DEFENCE UNIVERISTY COLLEGE OF ENGINEERING

DEPARTEMANT PRODUCTION ENGINEERING

PROJECT PROPOSAL
TITILE: DESIGN AND FABIRACATION OF ROLL
BENDING MACHINE

Proposed by: ID No
1.YARED BEFEKADU RDEG /340/09
2.FIKADU ERBELO RDEG/313/09
3.FANTAHUN GABRU RDEG/227/09
4.BALATE FISHE RDEG/303/09

Advisor: Abubeker Omer

Table of content page No

1.1 INTRODUCTION……………………………………………………………………………1

1.2 Background Rolling Bending Machine………………………………………………………2

1.3 Statement of Problem…………………………………………………………………………3

1.4 Objective………………………………………………………………………………...….4

1.4.1General objective……………………………………………………………………4

1.4.2 Specific
Objective…………………………………………………………………………………4

1.5 Methodology…………………………………………………………………………………5

1.6 Scope of
project……………………………………………………………………………………………6

1.7 Expected Outcome of project………………………………………………………………….7

1.8 Importance of The Proposed Project in The Context of Current Status……………………....7

1.9 Material Required and Cost Estimation……………………………………………………….8

1.10 Work Plan or Time

Schedule…………………………………………………………………………………………...9

Reference………………………………………………………………………………...10
1.1 Introduction

The main focus of this project is to design the manual roller bending machine. This machine helps bend the
different sheets according to the requirement. This machine does not involve any external force or
electricity; instead, it involved only a man force, i.e., a person can run the machine with the help of a hand.
The design of this machine is so that it requires a little force to perform the task. This machine helps us in
doing the bending tasks that required little effort. Different components that are used in this machine and its
mechanism will also be discussed in this project. This project is to vogue and constructs a negotiable roller
bending machine.
This machine uses to bend steel pipes and metal strips into a curve, so the choice curvature shapes. It is also
very convenient for movable work and is created of steel and easy to run. Moreover, it is easy to carry and
use at anytime and anywhere. It reduces human effort and, in addition, required low less talent to figure this
machine. Power is that the machine for pipe bending, and everyone works manually. Therefore, us
objective is to extend preciseness at low costs while not moving the pipe bending's productivity. This
machine works on the simple kinematic system instead of subtle vogue. Because of its mobility, it is usually
utilized by a tiny workshop or fabrication search. A bending machine is also, a standard tool in the workshop
that is accustomed bend a metal.
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. In bending machine designing several considerations
is taken into 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
sheet metal needs to put in the roller and then rolls around it until the desire shape is acquired.
 1.2 Background of Rolling Bending Machine

One thing had not changed in metalworking by the middle of the 18th century: it was still very hard manual
labor. But come the Industrial Revolution, more and more threaded rods made of wood and wooden beams
were replaced by metal parts; the closing function also consisted of levers, control shafts and eccentric
bearings of metal. The wooden bending table was often reinforced with metal, the so-called edge rail, to
achieve exact bending results. And mechanical sheet metal production really took off at the end of the 18th
century when the English industrialist John Wilkinson invented the reversing rolling mill.

The onset of the industrial revolution took place from the 17th century until the mid-18th. This revolution
was the reason for the existence of functioning machines today. The main branch of this revolution is
manufacturing since it allowed the use of machines that significantly made daily human tasks much more
accessible. Cold bending has been around since 1800B.C; it slowly developed until the industrial revolution
in the 1760s’. Many types of bending are available nowadays. A pyramidal type was chosen with a three-
roller bending setup because of its various capabilities with just two degrees of freedom. The goal is to
improve this type of process using analytical geometry and empirical techniques to achieve an ameliorated
design. These machines are involved many components that help bend the metal sheets. Bending of the
metal sheets is necessary for different industries to make the different parts according to the given
requirements. Metal structures are made up of different types of metal sheets and strips. These strips are
made over the roller bending machines. The metal sheet is placed between the roller, and through the rolling
force of the rollers, it bends in the forward direction.
The first bending machines were called “sheet metal bending brakes” or “folding benches” around 1875.
They were real heavyweights, but they certainly made work easier. This paper is considered with the design
and fabrication of rolling bending system in the DUEC of production engineering department work shop for
the pipe bending because of bending machine system in production work shop is not to bend properly. So
that the design and fabrication of rolling bending machine in DUEC of production engineering department
work shop is very necessarily.

Figure 1.1 design and fabrication of rolling bending machine

1.3 Statement of Problem
The Reasons to design Bending machine for pipe bending is because there is no proper bending machine to
bend a metal pipe for small scale. The bending machine found in the market comes from variety of types.
There are bending machine such as press brake bending machine, roll bending machine, three roll bending
machine. Moreover, the design for the bending machine for pipe bending machine for pipe bending is to
bend a metal pipe. It produces pipe metal bending with desire degree of bending except 90 degrees. Other
reason and regarding to the bending machine design, the bending machine in the market come with big size
and the bending machine expansive. In the last year of October 2021 Defense university, college of
engineering /DUCoE/ department of production engineering decides to manufacture wheelchair for the
support of disabled solider in cause of Ethiopian northern war. When the college engages on the
manufacture of those wheelchairs there was a huge problem bending machine for the bending of wheelchair
handle frame which should be bended 3600. Therefore, this problem should be addressed in order to solve
such unexpected obstacles during manufacturing of any circular structure in the future.

