TOPIC: DESIGN AND FABRICATION OF AN AUTOMATIC SPRING ROLLING

MACHINE

CHAPTER 1 : General Introduction

Spring rolling industry is a large and growing industrial. There are many special purposes

machines used in this industry today. The proper selections of the machines depends upon the

type of the work undertaking by the particular industry. There are many examples of springs,

which can be seen in our everyday lives. The metals generally used for spring rolling working

include; iron, copper, tin, aluminum, stainless steel and brass. Our project the (SRING

ROLLING MACHINE ) finds huge applications in all spring rolling industry. Rolling is the

process of bending metal wire to a curve form. The article in the shape of round is made by the

spring roller shaft. Rolling operation can be done on hand or power operated rolling machines. In

forming round spring shapes, a gradual curve is to be put in the metal rather than sharp bends.

The gap between the spring can be regulated by proper arrangement. The lock nut is used to

fixing the spring wire to the rolling shaft. The spring wire is supplied by a tare. This tare is fixed

to the stand by two end bearings. The is rotated freely during the time of spring rolling operation.

The single phase induction motor is couple with the spur gear arrangement by pulleys. The motor

is rotated by switching on the power supply of the single phase. The spur gear is rotated due to

the rotation of the motor. The spur gear is couple with the main shaft by bearing.

The aim of this study is to develop and realize an automatic spring rolling machine in other to

produce coil springs of different length. As compared to other spring rolling machines that are

manually operated, the automatic spring rolling machine is relatively simple in design as we

shall see.

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On the subsequent part of this document, we are going to briefly discuss on the following.

A. Statement of the problem.

B. Objectives of the predicting and analyzing the realization of an automatic. spring

rolling machine.

C. Research questions.

D. Research hypotheses.

E. Research methodology.

F. Technical difficulties.

G. Human and analytical difficulties.

H. Economic and commercial difficulties.

I. Lastly expected results.

1. The statement of the problem

Ahmed Ktari:-In his paper he has done Modeling and computation of the three-roller bending

process of steel sheets. This experiment consists of two-dimensional finite element model of this

process was built under the Abaqus /Explicit environment based on the solution of several key

techniques, such as contact boundary condition treatment, material property definition, meshing

technique, and so on.

P.G. Mehar:- In his M. Tech Thesis studied the manually operated and power operated sheet

bending machine. Experimentations were conducted on sheet in order to measure actual number

of passes, time required to complete bending process etc. Also, productivity of sheet bending

process is analyzed in depth. Design of various components of power operated sheet bending

machine considering various theories of failure in elastic region and values for bending force,

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power required, spring back radius etc. for different diameters, thicknesses and width of sheet

metal has been determined. Base on the analysis, some advisory lesson can be learned to help

improve on spring rolling machine performance.

2. Objectives

 To produce coil springs which are been use in coil spring clutches at low cost

 to produce springs that can be use in science laboratories(physics) which can be used for

simple harmonic and oscillating experiments.

 To produce coil spring which are used in between brake shoes as return springs.

 Improve on the efficiency production of coil spring.

 To satisfy the market demands.

3. Research Questions

A) what are the rubbing friction parameters at the level of the motor

 At the level of the gear assembly

 At the level of the pulleys

 How is friction avoided at level of the spring rolling shaft

B) How does the graph of this parameters above for the various level looks like?

C) What are the various difficulties faced by the automatic spring rolling machine manufacturers

in reducing the rubbing friction values?

D) How can the parameters contributing to high rubbing friction be modified to reduce this

friction and the implication on motor performance and electrical economy.

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E) How does the new graph after modification of the parameters looks like and how can we

analyze the data , use it to predict other rubbing friction values?

4. Research Hypothesis

a) The gears and the rolling shaft bearing increase linearly with the motor speed, while the

rolling shaft and the spring pressure decreases with the motor speed.

b) component loses all increase with the motor speed except that of the gear train.

c) At higher speed, the majority of the friction is from the rolling shaft bearing because it design

to support the axial trust force originating from the rotation of the motor which increases the

speed of the motor.

5. Research methodology

In this research, we shall collect, analyze and predict performance from data gotten from the

automatic spring rolling machine.

6. Technical difficulties

The lubricating oil and tools used for the analysis will be carefully chosen to make sure that the

results can be generalized to a variety of automatic spring rolling machine using current as a

source of energy to operate.

7. Human and analytical difficulties

Some of these difficulties are:

 Perfect use of instruments.

 Considering all speed of the motor when collecting data.

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  The vibration and the noise produce

 The present state of the motor

8. Economic and commercial difficulties

The collection, analysis and prediction of frictional loses and performance automatic spring

rolling machine will be costly because of the following:

 Renting of automatic spring rolling machine using electricity

 Replacing the lubrication oil with multi grades for a period of time.

 Renting the instrument needed for collection of data like the dynamometer.

 Interpretation of data.

9. Expected results

At the end of this research, I hope and desire that all my objectives be made. Its my wish also

that the findings of this research be useful to but the machine users and manufacturers to improve

on their satisfaction.

10. Conclusion

This is my thesis titled: (DESIGN AND FABRICATION OF AN AUTOMATIC SPRING

ROLIING MACHINE) I have as an objective to collect and analyze data that must be capable

of meeting all specific objectives mention above

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 TABLE OF NOMENCLATURE

NO PARTS MATERIALS COST

1 MOTO MOTOR STEEL BUT WILL BE RENTED

R HOUSING FOR AN ESTIMATED

STATOR COPPER PRICE OF 40000frs
ROTOR A PERMANENT
BUT THE COST PRICE IS
MAGNET WOUNDED
215,400frs
WITH COPPER

ARROUND IT
2 THE PULLEYS ALLUMINIUM ALLOY 35000frs A SET

3 SPUR GEARS BRASS OR BRONZE 80,776frs A SET

4 THE ROLLING CAST IRON 25000FRS

SHAFT
5 THE BEARINGS STAINLLES STEEL 1000frs/PIECE
6 THE HOUSING OR STEEL IRON 30000frs

THE STAND
7 COIL SPRINGS COPPER, STAINLESS 4000FRS

STEEL
Estimated total = 218775frs

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