Professional Documents
Culture Documents
Project Report On
Submitted By
HARSHDEEP SINGH
INAYATULLAH FAROOQUI
Under the guidance of
Prof. ALVI
Mr. H. Vishwakarma
Submitted as a partial fulfillment of
Bachelor of Engineering
B.E. (Semester VIII), MECHANICAL
[2013 - 2014]
from
Affiliated to
University of Mumbai
CERTIFICATE
This is certify that the project report entitled
“Title of the Project”
Submitted By
HARSHDEEP SINGH
INAYATULLAH FAROOQUI
of Rizvi College of Engineering, MECHANICAL has been approved in partial fulfillment of require-
ment for the degree of Bachelor of Engineering.
Date:
Acknowledgement
I am profoundly grateful to Prof. Alvi for his expert guidance and continuous encouragement
throughout to see that this project rights its target since its commencement to its completion.
I would like to express deepest appreciation towards Dr. Varsha Shah, Principal RCOE, Mumbai and
Prof. Hussain, HoD MECHANICAL whose invaluable guidance supported me in completing this
project.
I am particularly grateful to Mr. H. Vishwakarma (BISHNU AND CO.) who allows me to work in the
company.
At last I must express my sincere heartfelt gratitude to all the staff members of MECHANICAL who
helped me directly or indirectly during this course of work.
HARSHDEEP SINGH
INAYATULLAH FAROOQUI
ABSTRACT
The component that can be manufactured using 3-roller bar bending machine are circular washer having
internal radius more than 150mm, circular collars, component used for balancing of wind tower assem-
bly, high stiffness spiral spring, etc. For parametric specification of 3-point bar bending machine, it is
necessary to analyze the stress induced in rollers and gear teeth radial force. Thus Finite element mod-
eling is necessary and suitable software must be selected for analysis and observation.There are many
useful software are available in the market like ANSYS V-13, LS DYNA, ABAQUS and soon. Hence the
3-point bending machine consists of number of individual parts which to be model and assembled. The
AUTODESK INVENTOR professional 2013 is best suitable for modeling of this machine (AUTODESK
provides ease of man-machine interface, mating of parts both transitional to rotational, constrain edge-
surface etc.). It also assists for part detailing and presentation.The finite element analysis is carried out
using ABAQUS 6.10 for solving stress distribution across the rolling rollers with billet displacement of
67mm, stress distribution with roller rotation, Gear drive analyses for minimum load case without billet
and Gear drive analyses for maximum load case with billet thickness. It also requires the gear train
mechanism with the motor to drive roller, to transfer torque to overcome the vertical load acting during
operation, and speed reduction for ease bending & rolling process. Thus analysis of load acting on the
gear tooth is necessary to set the minimum inside radius of roll for 3-roller bending machine.
Keywords :Bar Bending Machine, Autodesk Inventor, Hyper Mesh, Abacus 6.1, Stress Analysis, and
Spur Gear
Contents
1 Introduction 1
1.1 PROBLEM DEFINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 LITERATURE REVIEW 3
3 PROCESS OF ROLLING 4
5 A Design process 12
5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.0.2 Concept of Iteration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.0.3 Definition Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.0.4 Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.0.5 Preliminary stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.0.6 Manually operated pipe bending machine . . . . . . . . . . . . . . . . . . . . . 15
6 Lead screw 17
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2 Design for Lead Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.3 Assumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.4 POWER SCREW FORCE AND TORQUE ANALYSIS . . . . . . . . . . . . . . . . . . 18
6.5 INSIGHT OF THREAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.5.1 DETERMINATION OF THE FORCES WHICH ARE ACTING . . . . . . . . 18
6.6 STRESS IN THREAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.6.1 Axial Stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.6.2 Shear stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.6.3 TORSIONAL STRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.7 MANUFACTURING FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.7.1 THREAD ROLLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.7.2 ADVANTAGE OF ROLLING V/S CUTTING . . . . . . . . . . . . . . . . . . 21
6.7.3 HEAD FORMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.7.4 STRENGTH OF STANDARD BOLTS . . . . . . . . . . . . . . . . . . . . . . 22
7 GEAR 23
7.1 INTRODUCTION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.2 GEAR NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.3 GEAR TOOTH THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.4 FUNDAMENTAL LAW OF GEARING . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.5 The Involute Tooth Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.6 Mesh Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.7 Changing Center Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.8 DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.8.1 Assumptions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.8.2 Virtual Number of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.9 Lubrication in gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.10 Manufacturing of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.10.1 Forming Gear Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.10.2 Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.10.3 Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.10.4 Roughing Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.10.5 Finishing Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8 Bearing 30
8.1 Material Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.2 Thrust Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.3 Bearing Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10 Coupling 37
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10.2 Rigid flange coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
13 Modelling 46
13.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
References 52
APPENDICES 52
A Project Hosting 53
List of Figures
Chapter 1
Introduction
It has been seen that the 3-roller bending machines are widely using in many industries for many different
applications such as, sheets are bent and roll to form a shell like structure which are used in pipe line.
