for the workpiece radius of curvature.
2.5.2.3. Boundary Conditions
The Master/Slave relationship is one of the boundary conditions that specify which is
the driver and which is driven. Another condition is allowing the top roller to rotate freely. The
3D model is illustrated in Figure 14. Moreover, a displacement input is assigned rather than a
 18

load since the load is unknown. A table is made to control the movement of the roller relative
to the steps in the table illustrated in (Figure 15 Stroke[mm] and Angular Velocity[rad/sec] vs.
Time[steps] (predicted results). At the initial state, the angular velocity is set to 0 rad/s while
the top roller achieves a downward stroke of 3mm during 10 steps which are sufficient for a
non-distorted load prediction. Then, the top roller stops moving downwards allowing the two-
bottom rollers to rotate one full rotation with a constant angular velocity. This cycle is repeated
multiple times to observe the changes after that the deformation of the workpiece occurs on
multiple stages.
2.5.2.4. Contact
The contact constraint was initially set between the master and slave with a plugin
readymade in DEFORM-3D that sets the friction factor to 0.13 as an assumption for cold work.
The contact definition was 0.01 to maintain accurate results. The contact is recalculated after
each step because the workpiece is in motion. Creep is also calculated in the primary, secondary,
and tertiary stages. Since the metal is ductile, the software also accounts for the prevention of
rupture, knowing that the chances increase with higher deformation
There are two unavoidable problems with this type of bending. One is the excessive
segment A that cannot be reached and the damaged zone B at the beginning and the end of the
roll-region, as shown in Figure 14.
Other than that, residual stresses will
remain in the strained region that was
processed to keep the curve in place.
An inaccurate bend can occur because
of the spring-back effect that is always
present due to the elastic region of the
material that will try to take back the
pipe to its original shape slightly.
Figure 14 Workpiece Strain Post-Simulation
2.5.3. Simulation Analysis
Prediction of vertical load to be exerted by the top roller
The workpiece is placed between the rollers with no force or torque applied in the initial
stage. Vertical displacement is applied to predict the force, which results in a 3mm displacement
at each stage. As shown in Figure 16, the predicted force starts to increase linearly until
reaching the yield strength [Point A] which later follows a prescribed curve that is analytically
made through a dog bone test conducted. After reaching the maximum displacement, the
maximum force turns out to be 190,000N, which is equal to around 19 tons reaching [Point B].
 19

A sudden force drop is witnessed at [Point C] in the small period just after the vertical
displacem1ent and before the start of the rolling process. It is advised to interpret the result
while simultaneously looking at Figure 15. Once rolling starts, the vertical force needed goes
back up to [Point D], remaining at an almost constant value. The cycle is repeated four times.
This number includes kinetic and static friction between the workpiece and the rollers (kinetic
coefficient of friction is 0.13, static friction factor of 0.45). All these generalizations are made
based on the predicted results by DEFORM-3D.
Linear Stroke
Figure 15 shows the plot of the Displacement of the top roller with respect to time; in
that case, the unit of time is steps. The roller starts descending by 3mm on each stroke and then
stops for a while, allowing the rollers to rotate and roll the workpiece. The process is repeated
multiple times to ensure the consistency of the results.
Angular Velocity
The data input shown in Figure 15 for the rotation is initiated during the intervals where
there is no downward stroke. This contributes to separating the force prediction from the torque
prediction. Moreover, the roller is given a relatively low angular velocity to avoid distortion
and to get accurate results needed for the gearbox design.
Force Predicted to Deform the Pipe
A maximum force of 18.8 tons is observed in Figure 16 indicates that this is the force
that must be applied by the hydraulic jacks. Considering a safety factor of 1.33 to overcome
friction and uncertainties in such a complex simulation, the force is assumed to be 25 tons. This
force is distributed into two bottle jacks located on both sliders mentioned in section 2.3.5.
Torque predicted to roll the pipe
Relating the angular velocity graph in Figure 15 to the predicted torque in Figure 17,
the torque input directly increases as the rollers start rotating. Setting the parameters in the
simulation to give an angular velocity to the two rollers. However, the third roller can rotate
freely. This leads to the value of the torque required on the two rollers in series to be around
450 N.m. Considering a safety factor of 2 to stay safe and conservative, the assumed torque
value is of 900N.m.
 20

