FABRICATION OF

MOTORIZED RADIAL
BENDING MACHINE
ABSTRACT
 CHAPTER I

ABSTRACT

The aim of this paper is to develop a radial bending machine which is useful to
bend a pipe in workshop . This project is to design and construct a portable pipe
bending machine. This machine is used to bend steel pipes into curve and the
other curvature shapes. The size of machine is very convenient for portable work.
It is fully made by steel. Moreover it is easy to be carry and use at any time and
any place. It reduces human effort and also required low less skill to operate this
machine. We are designing manually operated pipe bending machine with use of
pulley, motors, gears and support (frame). The pipe bending machine is power
and manually both operated. Therefore, our objective is to increase accuracy at
low prize without affecting the pipe bending productivity. This machine works
on simple kinematic system instead of complicated design. This machine can
bend up-to 4- 5mm thickness of pipe. Due to its portability it can be used by small
workshop or fabrication shop. Bending machine is a common tool in machine
shop that is used to bend a metal. It is widely used in various industrial operation
such as bending a pipe in required shape & size. In this project, designing a
bending machine specifically for portable pipe bending machine. There is no
proper small scale bending machine for bending a pipe.
INTRODUCTION
 CHAPTER II

INTRODUCTION

This study is about the work of designing a bending machine to bend a

pipe. A bending is a process of bending a metal. The metal can be a sheet metal,
tubes, square hollow, rod, and iron angle. This type of metal has its own thickness.
The bending machine designer will take into consideration a number of factors
including type of metal, type of the roller bender, power driven or manual and the
size of the bending machine. Usually, the difference of these types of bending
machine is only on the capacity of the bending machine that can bend a sheet
metal or tube. Today, the bending machine that available in the market is for the
sheet metal and tube bending machine. Many machine makers vary their products
based on the capacity of the bending machine and power driven or manual.
Moreover, most of the machine uses roll bending type. This type of machine has
3 rolls which is 1 roll is fixed and the other 2 are adjustable. The metal pipe needs
to put in the roller and then rolls around it until the desire shape is acquired. The
products that can be produced with this machine are various curves, structural
elements, automobile parts etc.

1.1 Roller for bending pipe

To give the required shape and size, roller is used. Primary function of the roller
is to achieve angular shape to the pipe. This is done through screw which apply
pressure on roller and also this roller achieved rolling action by using an AC
motor .

1.2 Functions of Bending Machine

1. To bend a pipe having thickness upto 5 mm in required angular shape.

2. To provide curvature shape to pipe.

3. Machine is convenient for portable work.

4. The machine is power operated to achive maximum accuracy in less time.

1.3 Roller requirement

1.Roller should be very accurate and easy to handle.

2. The effort required to bend pipe should be minimal.

3. The rolling attachment should also provide directional stability. This implies
that the pipe should have a tendency to move to & fro.

1.4 Pipe Bending Machine

A roll bending machine uses roller to bend a metal. The roller of bending machine
can be two rollers, three rollers, or four rollers. The common product of roll
bending machine are tube bending, plate bending and a coil. All modern roll
bending machine is power driven and some of the bending machine equip with
electronic control for more. During the roll bending process the pipe extrusion,
or solid is passed through a series of roller( typically 3) that apply pressure to the
pipe gradually changing the bend radius in the pipe. The pyramided style roll
benders have one moving roll, usually the top roll. Double pinch type roll benders
have to adjustable rolls, usually the bottom rolls, and a fixed top roll this method
of bending causes very little deformation in the cross section of the pipe. This
process is suited to producing pipe which is in require shape as well as long gentle
bends like those use in making structure of pipe.

1.4.1 Reason To Design A Pipe Bending Machine

The reason to design a bending machine for pipe bending is because there is no
proper bending machine to bend a metal pipe for small scale. The bending
machines found in the market come from variety of types. There are bending
machine such as press brake bending machine, roll bending machine and a folding
machine. Moreover, the design for the bending machine for pipe bending is to
bend a metal pipe. It produces sheet metal bending with desire degree of bending
except 90°. Other reason regarding to the bending machine design, the bending
machine in the market come with big size and the bending machine is expensive.
The existing bending machine in the market is created for huge capacity for
bending a metal pipe. With the capacity of bending machine that exists in the
market, the existing bending machine is not fulfilling the requirement of the
usage. The requirement of operation of bending machine is simple. Thus it is not
suitable to purchase existing bending machine to be used for simple bending
machine operation. Moreover, the machine is heavy and use up a lot of space. In
addition, the problem will arise when to move and put the bending machine due
to heavy and space.