I & L channel are bending to a required angle used to form structural stress (roofing) in construction
industries. Some of them are used for conical bending which are costly to produce using conventional
machines. As discussed above the two rollers A & B are connected to the shaft and are driven by the
gears, each rollers are interconnected by individual gear having same number of teeth on it to facilitate
same rotary motion to it. For construction of various structures as well as integral part of machines
various cylindrical sections are widely used. Such cylindrical sections are manufactured by various
methods and 3-roller conical bending process is one such process. It consists of two bottom rollers and a
top roller. Metal plates with specified contours are rolled without decrease in thickness to get the desired
cone angle. The plate undergoes plastic deformation and it is cold forming process and hence it has
higher. Dimensional accuracy. 3-roller shell bending process has four stages:
1. static bending,
2. forward rolling,
3. backward rolling, and
4. unloading.
The motor used here to generate a required torque consists of 7.5 HP with 960 rpm of speed. We know
that thisspeed cannot be used directly as a output speed and the torque obtain from this motor is also
very less, so tomanipulate the value of torque and to reduce the input speed on to the roller A&B a
proper gear train is necessary. Thisgear train is properly designed and used in this 3-roller bar bending
machine.A component for balancing of wind blades & wind tower assembly can easily mass produced
by the application of3-point bar bending machine. A unique process for manufacturing the above circu-
lar component is divided into 3 steps(clearly explained in component chapter). It was estimated that the
processing speed for manufacturing this component by3-point bar bending machine can greatly advance
by the amount of around 30 to 40% than that of using conventionalmachine. Although the use of raw
material for above manufacturing purposes is minimized up to 35-55%both conditionwill sets the com-
ponent MRP with lesser cost. This idea brought the Bishnu and co. to process the abovecomponent by
using 3-roller bar bending machine.
By visualizing the figure we can state that the load acting on the above roller is more than the roller
acting as a resistance to bend (A & B).
Chapter 2
LITERATURE REVIEW
Himanshu:
Himanshuhas done bendability analysis for bending of steel plates on heavy duty 3-roller bendingma-
chine. In this experiment they found out the equivalent thickness, equivalent width and maximum width
analytically &based on power law material model.
Ahmed Ktari:
have 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 treat-
ment, material property definition, meshing technique, and so on.
Jong GyeShin:
has done the experiment on Mechanics-Based Determination of the Center RollerDisplacement in Three-
Roll Bending for Smoothly Curved Rectangular Plates. The objective of this paper is to develop a log-
ical procedure to determine the center roller displacement, in the three-roll bending process, which is
required in the fabrication of curved rectangular plates with a desired curvature.
M K Chudasama:
have done the experiment on Analytical Model for Prediction of Force during 3-RollerMulti-pass Con-
ical Bending. In this paper, the total deflection of the top roller required is divided in steps to get the
multipassbending.
M. B. Bassett, and W. Johnson:
The bending of plate using a three rollpyramid type plate bending machine, J. strain Analysis
Processmanual, maintenance manual, machine capacity chart and technical specification of rolling-
machine,M/s Larsen& Toubro ltd,Hazira, Surat, India.
