Sheet Metal Bending Machine: Mechanical Enginnering

Metal Sheet Bending Machine
Department of
MECHANICAL ENGINNERING
A PROJECT REPORT ON
“Sheet Metal Bending Machine”
(2021-22)
PRINCIPAL:- HOD:- PROJECT GUIDE:-
PROF. R.S MRS. MADHURI MRS. AISHWARYA

BAWASKAR D. KULKARNI DIWANE
PROJECT SUBMITTED BY
ASHUTOSH SINGH (3213)
SUDARSHAN PATEL (3224)
ADITYA SINGH (3239)
ARIVIND SINGH (3232)-

Shree Sai Shiva Educational Trust’s

MUCHHALA POLYTECHNIC
SAI BABA VIHAR COMPLEX, GHODBUNDER ROAD, ANAND
j NAGAR, THANE (W) 400615
C 2021-2022
C CERTIFICATE
Certified that this Report submitted by
Shir/Kum _____________________________________________ Roll/Seat No. ___________
a student seminar / Project work as prescribed by the Board of Technical
Examination for the subject Project.
And that I have instructed/guided him for the project work from time to
time and I found him to be satisfactorily progressive; and those following
students were associated with him for his work. However, his Contribution
was proportionate.
And the project work has been assessed by me and I am satisfied that the
same is to the standard envisaged for the level of the course. And the project
work may be promoted to the External Examiner.
_____________________ ________________________ _______________________

c PRINCIPAL:- HOD:- PROJECT GUIDE:-
PROF. R.S MRS. MADHURI MRS. AISHWARYA
MUCHHALA POLYTECHNIC, THANE PAGE 2

CERTIFICATE
This is to certify that,

Following students of VIth Semester in Muchhala Polytechnic
have Satisfactory completed their final year project Metal Sheet
Bending Machine & submitted dissertation report prescribed by
Board of Technical Education Maharashtra State in the academic
year 2021-2022 in the Department of Mechanical Engineering of this
institute.
_______________ _______________
Internal Examiner External Examiner
____________________ _______________________ _______________________

PRINCIPAL:- HOD:- PROJECT GUIDE:-
PROF. R.S MRS. MADHURI MRS.AISHWARYA
DATE:- ____________________
Signature of students:
Ashutosh Singh ______________________________

Sudarshan Patel ______________________________
Aditya Singh ______________________________
Arivind Singh ______________________________

Shree Sai Shiva Educational Trust’s

MUCHHALA POLYTECHNIC
SAI BABA VIHAR COMPLEX, GHODBUNDER ROAD,
vdsvdvd ANAND NAGAR, THANE (W) 400615
C 2021-2022
C SUBMISSION
Shir/Kum __________________________________________ Roll/Seat No. _______________
student of Third year of the course Mechanical Engineering humbly submit
that I have complete from time to time the seminar/ Project work as described
in this report by own skill and study between the period from July 2021 TO
May 2022 as per the instruction/ guidance of MRS. AISHWARYA
DIWANE.
And the, following students were associated with me for this work,
however, the teacher has approved quantum of my contribution.
And that, I have not copied the Report, or it is any appreciable part from
any other Literature in contravention of the academic ethics.
DATE: _______________
Signature of students:
Ashutosh Singh ______________________________

Sudarshan Patel ______________________________
Aditya Singh ______________________________
Arvind Singh ______________________________

ACKNOWLEDGEMENT
We have taken lot of efforts in this project. However, it would not have been
possible without kind support and help of many individuals. We would like to
extend my sincere thanks to all of them.
We are highly indebted to “MRS. AISHWARYA DIWANE” for their

guidance and constant supervision as well as for providing necessary
information regarding the project & also for their support in completing the
project.
We thanks to our Workshop Sir for helping us in this project. We would like to
express our gratitude towards our parents & classmates for their kind co-
operation and encouragement which help me in completion of this project. We
would like to express my special gratitude and thanks to all of them.
My thanks and appreciations also go to those people who have willingly

helped us out with their abilities for developing the project.
At the end, we thank our “MRS. AISHWARYA DIWANE” for their overall
help on various design aspects, and fabrication. Without their support our
project would not have been successful.
Thanking you everyone for your Support.
ASHUTOSH SINGH
SUDARSHAN PATEL
ADITYA SINGH
ARVIND SINGH

