PIPE BANDER

DEBRE BERHAN UNIVERSITY

INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING

Mechanism of Machinery Group Project

3rd year

Extention

NAME OF THE STUDENT(S) ID NUMBER

1. Sahilye G/hana ………………………………………………. 1004/10

2.Belachew seyfe ……………………………………………………973/10
3.Beletew Teshome……………………………………………….. 1226/10

ADVISOR (S)
1. Asmamaw

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Simple manual pipe bender
Group project

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 Acknowledgement

I would like to express my special thanks of gratitude to my teacher Mr Yishaq as

who gave me the golden opportunity to do this wonderful project on the simple
manual pipe bender which also helped me in doing thise project asmamaw by
helping the deisign ,selmon by editig my project ,beletew by stiming the idia and i
came to know about so many new things I am really thankful to them.

Secondly i would also like to thank my parents and friends who helped me a lot in
finalizing this project within the limited time frame.

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 Abstract:

This paper presents the design and fabrication of combined pipe bending and pipe rolling
machine. There is no single machine made to perform both rolling and bending operations.
Hence we have selected this project to design and fabricate combined bending and rolling of
pipe using single power source. The defects occur during bending are too much tedious to
eliminate. While designing the machine we tried to minimize defects and minimize the initial
cost of the machine. Using this machine both bending and rolling of pipe of outer diameter 19
mm and thickness 1-2 mm is possible with single power source only.

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 CONTENT

 Acknowledgement
 Abstract:
 CONTENT
 Chapter one (1)………………………………………………………….6
 Introduction……………………………………………………………7
 Background)………………………………………………………….8
 Types Of Pipe Bending)…………………………………………………9
 1.2 Problem Statement)…………………………………………………15
 1.3 objective) )………………………………………………………….17
 1.4 Methodology)………………………………………………………….18
 1.5 Scopes of manual pipe bender)…………………………………………19
 1.6 limitation of manual pipe bender)……………………………………19
 Chapter Two 2 Literature review)…………………………………………20
 Chapter Three Embodiment design)……………………………………22
 Design of bolt and net)……………………………………………… ……24
 Chapter 4 Cost analysis)…………………………………………………25
 Chapter 5 Result and discussion)………………………………………26
 Chapter 6 conclusion and recommendation)…………………………27
 Chapter 7 Reference)………………………………………………28
 Appendices)………………………………………………………….29

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Chapter one (1)

What Is Bending??
 Bending implies the deformation of a work piece produced by loads perpendicular to its
axis as well as force couple acting in a plane passing through the axis of the bar.
 Bending is only occurred when load is acting perpendicular to the neutral axes of pipe
 Also bending occurred when force acting perpendicular to the neutral axes of pipe

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Introduction

In modern days, all area of industries are going to like automated, economically and accurate
machinery .There is many types of pipe bending machine are available in market like hydraulic
pipe bending machine, pneumatic pipe bending machine, manual pipe bending machine etc. The
utility model discloses a simple manual pipe bending machine. Whole machine is supported by a
base with bench legs which has enough strength to carry the weight and force of machine. Two
parallel shafts are Pulley are driven by human power with handle drive mechanism. clamped on
base by clamps which carry the lower pulley. Here plate guide ways are use for guide the
working pulley for right & left linear motion. Pulley gets that motion from Lead screw is
working as a nut and bolt mechanism. The lead screw is get rotary motion from manual force.
Guide way and lead screw are fitted between two horizontal supporting plate, which are fitted on
frame by the help of the two vertical parallel supporting plate. Microcontroller Unit consist of
transformer, rectifier, capacitor, display Production efficiency is improved, the production cost is
reduced, and the application range is wide

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1.1 Background

Pipe and Tube Bending

Pipe bending machines are typically human powered, pneumatic powered,
hydraulic assisted, or electric servo motor. In the pipe bending operation the
tube may be supported internally or externally to preserve the cross section of
the pipe. In operations where there is flexibility in the shape of the pipe, the
pipe does not need to be supported, however there will be some deformation
in the both the cross section of the overall pipe and the wall thickness in
different areas of the bend.
Tube 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. After that has been completed the fitter will start the bender,
while the tube is pulled around the forming die creating an elbow, U-bend, 2-D
or 3-D bent tubes. A three dimensional tube is a tube with each opening on
different planes. A two dimensional tube is a tube with each opening on the
same plane. The picture below shows a typical manual pipe benders with the
main parts named.