1.4 OBJECTIVE OF THE PROJECT

1.4.1 General Objective
The General objective of this project is to design and prototype fabrication of roll bending machine.
1.4.2 Specific objective

 To review and analyze roll bending machine related literatures

 Design and analysis of roll bending machine.
 Select the proper materiel for rolling bending machine.
 Preparation of the optimized process plan for manufacturing of roll bending machine
 Prototype manufacturing of the roll bending machine
1.5 Methodology
To successfully work on this project different method of analysis and different types of work are done. To do
these analysis works we were used the following source: We will start gathering primary data by asking our
advisor and other person that are helpful to this project and collecting secondary data by referring different
books and search different website. When we collect data from different sources: -
 Books which relate this project work.
 Internets accessories sources which relate this project
 Interview with workshop assistants and supervisors
 Workshop & industry visits in order to have full knowledge of roll bending machines optimized
design
The above source helps us to identify the general working principle and mechanisms of design and
fabrication of rolling bending machine for production engineering department work shop.
Steps we will follow in the design process: -
 Define problem: statement of the Problem
 Gather information: Observations, internet patents, references
 Concept generation &evaluation: creativity methods, systematic CATI software design methods.
 Mathematical modeling: design of components, bill or selection of material and sizing of
components
 Complete engineering drawings
1.6 Scope of Project
The scope of this project up to final design final analysis of geometric formulation and prototype
manufacturing of roll bending machine. The project will consider process of, conceptual design and final
product design of the rolling bending machine, material selection and prototype manufacturing of the roll
bending machine.
Since our project aims to manufacture a curve and bend machine, it also aims to make the design helpful in
Ethiopian defense university college of engineering. Also, the idea is to develop and design a small roller
bending machine that will help improve the use of roller bending machine in our college workshops at a
lower cost and make sure that our prototype is portable and can be easily used everywhere.
1.7 Expected outcome of project
The expected outcome of this project is firstly, use to solve the problems that the college faces during
manufacturing of circular structure components those should be manufactured with roll bending machine.
Secondly, it will serve as source of reference for other related project works in the future.

1.8 Importance of the proposed project in the context of current status

This machine is helpful in bending easily. It can bend the sheet and pipe without any electricity and
manually operated to do the task at domestic level. Also, helpful in moving from one place to another place.
Through this machine, no heavy labor is required. Easy to handle and operate. Little maintenance is
required for such type of machines.
 1.9 Materiel Requirement and Cost Estimation

No Material Type Dimension Quantity Price Total

(mm) (birr) Cost
1 Hydraulic jack small 1 2000 2000
2 U channel metal 12 m length 1 6000 6000
3 Bolt and nut 8 80*8 640
4 Plate metal 1000 1000
5 screw 6 30*6 180
6 journal bearing 6 300*6 1800

7 Roller 3 300*3 900

8 shaft 3 200*3 600
9 Spindle wheel 1 700 700

10 Labor 25 25*500 12500

Sub Total 26480
15% vat 3972
total 30452
 1.10 Work plan or time schedule

NO Tasks SEPTEMBER 2015 OCTOBER 2015 NOVEMBER 2015 DECEMBER 2015

Weeks
Weeks Weeks Weeks

1 2 3 4
1 2 3 4 1 2 3 4 1 2 3 4

1 Title selection

Review different
2 related literatures

Proposal
3 preparation and
presentation

Discus with advisor

4

5 Materiel selection
&component
design
Prototype
6 manufacture

Document
7 preparation

8 Final presentation
Reference

1. A.D. Zope. (2017). Review paper on design and development of metal bending

machine. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE), 3.

2. Got, H. (2008). Applications with a New 6-DOF Bending Machine in Tube Forming

Processes. Proceedings of the 7th JFPS International Symposium on Fluid Power, 7.

3. Head, Y. (2012). Advances and Trends on Tube Bending Forming Technologies.

Chinese Journal of Aeronautics, 1-12.

4. Hussain, H. A. (2014). Design and Development of Bicycle Integrated Pipe Bending

Machine. Journal of Mechanical and Civil Engineering (IOSRJMCE), 6.

5. Jayakumar, A. (2019). Design and Fabrication of Roll Bending Machine. ISSN-2349-5162, 3.

6. Khandare, P. P. (2016). Study of Portable 3-Roller Pipe Bending. International Journal

of Advanced Technology in Engineering and Science, 4.

7. Pachanga, R. (2019). DESIGN AND FABRICATION OF MANUAL ROLLER

BENDING MACHINE. International Research Journal of Engineering and

Technology (IRJET), 7.