ABSTRACT
Bending machine is used to bend a metal sheet. The aim of this

project is to develop a portable metal sheet bending machine.
This machine is used to bend sheets into require degree. The
size of machine is very small as compared to other machines.
And it is convenient for portable work. MS fully makes it, and it
is easy to be carry and use at any time and any place. It eases
human effort and no required skill workers to operate the
machine. We are developing manually operated metal sheet
bending machine with use of metal shaft, pedestal bearing and
support (frame).
This machine works on simple kinematic system instead of

complicated design. This machine can bend up-to 2 mm thick
sheet. Due to its light weight and it is portable so it can be used
by small workshop, fabrication shop, small scale industry etc.
Bending machine is a common machine in machine shop that is
used to bend a metal. There is no proper small scale bending
machine for bending a pipe. A Metal Bending machine uses plate
to bend metal sheet. There are 5 plates used in bending machine.
The common product of metal bending machine is metal sheet
bending if separate attachment of die is provided, sheet bending.
During the bending process, the sheet, plate is passed through
consecutive plate that gradually apply pressure on metal sheet .
Because of this pressure the change in design of metal sheet
occurs.

CONTENT
CHAPTE TOPIC PAGE
R NO. NO.
1. INTRODUCTION 8-10
2. LITERATURE REVIEW 11-13
4. ANALYSIS OF MECHANICAL 14-17

CALCULATION
5. DETAILS OF DESIGNS, WORKING, 18-26
PROCESSES
6. COST ESTIMATION 27-32
7. RESULTS 33-37
APPLICATION 38-39
8. ADVANTAGES & DISADVANTAGES 40-41
9. CONCLUSIONS & FUTURE SCOPE 42-43
10. BIBLIOGRAPHY 44-45

CHAPTER- 1
INTRODUCTION

Due to increasing globalization, it is very much essential for the

manufacturer to sheets a goods having highest reliability. Metal
Bending is used in fabrication as an alternative method for casting or
forging operations. Since it is related to human being hence it is
necessary to design the joint with prior attention to safely of its user.
Generally Bending is a process that seduces-shape, V-shape, or
channel shapes in ductile materials, most commonly in sheet metal
as per requirement on different types of bending machines.
Senthil Raja as we have studied bending is also called as flexure

which characterizes the behavior of structural element when
subjected to external load applied perpendicularly to a longitudinal
axis of the element. A beam is an element whose length thickness
and width are smaller than the length. A shell is a geometric
structure in which width and length are of same magnitude and the
thickness of this geometric structures smaller.
There are two different machines available in market for bending of

sheet and bending of sheet. There is no single machine available
which bends sheet as well as sheet in a single unit. Sheet bending
process can be used to deform a sheet or plate. Cylindrical shells are
the basic components used for the various engineering applications
like boiler chambers, cylindrical tanks, heat exchanger shells,
pressure vessels, etc.
The process can be performed using many materials such as carbon

and alloy steels, aluminum alloys and titanium alloys. Sheet bending
machines with both five dies are used to sheets of metals with
various curvatures. The bending process is performed by a five dies
bending machine often called as pyramid type, because of these
types of arrangement of the five dies.

The process consists of 3 steps:

1) Positioning of the sheet.
2) Lowering of central dies.
3) Repeating feed of sheet.
In first step, a flat blank sheet is fed into the machine by

two rotating side rollers until the sheet is properly positioned. In the
2nd step, center roller is displaced downward causes bending of the
sheet. In the final step, two side rollers rotate again, so that the sheet
is bending continuously.