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 Manual pipe benders for bending thin wall tube

Types Of Pipe Bending

 Simple manual bending
 Press Bending
 Rotary Draw Bending
 Mandrel bending
 3 Roll Bending
 Bending springs
 Heat induction bending
 Sand packing/hot-slab bending

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 Simple manual pipe bender

Press Bending
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

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 Press or Ram bending

Rotary Draw Bending

This is the most commonly used style of bender for bending pipe and tube
where maintaining a good finish and constant diameter is important.
Rotary draw benders (RDB) are precise in that they bend using tooling or "die
sets" which have a constant center line radius (CLR). The die set consists of
two 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 bend
die while traveling the length of the bend. Often a positioning index table
(IDX) is attached to the bender allowing the operator to reproduce complex
bends 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 and
much more. Rotary draw benders create aesthetically pleasing bends when the
right tooling is matched to the application

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 Mandrel Bending
Mandrel benders are similar to the rotary draw bender but use an additional
wiper die on the outside of the tube and a mandrel which is inserted into the
tube which remains inside the tube during the bend process. This internal
mandrel helps to support the shape of the wall when bending. Typically a
mandrel bender is needed when bending thin wall tubing to a radius much
tighter than the material can bend without collapsing or distorting.

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 Roll Bending
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 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.

Bending Springs
These are strong but flexible springs inserted into a pipe to support the pipe
walls 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.

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 Heat Induction Bending
section of the pipe to a temperature between 430 and 1,200 °C. The
temperature depends on the material. The pipe passes through the coil at a
gradual rate while a bending force is mechanically applied to the pipe. The pipe
is then quenched with either air or water spray. The products thus obtained
are generally of high quality, but cost significantly more to produce.

Sand Packing Hot-Slab Bending

In the sand packing process the pipe is filled with fine sand and the ends are
capped. The pipe is then heated in a furnace to 870 C or higher. The pipe is
then placed on a slab with pins set in it. The pipe is then bent around the pins
using a winch, crane, or some other mechanical force. The sand in the pipe
minimizes distortion in the pipe cross section. It is an old process but one that
hasn’t really been improved on for its flexibility when it comes to unique
applications, and so is still in common use.

Advantages of simple manual pipe bender

A variety of tube radii can be performed on the same machine including variable angles.

Sections such as pipe, bars, and angle can also be formed with this method

Disadvantages of simple manual pipe bender

Slower process as each tube is manually processed with difficulty in obtaining exacting results.

Thin walled tubing can easily collapse if the bend radii is too small.

Accuracy is poor

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Repeatability is Poor

Rotary Draw Bending

1.2 Problem Statemet

Metal Bending machines come in all sizes and types. They may be as simple as a finger brake or
as complex as a press brake. Technology, as in so many other industries also has an effect on the
operation of these systems. Automation has come to the metal bending machine industry. CNC
equipment is seizing control over various metal bending tools. Yet, there is still market for
dedicated manual metal bending tools, particularly in the tube industry. The reasons are various
and are provided in the article below.

Defining Dedicated Manual Metal Bending

Manual bending is self-explanatory. It indicates the process is performed manually or by-hand. A

person must be physically involved in some way. This may require pushing a button, placing
materials or being responsible for the bending in some way that does not involve programmable
controls.

Manual is the opposite of power or Computer Numerical Control or CNC. These machines are
computerized control systems. By punching in data and other pertinent information, they perform
the bending or other processes automatically in a specified fashion or pattern.

Dedicated is the opposite of versatile. It indicates the system is committed to one specific type of
bending. It will only perform its function in this one manner. It cannot, for example, in the case
of metal tubes, be adjusted to accept any other shape.

Manual tools of various types can be automated. Metal bending tools, even dedicated ones, can
comply with CNC controls to produce a hybrid or a fully automated bending machine. Yet, while
this may seem a good option, it may not always be the best one. Dedicated manual bending metal
equipment does have advantages over its automated counterparts including:

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A Fast Setup: As is the case with all setups, experience with the machinery will improve the
setup time over time. Familiarity with the machine and the process will increase setup time and
result in faster cycle times than initially

Rapid Cycle Times – often actually faster than CNC benders, although such factors as shape
complexity may reduce the disparity between the two piece of equipment somewhat

Consistency – the parts produced and reproduced are consistent in quality and shape

Training – the dedicated manual machines are easy to operate. Except for a few minor issues, a
company can instruct and train an operator with ease fairly quickly

As is the case with any piece of equipment, automated or not, much depends upon the
capabilities of the operator or the individual behind coordinating and putting in the data.