Chapter 3
PROCESS OF ROLLING
In the first stage the plate is kept between top roller and bottom rollers as shown in Figure and the top
roller is given vertical displacement to get the required bend. In next stage the bottom rollers are driven
using motors in forward direction to get the roll bending of the plate. Similarly the rollers are driven in
reverse direction to get better dimensional accuracy of the final product. The bent plate is than unloaded
by raising the top roller. For continuous single-pass four roll thin plate bending a model was proposed
considering the equilibrium of the internal and external bending moment at and about the plate-top roll
contact. They had considered varying radius of curvature for the plate between the rollers and proposed
a mathematical model to simulate the mechanics in a steady continuous bending mode for four-roll thin
plate bending process and also investigated Influence of material strain hardening on the mechanics of
steady continuous roll and edge-bending mode in the four-roll plate bending process For continuous
multi-pass bending of cylinder on 3-roller bending machines with non compatible (cylindrical) rollers,
Gandhi et al. had reported the formulation of spring back and machine setting parameters They incor-
porated the effect of change of flexural modulus during the deformation in the formulation to study the
effect on spring back prediction. For plane strain flow of sheet metal subjected to strain rate effects
during cyclic bending under tension He also included
Bauschinger factors in the model for stress reversal. The roll bending process is used for years, it can
be observed from the literature reviewed that conical bending process is untouched area as far as force
prediction is concerned. Even in the industries the normal practice of plate roller bending still heavily
depends uponthe experience and the skill of the operator. Working to templates, or by trial and error.
Chapter 4
The working by bending of work-pieces creates inner of this in deformed zone stresses in tangential
and radial directions. The metal strata placed to curving center are pressed in tangential directions,
becoming shorter and in especially cases are stretchingin transversal direction. The metal strata placed
to external piece are stretching in tangential direction and in especially cases are pressed in transversal
direction, making the piece narrowing. Between the stretching and pressing strata is founded the neutral
stratus M-N . The neutral status with the radius nis founding displaced to the curving center before the
weight center, what is placed on the median arc with radius m. The radius value where the tangential
direction stresses are null and is not produced the deformation in tangential direction is determined by
the following relation.
Practically, it is considered that the neutralstratus position coincides with the medianstratus with
nradius when the relativeradius bending has the value.
radial stresses by pressing notproduce resistant moment in bending process.This requests the work-piece
material atradial direction compression in bending zonewith maximum 10% of material flowingstress
cvalue.Because the sheet metal bending on machineswith rollers is making with relative radiusr/smuch
more than 5 value, it can consider thattransversal section, while the broad workpiecesis take place with
a very little breadthdeformation, because the great work pieceresistance deformation opposed the neu-
tral stratus coincides with the medialstratus If it is approximated the real coldhardening characteristic
of material atrequirement in tangential direction with alinear curve, correspondently figure the realtan-
gential stress can be determinate byrelation Or, if we consider the geometry of bending If the bended
work-piece has the sectionb x s and is bending on median stratus with mradius, the inner forces moment
M,according in figure 3, can be definite byrelation
In relation (7), the double of first integralrepresent the transversal section staticallymoment S, and
the double of second integralis the transversal section inertial moment . Thus, relation can be written
If it take account thatS/Wfrom relationis a section characteristic and is noted K1, and is a physics
and material characteristic and is noted K2, the relation (9) become The coefficient K1, because depend
onlyby geometrical transversal section form canbe named the profile coefficient.The coefficient K2 ex-
press coldhardening intensity of plastic banded material,can be named strengthening coefficient.
Taking account figure 5, the mechanical workof inner forces Li, for plastic bending of the work-piece
size Lscan be determined byrelation
The inner moment value creates theCurvier a current section betweensection can be calculate witrelation
, what become:
Replacing the My relation in relation andmaking calculus, it is obtained:
Taking account by the moment make at thebending on roller, relation (13) can be written thus:
Taking account by the moment make at thebending on roller, relation (13) can be writtenthus:
where Mt is defined by relation (21) in Nm;Mf friction moment necessary for defeatingrolling fric-
tion resistance between rollers and work-piece and rollers bearings in Nm; tangentialperipheral speed of
rollers, in transmission efficiency from electricmotor to rollers.
Figure 4.6: Scheme of positioning rollers with three and four symmetrical rollers.
Chapter 5
A Design process
5.0.1 Introduction
The notion of useful work is basic to machines functioning, as there is always some energy transfer
involved . The mention of forces and motion is critical to our concern as in converting energy from one
form to another , machine creates motion and develop forces . it is engineers task to define and calculate
those motion , forces and changes in the energy in order to determine the size shape and material needed
for each of the interrelated parts of the machine.