CHAPTER- 2
LITERATURE
REVIEW
The paper deals with manufacturing of sheets 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 psheetsuctivity of power
operated bending machine is higher. Author told in recent
year’s sheets bending machine is used in both industry and
domestic purpose for bending the sheets under the
required angles and dimensions. Sometimes Heat
treatment is used for sheets bending but the heat
treatment technique is not safe and have problems are
seduced in the sheets, such as wrinkling, curve forming,
reduced thickness, whole forming, reduced strength, easy
breakable.
In the hydraulic sheets bending machine having a good

advantage compared to heat treatment methods. In this
paper, a bicycle integrated sheets bending mechanism has
been designed and develop++ped. The applications of bent
sheets are in frames, barricades, handle of bicycle. Most of
industries uses bent sheets 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.
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 equipment to

bend sheets, sheets, and bars. The sheets or sheets to be

bending is kept between the rollers. With use of
hydraulic jack, we implement force on the sheets and bend
it too 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 sheets bending machine. The aim of this paper is
to develop a sheet bending machine which is useful to bend
a sheet in workshop. This project is to design and construct
a portable sheet bending machine. This machine is used to
bend steel sheets into curve and the other curvature
shapes.
The size of machine is very convenient for portable work. It

is fully made by metal. 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 sheets bending
machine with use of gears, motors, pulley, and frame. This
bending machine is manually operated.
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.

CHAPTER- 3
ANALYSIS OF MECHANICAL
CALCULATION

Analysis
• Clearance
– 4-8% but sometime 1% of thickness
– Too small – fracture does not occur requiring more
force.
– Too large – Get pinched and cause an excessive burr
– Clearance: c=a*t
– 1100S and 5052S
aluminum alloys,
all tempers (0.045)
– 2024ST & 6061ST
aluminum alloys;
brass, soft cold rolled
RYsteel, soft stainless steel (0.060)
– Cold rolled steel, half hard; stainless steel, half hard
and full hard (0.075)

Calculations Of Gear Drive:
1) FOR DRIVE 1 :-
i) Pd1 = Pr x K1
Where, Pd = Design power
Pr = Rated power
K1 = Load Factor, table XVI – 2, D.D. Book
there are 5% power losses
C Pr = 0746  5  0.95
[Motor used of 5HP]
Pr = 3.5435 KW
Pd1 = 3.5435 1.2
[load factor K1 = 1.25for medium shocks ]
Pd1 = 4.4293 KW
ii)Tooth load (Ft) =

where Vp – Pitch line velocity
Vp = rw
= d/2×2×N1
Vp = 1093.27 m/s
Ft = Pd1/Vp
Ft = 4.051 N
Module , m = 6.470 mm
where , d = Pitch diameter
T = No. of teeth

iii)Dynamic load, (Fd) =

Were,
C = Deformation factor , table XVI – D.D. book
e = Error in profile mm fig. 16. 1 D.D. book
b = Face width of gears
Fd = 29872.41 N.
We know that Fd = 29872.41 N

CHAPTER- 4
DETAILS OF DESIGNS,
WORKING, PROCESSES

DESIGNS
Top View

Bottom View

Front View

Left View

Right View

WORKING
• Cutting and forming thin sheets of metal usually
performed as cold working
• Sheet metal = 0.4 (1/64) to 6 mm (1/4in) thick
• Plate stock > 6 mm thick
• High strength, good dimensional accuracy, good
surface finish, economical mass production (low cost).
• Cutting, bending, drawing
• Metal Sheet working terminology
1) “Punch-and-die”- Tooling to perform cutting,
bending, and drawing.
2) “Stamping press”-
Machine tool that
performs most sheet
metal operation
3)“Stampings”-
Sheet metal products
• Cutting operation
– Plastic deformation
– Penetration (1/3 thickness)
– Fracture
• Shearing –using a machine called power shear or
square shear.
• Blanking –Shearing a closed outline(desired part
called blank).
• Punching – sheared part is slag (or scrap), and
remaining stock is a desired part.