Figure 15 Stroke[mm] and Angular Velocity[rad/sec] vs. Time[steps] (predicted results)

200000

180000
Pont B
160000
Point A
140000
Vertical Load [N]

120000

100000

80000 Point D
60000

40000

20000 Point C
0
1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67 70 73 76 79 82 85 88 91 94 97 100 103 106 109 112 115 118 121 124 127 130 133 136 139 142 145 148 151 154 157 160 163 166 169 172 175 178 181 184 187 190 193 196 199 202 205 208 211 214 217 220 223
Step Number

Figure 16 Vertical Load[N] vs. Time[steps] (predicted results)

Figure 17 Roller Torque [N.m] vs. Time[steps] (predicted results)

 21

2.6. Detailed Machine Design

2.6.1. Machine structure
The extruded structural steel element DIN
1026-1: 2000 UPN-260 [24] as mentioned in the
standards section 2.2, is used rather than metal sheets
to gain strength from the geometric inertia of their
designs. UPNs are well known for their ability to
withstand the moment and tensile threshold with
respect to their cross-sectional area, thus reducing
material to withstand these forces. They are also used
instead of the I beams for two reasons: on one hand, Figure 18 Preliminary Machine Overview
the top surface has to be large enough to fit all the
components, while choosing the same dimensions in an I beam would result in a larger cross-
section making it heavier. On the other hand, the UPN beams that are purchased for the vertical
towers have a standard length of 6m so the remaining parts can be used for bases 1 and 2 (refer
to figure 18) which leads to less scrap. The base holds the two lower shafts carrying the bottom
rollers using two pillow block bearings, and the tower structure is welded to it, carrying the
linear mechanism responsible for moving the top roller vertically. The top plate on this tower,
as shown in Figure 7, carries the load exerted by the bottle jack, since as mentioned before, the
25 ton-force is distributed to both symmetrical sides of the machine, leading to a 12.5 ton-force
on each plate. The table carrying this structure allows one side of the machine to slide on a V-
shaped metal rail for the operator to replace rollers and remove the workpiece after being rolled.
A separate structure will be responsible for carrying the gears. Moreover, the machine is set up
symmetrically to hold the rollers from both sides. The symmetry contributes to eliminating the
cantilever effect which would directly affect the free ends of the shafts. Cantilevers deflect
approximately ten times more compared to elements that are supported at both ends. Therefore,
instead of using a cantilever set up, it is now possible to use a shaft with a significantly smaller
cross-section area. This also reduces the reaction forces required to support the shaft. Moreover,
since the bearings support the shafts and the reaction forces are smaller, it is now practicable
to use bearings with smaller inner diameters and reduced radial loads. This set up optimizes
the cost of the shaft, the bearings, and their housing.
 22

2.6.2. Machine dynamics

The vertical roller should move linearly, due to a
force exerted by the hydraulic jack shown in Figure 19. It
is connected to a full rigid metal shaft 50mm in diameter
that is split into two parts connected by a 22mm bolt.
These two shaft parts are connected to four bearings.
Initially, the machine was designed with two bearings, but
the static simulations failed. Therefore, the values of the Figure 19 Hydraulic Jack
force are reduced by eliminating the cantilever effect and holding the shaft by its tip. The
bearings are fixed to a metal block, which is constrained on four sides giving it one degree of
freedom. The two bottom shafts are connected by a chain allowing them to rotate
synchronously. One of the two shafts is connected to the gearbox.