The goal in machine design is to size and shape the parts(machine elements) and choose the appro-
priate material for manufacturing process so that machine is expected to perform its intended function
without failure .In this design project there is negligible acceleration so static force analysis will be
suffice . Static force analysis deals with structure which are to be designed against failure to external
loading. The process of design is essentially an exercise in applied creativity. Various design process
have been defined to help organize to attack upon un-constructed problem definition is vague for which
many solution exist .some of this design process as shown below consist of 10 steps but can be extended
to 25 steps.
• Identification of need
• Background research
• Goal statement
• Task specification
• Synthesis
• Analysis
• Selection
• Detailed design
• Prototyping and testing
• Production
The initial step is Identification of need, usually consist of an ill defined and vague problem statement.
The development of the Back ground Research is necessary to fully define and understand the problem
after which it is possible to re state the goal in a more reasonable and realistic way than the original
problem statement. Step (4) calls for the creation of detailed set of task specification which bound the
problem and limit the scope .The synthesis step (5) is the one in which as many alternative possible
design approaches are sought , usually without regards of quality and value .We can also state this step
as ideation and invention step in which largest number of creative solution are generated.
In step (6) the solution of the previous steps are analyzed and they are accepted , rejected and modified
. the most promising solution is selected at step 7 once the acceptable design are filtered and once
the way is finalised then the Detailed design is done where all the loose ends are tied up complete
engineering drawing is made , vendors are identified and manufacturing specification is defined . The
actual construction of the working design is first done as a proto type in step (9)anfinally in quantity in
production at step (10)
5.0.4 Assumptions
• Plate is always having line contact with the roller which is parallel to roller axis during the process.
• The forces acting during the bending are larger than the self weight of the plate. So theself weight
of the plate is neglected.
• The shift of the neutral plane is zero, i.e., it is considered to be at the center line of the plate
thickness.
• Frictional force at the bottom roller and the plate interface is always tangent to the roller surface.
• Rollers are assumed to be rigid. Roller material and plate material is assumed to have stable
microstructure throughout the deformation process.
• Deformation occurs under isothermal conditions and E, i.e., Modulus of Elasticity Remains con-
stant during the process.
• Plane section remains plane, before and after the bending. Blank thickness (t) remains constant
during and after the bending.
• Baushinger effect is neglected. Blank is having uniform/constant radius of curvature for the sup-
ported length of the blank between two bottom rollers.
• Further simplifying assumptions are discussed as and when required during the Formulation.
Chapter 6
Lead screw
6.1 Introduction
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.
6.3 Assumption
• Type of thread i] Square thread
• Dimensions do = 55
• 2 TPI let us select fine thread as they are more resistant to vibration and this is due to the fact that
the helix angle in this case is small than the course thread from P.S.G. pg. no. 5.69 we get for do =
55 mm we get minor
• dia as 52 So,
• Pitch circle dia = = 53.
• Determination of the pitch P We know that the thread is configured with 2 TPI So Pitch = 9
• Now for square thread hl = 0.5 P a = 0.25 r = 0.12 H = hi + a = 1.25
The above fig. shows the free body diagram of the same nut as it slides up and down.
Here we can see the friction force, that will always oppose motion.
Now,
The screw torque Ts required to lift the load is
we can also express the above equation in the form of lead L rather than the screw torque is not only
the sole contribution to the torque, but the thrust collar also contribute a friction torque.
But in our case we do not have the thrust bearing so it want play any role in the calculation of torque.
The true stress will be between these values. Most likely to come closer to one thread value.
In any event we must assume degree of load sharing among the threads in order to calculate the stress.
One approach is to consider that since complete failure requires the thread to strip all can be considered
to share the load equally. This is probably a good assumption as long as nut or the screw is ductile to
allow each thread to yield as the same assembly begins to fail. However if both the parts are brittle as in
our case and the thread is poor one can envision each thread taking the entire load until it factures and
passes the job to the another thread.
Again the reality is between both the ends. If we could express the shear area in terms of number of
thread then we could define the degree of load sharing.
Striping area at minor diameter
d1 = minor dia
w1 = Factor defining % of pitch occupied by metal at minor diameter.
P = pitch
striping area at major diameter
Thread rolling should be done after hardening the bolt, IF POSSIBLE, as thermal hardening process
will relieve the desirable stress introduced by rolling.