PROCESS
Metal bending is a process by which metal can be
deformed when applying force to the subject, which
causes it to bend at an angle and form the anticipated
shape, which often results in a ‘V’ or a ‘U’ shape.
A press brake is a tool

used in order to bend
sheet metal and uses
a punch and die to do
this. Although press
braking may seem
straight forward, it can be quite difficult to remain
accurate throughout the process. There are several
types of press brakes which deliver various levels of
force applied.
Bending is the most widely used type of metal bending

and it is not difficult to see why, as there are many
advantages to this technique. Because the punch tip
does not need to be pushed past the surface of the
metal, much less weight is required to bend in
comparison to bottom bending and coining.

 Air Bending
During this process the work piece meets the
outside edges of the die, as well as the punch tip.
The punch is then forced past the top of the die
into the V-shaped opening without touching the V.
 Bottom Bending
The difference between air bending and bottom
bending is that there is a difference in radius
between the two. It differs from coining as the
punch and the tie do not make full contact with
the material, and there is not enough tonnage to
make an imprint into the metal.
 Coining
Coining is a bending process in which the punch
and the work piece bottom on the die. This
produces a controlled angle, which leads to little
spring back. There is more tonnage required on
this type of bending than in air bending and
bottom bending.

CHAPTER- 7
COST ESTIMATION
PRINCIPLES OF COST ESTIMATION

1. Cost estimation is used to predict the quantity, cost and price of the
resources required by the scope of a project. A project might be any
process that is started to perform work activities and/or create
assets. The accuracy of the estimate depends heavily on the level of
project scope definition: as the design and conditions of the project
become better defined, so do the estimated values. Think of the 5
estimate classes of AACE shared above.
2. Cost estimation is needed to provide decision-makers with the

means to make investment decisions, choose between alternatives
and to set up the budget during the front end of projects. For this,
estimates made by vendors and contractors need to be validated by
clients as well. In later phases of the project, the budget estimate is
used as a baseline to assess the performance of a project.
3. Estimating is done by breaking down the total scope of a project in

manageable parts, to which resources can be assigned and cost.
There are standardised ways of breaking down a project, like the
Work Breakdown Structure (WBS) and the Cost Breakdown
Structure (CBS), but depending on the needs of the project team and
external parties multiple structures are often implemented to align
reporting and sharing of cost data.
4. A cost estimate is more than a list of costs. It also includes a detailed

Basis of Estimate (BOE) report that describes the assumptions,
inclusions, exclusions, accuracy and other aspects that are needed
to interpret the total project cost. Otherwise, it would be a
meaningless number.

Sr no. Parts Weight Quantity Price

1.
25L 25mm
0.19 kg 2 NOS ₹36
2.
300L 10mm 0.19 kg 1 NOS ₹17
3. 152.2mm
50mm 10mm
Thickness 1.61 kg 2 NOS ₹145
4. 266 mm
42.3mm 10mm
5. 105mm
20mm 10mm
6. 230mm
30mm 12mm
7. 250mm

100mm 10mm 2.53 kg 1 NOS ₹228
Thickness
8. 60mm
20mm 10mm
9. 300mm
25mm 10mm
10. 250mm
l
30mm 20mm
11. 206.6mm
l
230mm 8 mm
12. 50mm
85.6mm 10mm
13. 85.8mm
l
25mm 10mm

14. 85.8mm
40mm 10mm
15. 126mm
138
mm 9.10 kg 2 NOS ₹1100
25mm 119.2°
Thickness
j
200 mm
16. 300mm
6mm Thickness 25mm 0.85 kg 2 NOS ₹154
17. 25mm
Thickness
0.20 kg 2 NOS ₹12
20mm
Diameter
18.
0.40 kg 2 NOS ₹700
19.
0.25 kg 9 NOS ₹150
20.
4 NOS ₹390