2.6.3. Gearbox
The results obtained from Deform 3D, as mentioned in
section 2.5.3, provide that the shafts originally require a 450
N.m torque, and 900N.m after multiplying it by a safety factor
of 2. This mentioned value responds to the operator’s input
force value of 100 N mentioned in the constraints. Gear spacing
Module 3 was chosen [25], with 20º Pressure Angle that can
easily be found in the local market.
Figure 20 Compound Gear Train
Nomenclature:

mt : Torque Ratio [Unitless]

Tin/out : Torque in/out [N.m]
Ndriver/driven : Product of number of teeth on driver/driven gears [Unitless]
rhandle : Length of handle distance [m]
Fin : Force Exerted by operator as mentioned in constraint [N]
N : Number of teeth [Unitless]
FOS : Factor of Safety [Unitless]
 23

Compounded Gear Train Ratio

𝑇 𝑤𝑜𝑢𝑡 𝑁
𝑚𝑡 = 𝑇 𝑖𝑛 = = 𝑁 𝑑𝑟𝑖𝑣𝑒𝑟 (5)
𝑜𝑢𝑡 𝑤𝑖𝑛 𝑑𝑟𝑖𝑣𝑒𝑛

Input Torque Calculation

For ergonomic and comfort reasons, the handle’s length is 40 cm.
The input force is 100N.
Hence, the input torque can be found using the following equation [6]:
𝑇𝑖𝑛 = 𝐹𝑖𝑛 ∗ 𝑟ℎ𝑎𝑛𝑑𝑙𝑒 = 100*0.4 = 40 N.m (6)

Ratio according to Number of Teeth

Figure 20 Compound Gear Train are the number of teeth combination that can be made to keep
all the stages aligned and keeping the gears as compact as possible. The combination of the
number of teeth is shown in the form of ratios below.
𝑁1 𝑁3 𝑁5 𝑁7 35 35 35 35 1 𝑇𝑖𝑛
𝑚𝑡 = ∗ ∗ ∗ = ∗ ∗ ∗ = = (7)
𝑁2 𝑁4 𝑁6 𝑁8 53 105 105 105 40.88 𝑇𝑜𝑢𝑡

Output Torque Calculation

The output torque is multiplied by the ratio obtained leading to a 900N..m torque required to
operate the machine:
𝑇𝑖𝑛
𝑇𝑜𝑢𝑡 = = 40.88 ∗ 40 = 1635.43[𝑁. 𝑚]𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 ≥ 900[𝑁. 〖𝑚]〗𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 (8)
𝑚𝑡

Resultant Factor of Safety

An additional factor of safety is added after the gear calculation. It compensates for the friction
between the spur gears, and it is the result of the ratio between the calculated and the required
torque.
𝑇𝑜𝑢𝑡,𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 1635.43
𝐹𝑂𝑆 = = = 1.817 (9)
𝑇𝑜𝑢𝑡,𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 900

Therefore, a four-stage spur gearbox is designed, where three stages have a 1:3 ratio
and the fourth has a 1:1.514 ratio as an additional safety factor accounting for frictional losses,
as shown in Figure 20. The pinion has 35 teeth and the other gear’s teeth number follows the
ratio.
 24

2.7. Machine Stress Analysis

Analysis simulations are made with SolidWorks with material configuration conforming to
American Iron and Steel Institute AISI Standards [24]. Simulations are made on critical parts
of the machine, which include the shafts, and pressure plates. Figure 21 below shows the FBD
(Free Body Diagram) of the load setup of the shaft.

Figure 21 Reaction Forces due to Action force of 250 [kN]

Material Properties
The material properties for the steel used for the machine components.
Name: AISI 4340 steel, annealed
Model type: Linear elastic isotropic
Yield strength: 470 MPa
Tensile strength: 745 MPa
Elastic modulus: 205,000 MPa
Poisson's ratio: 0.285
Mass density: 7,850 kg/m3
Shear modulus: 80,000 MPa
Table 1 Material Properties for Major Machine Components

Figure 22 von Mises Stress [MPa] : Deformation Scale x10

 25

2.7.1. Top Hydraulic Plate Simulation

A conical part is added to cancel the stress concentration enabling the part to succeed
without excessively thickening the steel plate. This force is distributed among six holes
dividing the load equally due to symmetry. The simulation result shows that a maximum of
268.2 MPa stress occurs as shown in Figure 22. The yield strength of the material is 470MPa
leading to a 1.75 safety factor.