Metal Bending Tools

While companies tend to see automation and computerization as the way to go to increase
production, this is not always the case. CNC equipment is not always capable of providing the
right type of bends. Such machinery may not even be able to complete them in the way
demanded. When this occurs, the only means of providing the perfect bend is to use manual
finish-up metal bending tools.

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1.3 objective

This project is developed to study about the automation in process of pipe bending industries.
Mainly preferable for small industries. The main purpose of this project are listed below:
•To increase the accuracy of product.

•To reduce the man effort.

•To reduce the time consumption.

•To reduce the material waste compare of the manual pipe bending

•Less Machine setup time is required

•To produce uneven shaped bend pipes or products.

1.3.1 General objective

Manual pipe benders are a popular choice for worksites where access to electrical power is
unavailable or in locations where mobility is needed. The main objective of a pipe bender is to
bend the pipe without any buckling (collapsing under pressure), and with as little crimping and
flattening as possible.

1.3.2 specific objective

– Pipe bending machine used to bend various types of pipes such as pipes, aluminum pipes,
stainless steel and copper pipes.
– Helps people to bend a lot.
– The degree of bending accuracy. Can be bent as desired.
– The work is seamless.
– Easy to use due to its simple operation.
– whole set Portable bag carrying portable.
– Reduce the cost of work. Because the pipe bender is a hand strap is cheaper than an electric
pipe bender. It also reduces fuel consumption in the work.
– Hand-bending pipe bending machine can bend steel 10-25 mm.

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1.4 Methodology
This link below is an animated explanation : 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, catia for plotting, and catia 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 1100birr which is less expensive than the automated counterpart which costs on at least
3000birr.

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1.5 Scopes of manuale pipe bender
Induction pipe bending machine can not only bending small radius, but also for bending large
diameter steel pipe, can bending large radius of steel pipe, Square tube, angle steel, Channel steel
and other profiles, for building and bridge etc. Induction pipe bending machine adopts
continuous heating to ensure bending the steel pipe with high precision, accurate bending
radius, low elliptical of pipe section, is now one of the indispensable pipe equipment in industry
field now.

Induction bending machine and pipe bending machine have advantages and disadvantages,
induction pipe bending machine is mainly suitable for large diameter and large wall thickness
pipe bending, bend simmer pipe bending machine is mainly suitable for small diameter and small
wall thickness of steel pipe for bending.

1.6 limitation of manual pipe bender

Often, in the bending and rolling industry, we see requests which push the limitations of tube
bending. This can occur in both large and small pieces. Sometimes a project may have been
designed without considering the physical effects curving has on the material. In these cases,
design plans can occasionally be evaluated and modified with the knowledge of an experienced
steel bender.

One of the most common examples in tube bending where material shape and size needs to be
evaluated is tube cross-section deformation. If you were to be rolling flat material to form a
cylinder, the plate rollers are designed to sandwich the material between the rolls, completely
and evenly supporting all material under the same stress levels. Even when curving angles,
rolling equipment can use dies of different shapes in order to brace the material on the interior
and exterior faces, so that pressure is applied evenly. However, when rolling a tube or pipe, the
fixed bending dies of the rolling equipment can only form around and support the exterior of the
material. This leaves the center of the tube open, and more vulnerable to deformation due to
uneven pressure. Tubes can experience concavity, or even changes in overall height or width on
particularly difficult bends.

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Chapter Two

2 Litrature reviw
[1] Akbar H KhanEt.al

This paper gives information about newly designed and developed manual pipe bending
machine. It states that the
machine can bend pipes of various thicknesses. These bent pipes have large applications in
industries. It summarises
the information about construction of pipe bending machine. The machine is able to bend pipes
into distinct angles
also in curve shape. The machine size is so convenient that it can be easily transported according
to need. The
material used for machine is steel. It doesn’t require highly skilled operator. This machine works
with the help of
gear, die and frame.
[2]e purpose of this paper is to construct pipe bending machine which can easily do pipe
bending operation in
industry as well as at workshops. The main objectives of this machine are it should be affordable
even for small
scale industry, that is the investing cost should be as low as possible. The mechanism used for
the machine is kept
simple instead of complicated one. Pipes with 4 to 5mm thickness can be bent easily with the
help of this machine.
The bent pipes can be used in industries as well as in small workshops. The machine reduces the
human efforts.