1.5 Types of Bending Machine

1.5.1 Tube Bending

The Forming Roller method of tube bending is recommended for all large
bends where the centerline radius is at least 4 times the outside diameter of the
tube. It can also be successfully employed for bending pipe or heavy wall tubing
to smaller radii and is the most practical method of bending very small diameter
tubing.
The Forming Roller and Radius Collar must be grooved to exactly fit the tube
and the tube must not be allowed to slip during the bending operation as even a
slight amount of slippage will cause distortion.

1.5.2 Circle Bending

This operation is somewhat involved by the fact that most materials “spring
back” after they have been formed. To compensate for this, it is often necessary
to use a Radius Collar having a smaller diameter than that of the circle required.
Actual size can best be determined by experiment, as the “spring back” varies in
different materials. Material should be precut to exact length before forming.

1.5.3 Channel Bending

The same general bending rules which cover the forming of channel with
“flanges out” also apply when it is formed with “flanges in.” Since it is necessary
to compress the flanges as they are bent inward, the operation shown below
requires considerably more bending pressure than when forming with the
“flanges out” and it is recommended that the largest possible radius be used to
allow for compression of the material. if a sharp 90° bend is desired, it can be
obtained by cutting a notch out of the channel flanges before forming around a
special Zero.
Radius Block as illustrated. It is sometimes possible to make a circle in channel
by using a segment of a Radius Collar similar. By following the procedure
outlined on, the circle can be formed in three operations. To form channel with
the flanges facing upward it is necessary to first fill it with Cerro bend or some
other commercial filler as it is not possible to support the flanges in this position
with a radius Collar.

1.5.4 Square Bending

Forming zero radius bends around square, rectangular, or other multisided blocks
employs the same principle used in scroll bending. Forming Nose “leads”
material between corners of the block. Any number of zero radius bends can be
obtained in one operation by this method in all types of solid materials. Both
centered and off-center square eye can also be formed by following the same
procedure outlined on.
This method of bending is limited by the size of the square block and the ductility
of the material. In general, when squares larger than 1” are needed, they should
be formed in progressive operations using the zero radius blocks.
LITERATURE SURVEY
 CHAPTER III

LITERATURE SURVEY

The paper deals with manufacturing of pipes which use power operated
sheet bending machine and manually operated sheet bending machine. It also
includes limitations of manually operated bending machine. From the results of
the paper the productivity of power operated bending machine is higher.P. S.
Thakare[1].

Author told in recent year’s pipe bending machine is used in both industry
and domestic purpose for bending the pipe under the required angles and
dimensions. Sometimes Heat treatment is used for pipe bending but the heat
treatment technique is not safe and have problems are produced in the pipes, such
as wrinkling, curve forming, reduced thickness, whole forming, reduced strength,
easy breakable. In the hydraulic pipe bending machine having an good advantage
compared to heat treatment methods.V. Senthil Raja[2].

In this paper, a bicycle integrated pipe bending mechanism has been

designed and developed. The applications of bent pipes are in frames, barricades,
handle of bicycle. Most of industries uses bent pipes as air conditioning,boiler,
power generation, ship building, furniture, railroad, automotive, off-road and
farm equipment, aircraft etc. Due to adequate human power in countries like
India, the human powered machine will result in improvement of the economy
and employment of nation.In Asian countries people are facing electricity cut-off
during most of the days so such system plays an important role in rural areas.H.
A. Hussain[3].

Hydraulic equipment has wide use in various automobile fields. These

hydraulic instruments are used for lowering and raising chair in Barber shops and
in dental clinics.Hydraulic bending machine is the suitable equipmentto bend
pipes, rods and bars. The pipe or rod to be bending is kept between the rollers.
With use of hydraulic jack we implement force on the pipe and bend it to the
required angle depending on the dies used. Hydraulic bending machine is less
expensive,flexible and portable compared to those which are discussed earlier.
Hence it is better to replace current standard machines by hydraulic pipe bending
machine.Mohan Krishna S. A.[4].

The aim of this paper is to develop a pipe bending machine which is useful
to bend a pipe in workshop. This project is to design and construct a portable pipe
bending machine. This machine is used to bend steel pipes into curve and the
other curvature shapes. The size of machine is very convenient for portable work.
It is fully made by steel. Moreover it is easy to be carry and use at any time and
any place. It decreases human effort and requires low skill labors for operating
the machine. In this paper they designed manually operated pipe bending machine
with use of gears, motors,pulley, and frame. This bending machine is both
manually and power operated.Prashant P. Khandare[5].