2.7.2. Shaft Force Simulation

A 25-ton force is applied, reflecting the reaction force exerted by the workpiece on the
roller through which the shaft enters. Using a sensor in SolidWorks Simulation, the resultant
forces are extracted for future bearing selection. All the shafts can be disconnected in their
respective centers to account for the removal of the workpiece after being rolled into a full
rotation. They are disconnected using a center 22mm screw. The mesh used is displayed in
Figure 23 showing the finite elements calculated. The material used for the shaft has a yield
strength of 710MPa following the standards mentioned in section2.2.
The force and torque are applied separately to visualize their effect separately and are
shown in Figure 24 and Figure 25 respectively.
The force results in 335 MPa stress on the top and bottom regions where there are sharp
cuts. This indicates that a small fillet is essential to reduce stress concentrations due to stress
raisers. Knowing that the yield strength value is 710 MPa, this component is left with a safety
factor of 2.12.

Figure 23 Mesh Size Preview

 26

Figure 24 Stress Along Shaft

Similarly, a torque of 900N.m is applied to the shaft. This torque is designed to

overcome the friction in the rollers and gives sufficient energy to the pipe to overcome the
elastic region and initiate roll deformation. The same boundary condition as the previous shaft
is applied, with only the force replaced by the torque. It results in even lower stress of 141.3
MPa, with a safety factor of 5.1 that is relatively more than enough for this kind of use.
Moreover, we applied in our simulations the force and torque separately on the shaft.
 27

Figure 25 von Mises Stress Under Torsion [MPa]

3. Manufacturing
The manufacturing process is composed of three main stages: machining, manufacturing,
and finishing. All part numbers in this section are referred to in figure 27 below.
3.1. Machining
Machining is the process of material removal from a workpiece utilizing power-driven
machine tools reaching the desired geometry. Most of the machine’s parts are made of metals.
The following are types of machining used along with the corresponding parts machined.

Figure 26 Machine Components Figure 27 Slider

3.1.1. Cutting
A band saw is used to cut parts 1, 2, 3, and 5. All linear profiles come in a standard
length of 6m stock. The tower supports are structural steel elements DIN 1026-1: 2000 UPN-
140 as mentioned in section 2.2, and are then cut to the specified length of 900mm. The top
and bottom shafts of 50 mm diameter, requires cutting to specified lengths of 500 mm. A
modification to the housing of the bearings is done; three pairs of concentric bushings referred
to as part 3, have an inner diameter of 80 mm, an outer diameter of 140 mm, and a length of
100 mm, and they are cut from an 800 mm long bushing. Six holding plates referred to as part
 28

5, of 5 mm thickness are cut from the same bushing. The holding plates are used to hold the
bearings in the housing and prevent slipping outwards.

3.1.2. Lathing
Boring is done using a metal lathe to expand the inner diameter of the bearing housing
shown as part 3, to reach the required outer diameter of the bearing, taking into account the
tolerance of 26 μm of capped bearings following bearing number 6310 in SKF catalog [19].
Thus, this delicate process has to be done with extreme precision. Facing is done to the shaft
to reduce its diameter reaching the required 50 mm inner diameter of the bearing, considering
the tolerance of 9 μm [19]. Next, a CNC lathe is used to shape the semi-circle cut into the roller
referred to as part 8, the cut is shown more clearly in the section view in Figure 28 below.