The shank of the bolt to be gripped tightly in the cold heading machine with appropriate length stick-
ing out. A die of desired head diameter surrounds this exposed end when the hammer comes down, it
cold flows the material into the round head. IF POSSIBLE Heat & Treatment should be done.
Chapter 7
GEAR
7.1 INTRODUCTION:
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.
shows two teeth of a gear with the standard nomenclature defined. The tooth height is defined by the
addendum (added on) and the dedendum (subtracted from), which are referenced to the nominal pitch
circle. The dedendum is slightly larger than the addendum to provide a small amount of clearance
between the tip of one mating tooth (addendum circle) and the bottom of the tooth space of the other
(dedendum circle). The tooth thickness is measured at the pitch circle. and the tooth space width is
slightly larger than the tooth thickness. The difference between these two dimensions is the backlash.
The face width of the tooth is measured along the axis of the gear. The circular pitch is the arc length
along the pitch circle circumference measured from a point on one tooth to the same point on the next.
The circular pitch defines the tooth size. The definition of circular pitch Pc.
gearing, which states that the angular velocity ratio between the gears of a gearset must remain constant
throughout the mesh. The angular velocity ratio mv is equal to the ratio of the pitch radius of the input
gear to that of the out gear.
• A tangent to the involute is always normal to the string, which is the instantaneous radius of curva-
ture of the involute curve.
Figure shows two involutes on separate cylinders in contact or in mesh. These represent gear teeth.
The cylinders from which the strings are unwrapped are called the base circles of the respective gears.
Note that the base circles are necessarily smaller than the pitch circles, which are at the radii of the orig-
inal rolling cylinders, rp and rg. The gear tooth must project both below and above the rolling-cylinders
surface (pitch circle), and the involute only exists outside of the base circle. The amount of tooth that
sticks out above the pitch circle is the addendum, shown as ap and ag for pinion and gear, respectively.
These are equal for standard, full-depth gear teeth.
There is a common tangent to both involute tooth curves at the contact point, and a common normal,
perpendicular to the common tangent. Note that the common normal is, in fact, the strings of both in-
volutes, which are collinear. Thus the common normal, which is also the line of action, always passes
through the pitch point regardless of where in the mesh the two tooth are contacting. The pitch point has
the same linear velocity in both pinion and gear, called the pitch-line velocity. The angle between the
line of action and the velocity vector is the pressure angle .
If the gear tooth form is not an involute, then an error in center distance will cause ripple, in the output
velocity. The output angular velocity will then not be constant for a constant input velocity, violating the
fundamental law of gearing. However, with an involute tooth form, center-distance errors do not affect
the velocity ratio. This is the principal advantage of the involute over all other possible tooth forms and
is the reason why it is nearly universally used for gear teeth. Figure shows what happens when the center
distance is varied on an involute gearset. Note that the common normal still goes through the pitch point,
and also through all contact points within the mesh. Only the pressure angle is affected by the change in
center distance.
7.8 DESIGN
Since we have reverse gear meshing so we use helical gear as they are quite and dont make noise as
parallel Helical gears mesh with the combination of rolling and sliding with the contact starting at the
one end and whipping at the another across its face width.
• Power to be transmitted Pm = 10 Hp
• Input speed to the pinion = 15 rpm
• Output speed desired = 4 rps
• Assume helix angle B1 = B2 = 170
• Pressure angle = 200 for involute profile
• Velocity ratio = i = 3.5
7.8.1 Assumptions:
Let us take tooth profile as n = 200 full depth
Gear Quality we have selected prevision cut gears to control dynamic load and wear
Type of gear standard Sn gear has been selected
Helix angle
For1 Pinion Right Hand Helix
B1 = 170
For Gear Left Hand Helix
B2 = 170
7.10.2 Casting
Teeth can be sand cast or die cast in various metals. The advantage is low cost, as the tooth shape is built
into the mold. No finishing operations on the teeth are typically done after casting, though they could
be.
7.10.3 Machining
The bulk of metal gears used to transmit power in machinery are made by a machining process from cast,
forged, or hot-rolled blanks. Roughing processes include milling the tooth shape with formed cutters or
generating the shape with a rack cutter, a shaper cutter, or a hob. Finishing processes include shaving,
burnishing, lapping, honing, or grinding. Each of these methods will be briefly described.