Total: 29.08 kg 45 NOS ₹4154
Total Expenditure
Sr no. Expenditure Price
1. Parts ₹4154
2. Painting ₹796
3. Machining ₹2250
4. Labour (Welding) ₹500
5. Shipping (Raw material) ₹300
Total:- ₹8000/-

CHAPTER- 8
RESULTS

LEFT VIEW

RIGHT VIEW

FRONT VIEW

TOP VIEW

CHAPTER- 9
APPLICATION
Sheet bending machine is used to deform or shape metals

into desired shapes and sizes. The metal is subjected to
higher stress causing it to deform because of disturbance in

its yield and tensile strengths. Here a powerful force is
applied on a metal part to be shaped causing it to deform in a
particular direction. For metal to be casted into customized
irregular shape, a sequence of operations is to perform on
the metals with this sheet bending.
Press brake is one of the most important variants of sheet

bending machine tool used for bending metal sheets and
plates into customized shapes. Various kinds of press brakes
are employed for metal bending applications in industries.
Mechanical, pneumatic, and hydraulic press brake models
are most famous. Different metal forming jobs like curling,
angled shaping, bending, bottoming, seaming, hemming etc.
are possible with any of these press brakes using various
kinds of dies. Bending roller can be used for bending and
straightening sheet metal covers and parts of boiler tanks,
pressure vessels and converters whereas shearing tool like
mechanical and hydraulic shearing can be employed for
cutting sheet metal to size out of a larger stock.
Large sheets, bars and plates of metallic and non-metallic

materials can be easily and accurately cut into different
shapes with the help of shearing machine. Another important
variant of sheet bending machine, called power press is the
best metal bending equipment with which most accurate
metal cutting, bending, and shaping tasks can be executed for
bulk industrial processes.

CHAPTER- 8
ADVANTAGES &
DISADVANTAGES

ADVANTAGES:-
 High speed, high production efficiency and low energy
consumption
 Simple routine maintenance and low maintenance cost.
 High degree of automation, simple operation, no need to
replace the upper and lower mold, save time.
 The bending tool can complete the shape of non-right
angle, right angle, circular arc, pressing dead edge, etc.
 It’s suitable for flat molding of various materials.
 Made a low cost and a portable project
DISADVANTAGES:-
 Variation in thickness of the material and wear on the
tools can result in defects in parts produced
 High labour cost
 The sheet does not stay in full contact with the dies
 High tooling and equipment costs
 The bending of sheet is not more than 2mm, as
compared to automated body machine

CHAPTER- 9
CONCLUSIONS &
FUTURE SCOPE

As compared to the manually operated sheet bending

machine the power operated sheet bending machine is
better. The productivity of power operated sheet bending
machine is higher. The part of machine can handle the
heavy load on machine. The time required to complete
bending operation is less and the requirement of extra
workers reduced. Power operated sheet bending is less
time-consuming process with high productivity.
After performing actual experiment force calculation and

fem analysis on metal sheet at different materials, we
conclude that the force which required for bending the
sheet is found by virtually it is tested in terms of factor of
safety as well as material safety while bending operation.
Based on the results and its analysis, following conclusion
can be drawn. From the result’s analysis for constant
radius of curvature (R) ,constant dimensions by changing
the material, load(W) increases as the value of modulus of
elasticity(E) increases i.e., Load is directly proportional to
the modulus of elasticity.
Load increases as the thickness changes in increasing

order. Required surface finish of cylinder or any circular
product is directly affected by skilled labour as they
lowered the top roller with the help of power screw in
some extent