Figure 26 Slider Section View

3.1.3. Drilling and threading

The supporting plate and the bushing are drilled with a 3.30 mm tap drill [21] to achieve
the M4 screw hole required. A total of three drills are made on each of the bushing supporting
plates and bushings. Figure shows the screws holding array on the housing supporting plate
and the bearing housing.

3.1.4. Plasma cutting

A conventional plasma cutting machine is used to cut the top plate shown as part 7, the
faces required to assemble the slider demonstrated as part 6, and the bearings housing supports
shown in part 4. Plasma cutting is chosen because it achieves clean cuts at 25 mm thicknesses.
 29

Moreover, it is much cheaper than laser cutting. 2-D drawings are drafted on AutoCAD and
then converted into a g-code driving the CNC machine.
3.1.5. Keyway cutting
Keyways are made between each roller and shaft using
the shaping process where the tool reciprocates across the
stationary workpieces. Shaping is a good option for cutting
blind keyways. For a shaft diameter of 50 mm [26], the keyway
width W shown in Figure 29 is 14 mm  0.026 mm as tolerance
and a depth T2 of 5.5 mm  0.1mm and keyway radius R of
0.5mm  0.1mm.
Figure 27 Keyway Dimension Diagram

3.2. Assembly
Tower supports’ U-channels shown as part 1 are placed on the
base support and checked for alignment using level rulers. After
approval, the U-beams are welded onto the corresponding base support
using MAG [metal active gas] welding. MAG welding uses active
shielding gases, primarily used for the welding of aluminum and steel.
The active shielding gas used is pure CO 2, it enables high working
speeds, increasing penetrations, with lower heat effects on the
surrounding metal, and increased protection against oxidization.
Vertical alignment check is done after the weld is applied and
Figure 28 Insertion of Bearing
adjustments are made where necessary. In parallel with the welding Inside Housing

process, the bearings are carefully pressed inside of the corresponding

housings using a hydraulic press machine, avoiding buckling in the
process as shown in Figure 30.
Assembling the slider shown as part 6 requires the welding of
bearing housings referred to as part 3. The front and back face-plates
of the slider. The front and back face-plates are aligned after inserting a
shaft in their corresponding bearings. Top, bottom, and side plates of the
slider are then welded to the front and back face-plates of the bearing
housings shown in Figure 31.
Figure 29 Slider Alignment
 30

A circlip for the 50mm shaft to keep it in place is chosen

from DIN 471 as mentioned in section 2.2. It has an internal
diameter of 45.8 mm (not under tension), and a thickness of 2mm.
SKF [19] 6310/VA201 ball bearings are selected (refer to Figure
32) having an internal diameter of d = 50 mm and an outer
diameter of D = 110 mm with a basic static load rating C0 = 38 kN
to withstand the force calculated in the static simulations. The
bearing has a limited speed of 110 rd/min which is larger than
desired angular velocity. After assembling the slider, the top plate
is welded holding both UPN towers in place. Figure 30 Ball Bearing
Cross-Section from SKF
After assembling the parts mentioned above, the rollers are Catalogue [19]
placed and fastened with two heavy-duty washers and a screw
securing it in place.
Sprockets are assembled on the backside of the bottom
shafts. 10B-1 size sprockets [20] are chosen with a number of
teeth Z = 18. As shown in Figure 33, the sprocket has D1 = 40
mm; therefore, the shaft is lathed to meet this diameter. Another
18-tooth sprocket is mated with a 54-tooth sprocket to match a 1:3
ratio before reaching the gearbox. Then a matching 10B-1 chain
[20] is placed and locked with a key.
Following these steps, the hydraulic jack is placed between Figure 31 Sprockets for roller
chains DIN 8187 - ISO 606
the slider and the top plate and the roller is ready for its first run.
However, the manufacturing phase was not finalized due to the lockdown and the machine was
not put to test.
 31

3.3. Pricing Sheet

Table 2 below shows the list of prices separately. Nontaxable items are deducted from
the tax calculations and the total lump sum price is shown below. The table also illustrates the
net cost of purchasing the required materials along with all manufacturing overheads required
for producing the machine.