Metal forming is a process in which the desired shape and size are obtained
through plastic deformation of a material without any loss of material. Bending
is a metal forming process in which straight length is transformed into a curved
length. Roller forming process is a continuous bending operation in which a long
strip of metal is passed through typical roller adjustments, until the desired
curvature shape is obtained. The bending changes according to material and
according to the loading condition and thickness of sheet.Mahesh Gadekar [6]
COMPONENT
DESCRIPTION
 CHAPTER IV

COMPONENT DESCRIPTION

4.1 Lead Screw

The nuts and bolts might seem to be one of its least interesting but the fact is one
of the most fascinating. The success and failure of design can hinge on a proper
selection and use of its literally thousands of different designs of fasteners are
offered by vendors we will investigate the application of screw as a fastener can
be arranged to take tensile load, shear load or both which can have significant
bending to load carrying abilities.

4.2 Spur Gear

Gears are used to transmit torque and angular velocity in a wide variety of
applications. There is also a wide variety of gear types to choose from. The
simplest type of gear, the spur gear, designed to operate on parallel shaft and
having teeth parallel to the shaft axis. Other gear types such as helical, bevel, and
worm can accommodate nonparallel shafts. Gears have a long history. The
ancient Chinese South-Pointing Chariot, supposedly used to navigate across the
Gobi desert in pre-Biblical times, contained gears. Leonardol Da Vinci shows
many gear arrangements in his drawings.

Early gears were most likely made crudely of wood and other easily
worked materials, their teeth merely being pegs inserted in a disk or wheel. It was
not until the industrial revolution that machines demanded and manufacturing
techniques allowed, the creation of gears as we now know them with specially
shaped teeth formed or cut into a metal disk.

4.3 Bearing

We use the term bearing here in its most general sense. Whenever two parts
have relative motion, they constitute a bearing by definition, regardless of their
shape or configuration. Usually, lubrication is needed in any bearing to reduce
friction and remove heat. Bearings may roll or slide or do both simultaneously. A
plain bearing is formed by any two materials rubbing on one another, whether a
sleeve around a shaft or a flat surface under a slider. In a plain bearing, one of the
moving parts usually will be steel or cast iron or some other structural material in
order to achieve the required strength and hardness. Transmission shafts, links,
and pins are in this category. The parts that move against will usually be made of
a bearing material such as bronze, Babbitt, or a nonmetallic polymer.

A radial plain bearing may be split axially to assemble it to the shaft, or

may be complete circle called a bushing. A thrust bearing supports axial loads.
Alternatively, a rolling-element bearing, which has hardened steel balls or rollers
captured between hardened steel raceways, may be used to provide very low
friction. Plain bearings are typically custom designed for the application, while
rolling-element bearings are typically selected from manufacturers catalogs to
suit the loads, speeds, and desired life of the particular application.
SELECTION OF
MATERIALS
 CHAPTER V

SELECTION OF MATERIALS

1.Properties:

The material selected must possess the necessary properties for the proposed
application. The various requirements to be satisfied can be weight, surface
finish, rigidity, ability to withstand environmental attack from chemicals, service
life, reliability etc. The following four types of principle properties of materials
decisively affect their selection

− Physical

− Mechanical

− From manufacturing point of view

− Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific gravity,
electrical conductivity, magnetic purposes etc. The various Mechanical
Properties Concerned are strength in tensile, Compressive shear, bending,
torsional and buckling load, fatigue resistance, impact resistance, elastic limit,
endurance limit, and modulus of elasticity, hardness, wear resistance and sliding
properties. The various properties concerned from the manufacturing point of
view are,

− Cast ability

− Weld ability

− Surface properties

− Shrinkage
2. Manufacturing Case

Sometimes the demand for lowest possible manufacturing cost or surface

qualities obtainable by the application of suitable coating substances may demand
the use of special materials.

3. Quality Required

This generally affects the manufacturing process and ultimately the

material. For example, it would never be desirable to go casting of a less number
of components which can be fabricated much more economically by welding or
hand forging the steel.

4. Availability of Material

Some materials may be scarce or in short supply, it then becomes

obligatory for the designer to use some other material which though may not be
a perfect substitute for the material designed. The delivery of materials and the
delivery date of product should also be kept in mind.

5. Space Consideration

Sometimes high strength materials have to be selected because the forces

involved are high and space limitations are there.