Chapter 8
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.
Figure shows a nut and lock-washer arrangements used to clamp the inner ring to the shaft to avoid
a press fit. Bearing manufacturers supply special nuts and washers standardized to fit their bearings.
Figure (b) shows a snap ring used to axially located the inner ring, which would be pressed to the shaft.
Figure (c) shows the outer ring clamped axially to the housing and the inner ring located by a sleeve
spacer between the inner ring and an external accessory flange on the same shaft.
Chapter 9
The term shaft usually refer to rotating machine element, circular in cross section, which supports trans-
mission element like gear, pulley and sprocket and transmit power. The shaft is always stepped with
maximum diameter in the middle portion and minimum dia at two ends. Shafts are given specific names
in typical application although all application involve transmission of power motion and torque. Ordi-
nary transmission shafts are made up of medium carbon steel with the carbon content from 0.15 to 6.40
such as 3068 and 4068 these steels are commonly called machinery steel for the purpose where greater
strength is required high carbon steel 45 c8 and 50 c8 alloy steels are also provided for the same purpose
16 Mn 5cr4. Alloy steels are costly compared to plane carbon steel but serves the purpose when it comes
to strength, hardness and toughness, they also serve high resistance so corrosion as compare to plane
carbon steel so the increase in the price of the same is justified.
in Figure, which also shows a collection of features commonly used to attach or locate elements on a
shaft. Steps or shoulders are necessary to provide accurate and consistent axial location of the attached
elements as well as to create the proper diameter to fit standard parts such as bearings.
Keys, are often used to secure attached elements to the shaft in order to transmit the required torque
or to capture the part axially. Keys require a groove in both shaft and part and may need a setscrew to
prevent axial motion. Snap rings groove the shaft, and cross-pins create a hole through the shaft. Each
of these changes in contour will contribute some stress concentration and this must be accounted for in
the fatigue-stress calculations for the shaft.
that shown in Figure 4-38c. Another common source of stress concentration is a key needed to torque-
couple gears, pulleys, fly-wheels, etc. to a shaft. The keyway groove creates sharp corners at location of
maximum bending and torsional stresses. Different key styles are available, the most common being the
square key and the circular-segment. Woodruff key as shown in Figures 4-38b and 4-38c.
Another example of removing material to reduce stress concentration (not shown) is the reduction of
the unthreaded portion of a bolt shanks diameter to a dimension less than that of the root diameter of the
thread. Since the thread contours create large stress concentrations, the strategy is to keep the force-flow
lines within the solid (unthreaded) portion of the bolt.
6. Deflections at gears carried on the shaft should not exceed about 0.005 in and the relative slope be-
tween the gear axes should be less than about 0.03O
7. If plain (sleeve) bearings are used, the shaft deflection across the bearing lenth should be less than the
oil-film thickness in the bearing
8. If non-self-aligning rolling element bearings are used, the shafts slope at the bearings should be kept
to less than about 0.04
9. If axial thrust loads are present, they should be taken to ground through a single thrust bearing per
load direction. Do not split axial loads between thrust bearings, as thermal expansion of the shaft can
overload the bearings.
10. The first natural frequency of the shaft should be at least three times the highest forcing frequency
expected in service, and preferably much more. (A factor of 10x or more is preferred, but this is often
difficult to achieve in mechanical systems.
Chapter 10
Coupling
10.1 Introduction
A coupling can be defined as a mechanical device that permanently joins two rotating shafts to each
other. The most common application of coupling is joining of shafts of two separately built or purchased
units so that a new machine can be formed. There is a basic difference between a coupling and a clutch
can connect or disconnect two shafts at the will of the operator.
A wide variety of commercial shaft couplings are available, ranging from simple keyed, rigid cou-
plings to elaborate designs that utilize gears, elastomers, or fluids to transmit the torque from one shaft to
another or to other devices in the presence of various types of misalignment. Couplings can be roughly
divided into two categories, rigid and complaint. Compliant in this context means that the coupling can
absorb some misalignment between the two shafts and rigid implies that no misalignment is allowed
between the connected shafts.