CHAPTER- 10
BIBLIOGRAPHY

PROJECT BIBLIOGRAPHY
 Machining done at “Sudarshan. Engineering workshop”
by team.
 Assembling done at “Sudarshan Engineering workshop”
by Team
 Technical work done by Ashutosh Singh.
Book Reference
Sheet Metal Bending & Operational Techniques
-Emiliano Cirrieri
Sheet Metal Work & Designing Techniques
-Marcus Bowman
Link
 https://youtu.be/VYwkXeNqfzI
 https://machinetools.bhavyamachinetools.com/
features-of-a-sheet-bending-machine
 https://en.m.wikipedia.org/wiki/
Bending_machine_(manufacturing)

Sheet Metal Bending Machine: Mechanical Enginnering

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Metal Sheet Bending Machine

PRINCIPAL:- HOD:- PROJECT GUIDE:-

PROF. R.S MRS. MADHURI MRS. AISHWARYA

SUDARSHAN PATEL (3224)

ADITYA SINGH (3239)

ARIVIND SINGH (3232)-

Shree Sai Shiva Educational Trust’s

_____________________ ________________________ _______________________

MUCHHALA POLYTECHNIC, THANE PAGE 2

This is to certify that,

____________________ _______________________ _______________________

Ashutosh Singh ______________________________

MUCHHALA POLYTECHNIC, THANE PAGE 3

Shree Sai Shiva Educational Trust’s

Ashutosh Singh ______________________________

MUCHHALA POLYTECHNIC, THANE PAGE 4

We are highly indebted to “MRS. AISHWARYA DIWANE” for their

My thanks and appreciations also go to those people who have willingly

Thanking you everyone for your Support.

MUCHHALA POLYTECHNIC, THANE PAGE 5

Bending machine is used to bend a metal sheet. The aim of this

This machine works on simple kinematic system instead of

MUCHHALA POLYTECHNIC, THANE PAGE 6

2. LITERATURE REVIEW 11-13

4. ANALYSIS OF MECHANICAL 14-17

9. CONCLUSIONS & FUTURE SCOPE 42-43

10. BIBLIOGRAPHY 44-45

MUCHHALA POLYTECHNIC, THANE PAGE 7

MUCHHALA POLYTECHNIC, THANE PAGE 8

Due to increasing globalization, it is very much essential for the

Senthil Raja as we have studied bending is also called as flexure

There are two different machines available in market for bending of

The process can be performed using many materials such as carbon

MUCHHALA POLYTECHNIC, THANE PAGE 9

The process consists of 3 steps:

In first step, a flat blank sheet is fed into the machine by

MUCHHALA POLYTECHNIC, THANE PAGE 10

The paper deals with manufacturing of sheets which use

limitations of manually operated bending machine. From

In the hydraulic sheets bending machine having a good

Hydraulic equipment has wide use in various automobile

MUCHHALA POLYTECHNIC, THANE PAGE 12

bend sheets, sheets, and bars. The sheets or sheets to be

The size of machine is very convenient for portable work. It

Bending is a metal forming process in which straight

MUCHHALA POLYTECHNIC, THANE PAGE 13

MUCHHALA POLYTECHNIC, THANE PAGE 14

MUCHHALA POLYTECHNIC, THANE PAGE 15

Calculations Of Gear Drive:

ii)Tooth load (Ft) =

MUCHHALA POLYTECHNIC, THANE PAGE 16

iii)Dynamic load, (Fd) =

MUCHHALA POLYTECHNIC, THANE PAGE 17

MUCHHALA POLYTECHNIC, THANE PAGE 18

MUCHHALA POLYTECHNIC, THANE PAGE 19

MUCHHALA POLYTECHNIC, THANE PAGE 20

MUCHHALA POLYTECHNIC, THANE PAGE 21

MUCHHALA POLYTECHNIC, THANE PAGE 22

MUCHHALA POLYTECHNIC, THANE PAGE 23

MUCHHALA POLYTECHNIC, THANE PAGE 24

A press brake is a tool

Bending is the most widely used type of metal bending

MUCHHALA POLYTECHNIC, THANE PAGE 25

_ ___

________ _ _____________