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[3]Łukasz WargułaEt.al
This paper examines the dynamic characteristics of a 3 PH induction motor. The results we get
from examination
will further used for examine the capability stepper motor as actuator. It describes various
characteristics of stepper
motor. It includes the construction and working of motor. It also includes various applications of
motor and possible
usage of motor in different regions.

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Chaptere Three

Embodiment design

The diameter of pipe (Dp) is 50mm. The material selected for the roller is Case hardened steel. For fewer defects in
bending take roller diameter 3 times pipe diameter and small roller diameter 3times pipe diameter

V. Thorave Rohit; International Journal of Advance Research, Ideas and Innovations in Technology

So
Big Roller diameter = 150 mm
Small Roller diameter =145mm

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design of Clamp dimensions are

Design of seport plate

Clamp dimensions are,

Width (w) = 300mm
Height (h) = 30 mm
Length (l) = 300 mm
Circular groove radius (r) = 45 mm

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Design of bolte and nete

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Chapter 4 Cost analysis

No Name Quantity cost

1 Base plate 1 1000Birr
2 Small rolling die 1 200Birr
3 Large rolling die 1 300Birr
4 Rolling handle 1 600Birr
5 Bolt and nets 1 50Birr
6 Total 5 2150Birr

Chapter 5

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Result and discussion

Our simple manual Pipe Bender is the backbone of our tube and profile bending machines.
Their rigidity, stability and untouchable precision in exceptional conditions such as humidity or
harsh temperatures is what makes them stand out from the crowd.

Ranging from 10mm up to 420mm OD these pipe bending machines are adapt for use in a wide
range of pipe manufacturing sectors and industries.

The range includes the fully manual pipe bender version, for wich all three axis are automatic in
a single stack machine. There’s also the option to add welding detection, punching/cutting
mechanisms and integrated loading and unloading systems if necessary.

The simple manual tube bending machine come equipped with the AMOB NC touch screen
easy-to-operate controls, or in the CNC version, the latest user-friendly AMOB 3D bending
software.

So, this stores tooling configuration, allows spring-back compensation and boasts anti-collision
technology, amongst other features.

These multi-faceted models are easy to operate and suitable for almost all types of applications
and industries.

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Chapter 6

conclusion and recommendation

6.1 conclusions

The project design and fabrication work completed successfully. After experimentation on the machine we conclude
that we can perform both pipe bending and pipe rolling operation on this machine (one operation at a time). Machine
uses single power source i.e. three phase motor which reduced the capital cost of the machine. The setup change
required for performing operations which is quite easy. The machine is capable of bending and rolling off only 19
mm diameter pipe, however, the pipe used during test is of mild steel, therefore, we can conclude that the pipes of a
softer material than mild steel can also be bend using this machine.

6.2 recommendations

Recommendation is 3 to 4 times the OD of the tube or pipe. A Tube-Mac high quality bender
will help make the job easier, reduce the time to complete and reduce scrap as the Tube-Mac
Tube Benders are designed for just this purpose.

Chapter 7 Reference

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•Books Reference
•Manufacturing engineering and Technology By Serope Kalpakjian

•Metal Forming Technology and Process Modeling By Uday S. Dixit

•Fluid Mechanics and Hydraulic Machines By R.K.Rajput

•Fluid Mechanics and Hydraulic Machines By Dr. R.K.Bansal

•Mechanics Of Material By Dr. B.C.Punmia

•Machine Design By Dr. P. C. Sharma

References Of Research Papers

•Final Working of Rolling Pipe Bending Machine ISSN : 2249-5770
•EXPERIMENTAL DESIGN AND FABRICATION OF A PORTABLE HYDRAULIC PIPE
BENDING
•MACHINE ISSN: 2230-9926
•Design of a Hydraulic Pipe Bending Machine FPL−GTR−148

Appendices

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Extra information

Rigidity, stability and precision is what makes them stand out from the crowd! Easy to operate and
suitable for almost types of applications and industries! Know more!

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