Chapter 11
First off, let me explain that gear reduction in the context of this help section refers to speed reduction
in general whether it be by traditional gear, chain and sprocket, or belts. The goal of this section is to
give anyone a basic understanding of what gear reduction is and how it can be used to help give an idea
on how to implement it in a robot. Because there are different areas in a robot that could benefit from
gear reduction we will focus on the most important one, the drive train. And, we will talk only about
AC electric motors but the fundamental can be applied to other motors as well.
The reason that we need to know about gear reduction is because the output speed of a motor is
usually too fast for normal use. Most DC motors at normal operating voltages spin at well over 1,000
rpm (revolutions per minute) and some even as high at 50,000 rpm for brushless DC motors. If we had
a motor than spun at say, 3,000 rpm, and we attached a 6 inch wheel to it then the wheel would theoret-
ically be able to move the bot at almost 54 miles per hour! That is way too fast to control in an arena
due to other considerations that wouldn’t happen but we’ll get into that later. So we need to reduce the
rate at which the wheel spins so that we get a robot that we can at least control. Hint, the quick way
of determining the speed of a wheel is to multiply the diameter (in inches) of the wheel by the rpm and
divide the result by 336.
Quite simply, gear reduction involves using gears/sprockets/pulleys of two different sizes to work
together. Because they are of differing sizes they will have different circumferences (distance around
the outer edge) and we can use this to our advantage. Let’s take a look at what this circumference thing
really means. To the left is a representation of a 4 inch diameter wheel.
Well, how do we determine the final reduction of a multistaged gearbox? It’s really pretty easy. Mul-
tiply the reduction of the first set of gear times the reduction of the next set times the reduction of the
next set and so on until you have included them all. That will give you the total gear reduction. So, if
we had a three stage gearbox where the first gear set was reduced 4:1, the second set reduced 5:1, and
the third set 6:1 then we would multiply 4 x 5 x 6 to get 120:1. Now, let’s use the motor that we talked
about at the beginning and put this gearbox on it and then attach a wheel to the output shaft. Input rpm is
3000. With a 120:1 reduction we divide 3000 by 120 to get 125 rpm. If we attach a 6 inch wheel to that
then our bot would move at 2.32 miles per hour. That’s a little slow for our taste so we’ll have to come
up with a gear box that gives us what we are looking for. So, let’s determine what type of reduction
we would need to achieve a target speed of 15 miles per hour for our bot. First, we know that we are
using 6 inch wheels and our motor spins at 3000 rpm and are target speed is 15 mph and our constant is
336. Plug them into this formula ((wheel size) x (motor rpm))/((target speed) x 336). If we plug in our
numbers we would get (6 x 3000)/(15 x 336) = 3.57:1. It would be pretty hard to get that exact reduction
but we can get close using a 10 tooth input sprocket or gear and a 35 or 36 tooth output sprocket or gear.
But, also remember that the 3000 rpm is for an unloaded motor. Loaded motors will spin at a slower
speed but determining that speed is beyond the scope of this help section.
Well, the two main disadvantages are 1 you lose speed and 2 you have added weight for the gear
box. But, on the other hand, there are some great advantages to using gear reduction. First, you bring
the bot down to a manageable speed. Second, the motor doesn’t have to work as hard to spin the wheel
which means it won’t draw as much current from your batteries. And third, along those lines, the torque
produced by the output is inversely proportional to the amount of reduction in the gear box. Say what?
Basically, if you have a 4:1 gear box then the bot moves 1/4 as fast but has 4 times the torque!
The optimum configuration will give you greatest speed but still have enough torque to cause the
wheels to break traction (peel out) before the motor stalls. That optimum configuration varies from bot
to bot and is up to you to figure out how to best implement it with your own robot.
Chapter 12
An induction or asynchronous motor is an AC electric motor in which the electric current in the rotor
needed to produce torque is induced by electromagnetic induction from the magnetic field of the stator
winding. An induction motor therefore does not require mechanical commutation, separate-excitation
or self-excitation for all or part of the energy transferred from stator to rotor, as in universal, DC and
large synchronous motors. An induction motor’s rotor can be either wound type or squirrel-cage type.
In both induction and synchronous motors, the AC power supplied to the motor’s stator creates a
magnetic field that rotates in time with the AC oscillations. Whereas a synchronous motor’s rotor turns
at the same rate as the stator field, an induction motor’s rotor rotates at a slower speed than the stator
field. The induction motor stator’s magnetic field is therefore changing or rotating relative to the rotor.