6. Cost

As in any other problem, in selection of material the cost of material plays

an important part and should not be ignored. Sometimes factors like scrap
utilization, appearance, and non-maintenance of the designed part are involved in
the selection of proper materials.
WORKING PRINCIPLE
 CHAPTER VI
WORKING PRINCIPLE
Pipe bending as a process starts with loading a tube into a pipe bender and
clamping it into place between two dies, the clamping block and the forming die.
The tube is also loosely held by two other dies, the wiper die and the pressure die.
A pipe bending machine is a simple bending machine which is operated by a a.c
or d.c motor. The motor is attached to the frame of the machine and also consist
of a circular die on which a vice to hold the rod is welded.

First of all the rod to be bend is set in the vice of the machine and then power
supply is put on, then the motor begins to produce torque and depending upon the
dimension of the rod it is bend. The power from the motor is transferred which
rotates the circular plate in anticlockwise direction and bend the rod for given
radius. Various die can be used as per requirements namely v-die, wiping die,
roller die, etc.
DIAGRAM
 CHAPTER VII

DIAGRAM

1. Handle
2. Lead screw
3. Workpiece
4. Motor with spur gear
5. Spur gear
6. Roller with sliding block
7. Spur gear
COST ESTIMATION
 CHAPTER VIII

COST ESTIMATION

S.No Component Qty Price

1 Roller 3 Rs.900

2 Spur gear Rs.1200

3

3 Lead screw 1 Rs.250

4 Support frame - Rs.340

Total Rs.2690/-

LABOUR COST

➢ Welding

➢ Grinding

➢ Power hacksaw

➢ gas cutting cost

OVERGHEAD CHARGES:

The overhead charges are arrived by ”manufacturing cost”

Manufacturing Cost =Material Cost +Labour Cost

= Rs. 2690 + Rs. 1500

= Rs. 4190

Overhead Charges = 20% of the manufacturing cost

= Rs. 838

TOTAL COST

Total cost = Material Cost +Labour Cost +Overhead Charges

= 2690 + 1500 + 838

= Rs. 5028

Total cost for this project = Rs. 5028 /-

FEATURES
 CHAPTER IX
FEATURES
Applications:
1. Angle Bending
2. Metal Folding
3. U Hook
4. Marine Tube
5. Heat Exchanger
6. Scroll Bending
Advantages
1. Easily operated
2. Simple construction
3. Low cost
4. Rigid construction
CONCLUSION
 CHAPTER X
CONCLUSION

Such type of bending machine more important for small scale work as well
as industrial work in less cost and more precision and accuracy of different type
of pipe bending. The machine capacity can be increased according to the need.
Manual bending tends to minimize wrinkles and can reduce springbuck. By its
design the defects can be easily overcome. Simpler design not only reduces the
defects but also contributes to fluid pressure test during bending. It should be
noted the tendency to wrinkle and the cross section of tube deformation are
reduced. Thus, this approach can be used for bending a thin walled tube over a
small radius of the die, which can be achieved with a conventional method of
bending the tube. In this paper, the problem of bending and axial stretching the
internal pressure is investigated using the machine coordinate system (CMM)
measurement. The objective of the study is to develop a tool that accurately
predicts the change of the wall thickness and the cross-section of the tube
distortion under different loading conditions.
REFERENCES
 CHAPTER XI
REFERENCES
[1] V.B.Bhandari (2012) “Design of Machine Elements” Mc Graw Hill, ISBN.
[2] Hiroyuki goto,Ken ichiru, Hidenobu saitro, Yuu ishikura and Yutaka
tanaka[,"Applicationswith a new 6- dof bending machine in tube forming
processes".
[3] Jose VitorSouze,International Journal of Machine Tools &Manufacture,
2002.
[4] Z. Hu, R.Kovacevic, M.Labudovic, “Experimental and numerical modelling
of buckling instability of laser sheet forming”, International Journal of Machine
Tools & Manufacture, 2002..
[5] Nayyar, P.E., Mohinder L. (2000). "A1". In Mohinder L. Nayyar, P.E...Piping
Handbook (7th Ed.). New York: McGraw-Hill. ISBN,
[6] Effect of internal pressure and shape imperfections on plastic loads of pipe
bends under in-plane closing moment,T. Christo Michael,A.R.Veerappan, S.
Shanmugan, Engineering Fracture Mechanics 105(2013)1 – 15.

[7] Cherniy.V.P. 2001. Effect of Curved Bar Properties on Bending of Curved

Pipes. Journal of Applied Mechanics, Vol. 68, pp.650 – 655. Cherniy. V. P. 2003.
The Bending of Curved Pipes With Variable Wall Thickness. Journal of Applied
Mechanics, Vol. 70, pp. 253 – 259..
CHAPTER XII
PHOTOGRAPHS