Lebanese American University Quotation

Mechanical Engineering Departement
DATE 5/18/2020
Byblos Quotation # 1
Jbeil MOF 123100-601
Phone:09/547254

Quotation For: Quotation valid until: 5/28/2020

Dr. Wassim Habchi Prepared by: Kevin and Hassan

FYP-I
Street Address
City, ST ZIP Code
Phone

QUANTITY DESCRIPTION UNIT PRICE TAXABLE (Yes/No) AMOUNT

6 Roller Bearing [Unit] $ 21.00 Yes $ 126.00

1 Hydraulic Jack 50Ton [Unit] $ 70.00 Yes $ 70.00

75 UPN140X6 [KG] $ 2.00 No $ 150.00

Top Roller
40 [KG] $ 2.00 Yes $ 80.00
Enncasement

28 Shaft 55mm [KG] $ 2.00 Yes $ 55.00

Bearing
80 [KG] $ 2.50 Yes $ 200.00
Encasement

23 Top Plate [KG] $ 2.50 Yes $ 57.50

10 Workpiece [KG] $ 2.50 Yes $ 25.00

60 Roller Die [KG] $ 2.50 No $ 150.00

1 Gear box [Unit] $ 180.00 Yes $ 180.00

18 Legs [KG] $ 1.50 Yes $ 27.00

1 Lathing [Manufacturing] $ 385.00 No $ 385.00

2 Chain [Unit] $ 10.00 Yes $ 20.00

4 Spruckets [Unit] $ 8.00 Yes $ 32.00

30 Welding [Manufacturing] $ 1.00 No $ 30.00

SUBTOTAL $158,705.00

TAX RATE 11.00%

SALES TAX $ 95.98

TOTAL $ 1,683.48

If you have any questions concerning this quotation, contact name, phone number, e-mail.

THANK YOU FOR YOUR BUSINESS!

Table 2 Total Machine Price Including Material and Labor Cost

 32

4. Conclusion
A basic geometry was parametrically designed. This geometry was used for setting up
boundary conditions for a simulation to forecast the required force and torque to operate the
cold roller bending machine. A complete 3D-model was then drafted and continuously
modified after testing it in static simulations. The machine was then manufactured and tested.
For the roller geometry the first design parameters of the roller constitutes of 400 mm
spacing and a 7.5cm roller radius. The values are obtained using trigonometric relationships,
MATLAB for plotting, and SolidWorks for 2D-visualization. These parameters are validated
as feasible since they succeeded in all the future simulations.
The findings in section 0 show that an 18.8 ton-force is required to bend the 50mm pipe
with 5mm thickness to reach a radius of curvature of 100mm. Accounting for a safety factor of
1.33 to overcome internal losses like friction and other uncertainties, a 25-ton force is chosen
as a bending force for static simulation demonstrated in section 2.7. On another note, a 450
N.m torque is required to overcome plastic deformation, adding a safety factor of 2, the
machine and the gearbox are designed to withstand a 900 N.m torque. These results are based
according to a 3mm downward displacement of the top roller for every pass the workpiece
does. The machine design is based on these two numbers keeping the machine components
within the factor of safety of 1.75 accounting for creep, wrinkling, local and global buckling.
Static simulations are done on the most critical parts of the machine such as the shafts
and the top plate. These simulations yield a minimum safety factor of 1.75 applied to the shaft
carrying the roller. A three-roller bending machine is first selected as the most convenient
structure to the desired constraint. Then, the geometric difficulties accounting for both
geometrical constraints, force, and torque reduction. An assessment for every component of the
machine is done by running a static simulation to make sure the machine is running within a
safe safety region.
Finally reaching the merit aspect of this machine, the material used in the machine is
steel, which is fully recyclable resulting in a limited effect on the environment. Economically,
the project is a manual bending machine that costs 1638$ which is less expensive than the
automated counterpart which costs on at least 3000$.
 33

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