This induces an opposing current in the induction motor’s rotor, in effect the motor’s secondary winding,
when the latter is short-circuited or closed through an external impedance. The rotating magnetic flux
induces currents in the windings of the rotor in a manner similar to currents induced in a transformer’s
secondary winding(s). The currents in the rotor windings in turn create magnetic fields in the rotor that
react against the stator field. Due to Lenz’s Law, the direction of the magnetic field created will be
such as to oppose the change in current through the rotor windings. The cause of induced current in the
rotor windings is the rotating stator magnetic field, so to oppose the change in rotor-winding currents
the rotor will start to rotate in the direction of the rotating stator magnetic field. The rotor accelerates
until the magnitude of induced rotor current and torque balances the applied load. Since rotation at
synchronous speed would result in no induced rotor current, an induction motor always operates slower
than synchronous speed. The difference, or ”slip,” between actual and synchronous speed varies from
about 0.5 to 5.0% for standard Design B torque curve induction motors.
Chapter 13
Modelling
13.1 Introduction
The modelling of 3-roller bar bending machine consists of many number of part components and requires
proper connectivity between its neighbouring components. A minute error in the assembly causes the
machine a major damage during it run. Hence this machine build-up high stress on its component (gear,
shaft & roller) during bending and rolling of billet. The modelling of this machine must be carefully
selected; the best suited modelling software for the above machine is Autodesk Inventor Professional
2013.It contains some special features like error correction, mating transitional, mating rotational, mat-
ing constrain set, mating transverse to rotational, backup detailing, parting, presenting etc. these features
makes convenient and ease of modelling. The 3-D model drawing created from solid edge are shown
below.
Chapter 14
Chapter 15
References
1. Bend ability Analysis for Bending of C-Mn Steel Plates on Heavy Duty 3-Roller Bending
Machine, International Journal of Aerospace and Mechanical Engineering 1:2 2007, presented by
Himanshu V. Gajjar, Anish H. Gandhi, Tanvir A Jafri, and Harit K. Raval.
2. Modeling and computation of the three-roller bending process of steel sheets, Journal of Me-
chanical Science and Technology 26 (1) (2012) 123 128, presented by Ahmed Ktari, ZiedAntar,
Nader Haddar and KhaledElleuch. (Manuscript Received July 9, 2010; Revised December 13,
2010; Accepted September 18, 2011).
3. Mechanics-Based Determination of the Centre Roller Displacement in Three-Roll Bending
for Smoothly Curved Rectangular Plates, KSME International Journal Volume 15. No.12, pp.
1655-1663, 2001. Presented by Jong Gye Shin, Jang Hyun Lee, HyunjuneYim and Iu Kim.
4. Analytical Model for Prediction of Force During 3-Roller Multi-pass Conical Bending And Its
Experimental Verification, international journal of mechanical engineering and robotics research,
ISSN 2278-0149S, VOL.1, NO.3, October 2012, presented by M K Chudasama1* and H K Ra val.
5. Analyses of Non-Kinematic Conical Roll Bending Process with Conical Rolls, proceedings of
the ASME 2010 International Design Engineering Technical Conference(IDETC), August 15-18,
presented by zhengkunfengandhenrichampliaud.
6. Boresi, A. P. and Schmidt, R. J. and Sidebottom, O. M., 1993, Advanced Mechanics of
Materials, John Wiley and Sons, New York.
7. Libai, A. and Simmonds, J. G., 1998, The Nonlinear Theory Of Elastic Shells, Cambridge
University Press.
8. Timoshenko, S. and Woinowsky-Krieger, S., 1959, Theory of Plates and Shells, McGraw-Hill.
9. Shigley J, ”Mechanical Engineering Design”, p44, International Edition, pub McGraw Hill,
1986, ISBN 0-07- 100292-8.
10. Gere, J. M. and Timoshenko, S.P., 1997, Mechanics of Materials, PWS Publishing Company.
11. Cook and Young, 1995, Advanced Mechanics of Materials, Macmillan Publishing Company:
New York.
Appendix A
Project Hosting
The project is hosted at Google Code. The complete source code along with the manual to operate the
project and supplementary files are uploaded.
QR CODE: