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GUJARAT TECHNOLOGICAL UNIVERSITY

CHANDKHEDA, AHMEDABAD

L. J. INSTITUTE OF ENGINEERING AND TECHNOLOGY

A REPORT ON
PNEUMATIC SHEET BENDING MACHINE
Under the Subject of

DESIGN ENGINEERING
B.E. SEMESTER – V
(MECHANICAL ENGINEERING)

Submitted by
1 Kachhadiya Prince (190320119052)

2 Kalavadiya Jay (200320119055)

3 Prajapati Jitendra (200320119068)

4 Prajapati Jagdish (200320119083)

5 Modi Karan (200320119115)

Ms.Anilkumar Rathour Mr. Tushar Thakkar

(Faculty Guide) (Head of Department)

Academic Year

2022 – 2023
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L. J. INSTITUTE OF ENGINEERING AND TECHNOLOGY

Department of Mechanical Engineering
2022 – 2023

CERTIFICATE
Date:
This is to certify that the Design Engineering – 2A. Work entitled
“PNEUMATIC SHEET BENDING MACHINE”
carried out by the group of students mentioned below under my guidance is approved for the
Degree of Bachelor of Engineering in Mechanical Engineering (Semester - V) of Gujarat
Technological University, Ahmedabad during the academic year 2022-23.

List of Students:-
1 Kachhadiya Prince (190320119052)

2 Kalavadiya Jay (200320119055)

3 Prajapati Jitendra (200320119068)

4 Prajapati Jagdish (200320119083)

5 Modi Karan (200320119115)

Guide Head of Department

Mr. Anilkumar Rathour Mr. Tushar Thakkar

Mechanical Department Mechanical Department

L.J.I.E.T L.J.I.E.T
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L. J. INSTITUTE OF ENGINEERING AND TECHNOLOGY

Department of Mechanical Engineering
2022 – 2023

REPORT APPROVAL CERTIFICATE

This is to certify that the Design Engineering – 2A. Work entitled

“HYDRAULIC DISC BRAKES”,

carried out by the group of students mentioned below under my guidance is approved for
the Degree of Bachelor of Engineering in Mechanical Engineering (Semester - V) of
Gujarat Technological University, Ahmedabad during the academic year 2022-23.

List of Students:-
1 Kachhadiya Prince (190320119052)

2 Kalavadiya Jay (200320119055)

3 Prajapati Jitendra (200320119068)

4 Prajapati Jagdish (200320119083)

5 Modi Karan (200320119115)

Guide Head of Department

Mr. Anilkumar Rathour Mr. Tushar Thakkar

Mechanical Department Mechanical Department

L.J.I.E.T L.J.I.E.T
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PAGE
INDEX

CHAPTER 1. INTRODUCTION
6
Introduction about team members
Introduction to Faculty Guide Understanding
about Reverse Engineering
Identification of Component for Reverse Engineering

CHAPTER 2. LITERATURE REVIEW

8
Review about the hydraulic brakes.

CHAPTER 3. EMPATHY MAPPING

10
Domain selection
AEIOU sheet and its summary
Snapshot of AEIOU summary Selected
users and its stakeholders
Activities of user and its stakeholders
Story telling
Snapshot of empathy mapping

CHAPTER 4. IDEATION CANVAS

18
Explanation of People and their Activities Understanding
about Situation/Context and Location Relevant and
Irrelevant Props

CHAPTER 5. PRODUCT DEVELOPMENT CANVAS

Description of Final Problem Statement 21

Description of Problem Solution
Explanation of Product Components, Functions and
Features.
Discussion on Product Experience
Customer Revalidation
Discussion of Reject, Redesign and Retain Parameters
Snapshot of Product Development Canvass
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CHAPTER 6. MIND MAPPING 24

Snapshot of Mind Mapping.

CHAPTER 7. LEARNINGN NEED MATRIX 25

Introduction to Learning need matrix. Description

of Learning need matrix.
Snapshot of Learning need matrix.

CHAPTER 8.REVERSE ENGINEERING 26

Reverse engineering
Reverse engineering of Hydraulic Brakes

CHAPTER 9.DIACHRONIC AND SYNCHRONIC ANALYSIS 28

CHAPTER 10.SCAMPER TOOL 31

CHAPTER 11.DESIGN CALCULATION 32

Size of different components
Description about the design

CHAPTER 12. SECONDARY RESEARCH AND REFERANCE 35

Art search
Summary of research paper and reference
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CHAPTER 1. INTRODUCTION

Introduction About Team Members

We all five are mechanical engineering sem-5 students. We all are interested and eager to
know anything related to mechanical affairs. We all share our research with each other.
We believe in getting knowledge as much as possible. We often discuss about our ideas
related to current automobile affairs. We do online research on the various kinds of
vehicles and mechanical instruments. And we are excited about design engineering as it
gives us knowledge about mechanical engineering.

Introduction to Faculty Guide

M. Anilkumar Rathour a very decent being. She has wide range of knowledge in almost
every area related to Mechanical. She completed her M.E in CAD-CAM. She helps
student by sharing her knowledge and her knowledge is really beneficial to us
.She understands our problems and fixes them very easily and fast. It was great working
with her on this project.

Understanding about Design Thinking

A primary purpose of design thinking is to summarize and synthesis the research on

design thinking to better understand its characteristics and processes as well as the
difference between novice and expert design thinker. It is very important for upcoming
engineers like us to develop critical thinking skills, working and managing a team,
completing work on or before time, enhancing the way to look at things, approaching a d
facing problems with different point of view etc. Design thinking helps us enhance and
improve our skills.
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Importance of Design Thinking

Introduction of this project is very important in lives of beginners like us. This project
makes us aware about how things work in actual world. Firstly, a team is chosen by us,
we have to work in that team throughout the project which obviously improves our
management and team-working skills. This project helps us to develop critical thinking
skills, the way we approach towards a problem also become more simplified and
distinct. Throughout our project we constantly solve and fix different kind of problems,
hence enhance problem facing and solving capability. A secondary communication skill
also improves. With help of this project, we got a good knowledge about designing which
would be helpful in future. Also, it helps to apply the findings from the literature regarding
the application of design thinking to our education system.
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CHAPTER 2. LITERATURE REVIEW

Sheet metal bending is one of the most widely applied sheet metal forming
operations. The understanding of the bending mechanics is aimed at obtaining two kinds of
information important for industrial applications. The first one is the spring back prediction
for die design and shape control. The second is an estimation of the bend force for
selection of press capacity, strength analysis and design of dies. Vallance and Matlock
(1992) studied the friction behavior of zinc-based coated sheet steels and laboratory scale
friction analysis techniques that involve sheet sliding over cylindrical dies. Wenzlaff et al
(1992) introduced a new test procedure for the bending under tension friction test. Mai
Huang and Gardeen (1994) presented a literature review of the spring back of doubly
curved developable sheet metal surfaces and provided a bibliography on the spring back in
sheet metal forming. Reviewing the literature, it is found that researchers have been
studying the phenomenon of spring back for nearly six decades. There have been diverse
efforts to evaluate and/or decrease spring back in the sheet metal forming industry for a
long time. Perduring and Hogeboom (1995) derived a simple explicit bending couple
curvature relation for small and larger curvatures and they verified the model with
experimental results. A simple approach for calculating bendability and spring back in
bending based on the normal anisotropic value, strain hardening exponent and sheet
thickness has been presented as described elsewhere by Daw Kwei Leu (1997).

Kwei Leu (1997). You-Min Hang and Daw-Kwei leu (1998) described the effects of
process variables like punch radius, die radius, punch speed, friction coefficient, strain
hardening exponent, normal anisotropy on V-die bending process of steel sheet. Sanchez
(1999) focused on a systematic analysis of testing equipment as a measurement system of
the friction phenomena on sheet metal under plane strain. It provides experimental
references in order to optimize the usage of lubricants and sheet metal. Weilong Hu (2000)
proposed anisotropy hardening models with simple loading conditions that include
exponential hardening model, linear hardening model and multi linear hardening model.
Samuel (2000) analyzed the spring back in axisymmetric U-bending processes with a finite
element program and discussed the effect of tool geometry and blank holder force on the
final shape after spring back
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Zafer Tekiner (2004) examined the springback of sheet metals with various thicknesses
and properties in bending dies. Carlos Gomes et al (2005) investigated the variation of
springback in high strength steels based on experimental and numerical analysis. Ihab Ragai
et al (2005) discussed the effect of sheet anisotropy on the springback of stainless steel 410
draw bend specimens and lubrication. Ozgur Tekaslan et al (2006) carried out the
experiment to determine springback of steel sheet with V shaped die. Dongye Fei and
Peter Hodgson (2006) investigated the springback behaviour of cold rolled transformation
induced plasticity (TRIP) steels in air v bending process

Bruni et al (2006) investigated the effect of the process parameters on

springback of AZ31 magnesium alloy in air bending under warm and hot forming
conditions. Garcia Romeu et al (2007) presented new springback graphics for air vee bent
sheet metal parts based on an experimental work. Se Young Kim et al (2007) examined the
effect of tool design and process parameters on the springback of GLARE and the
parameters studied include punch radius, punch speed, forming load and forming
temperature.
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CHAPTER 3. EMPATHY MAPPING

Domain Selection

We wanted to improve the “Sheet Bending Machine” and bending

facilities as there are lots of loopholes and lack of proper programming Our
project “Pneumatic Sheet Bending Machine” too is a Mechanical

based so we have selected “Bending Machine” as our Domain Many

precious non-renewable resources can be saved by increasing use of

usage of renewable resources like wind and solar.

AEIOU Sheet and itsSummary

Here AEIOU stands for Activities, Environment, Interaction, Object and User. The summary
contains all the points of AEIOU

• Activities

We were reading about the major reasons for car accidents, and we realized most of
them were caused due to mechanical brake failure. We researched a lot by going through
the various accidents related articles cum cases in newspapers and online portals.
We also came across a few people who met with an accident and we got a chance to talk to
them, and we found that most of the accidents were caused due to either failing of the
brakes or inefficiency of the brakes.

• Environment

There were many things that were creating environmental problems. One of the major
problems was fuel wastage. As the mechanical brakes have less efficiency, it requires
more fuel. Mechanical brakes create a lot of noise pollution by the friction in the
mechanism. The mechanical brakes need a highly controlled environment and high
frequency of service as they tend to fail easily in moisture due to corrosion, but the
hydraulics also corrode eventually, but do not fail suddenly and so do not pose a high
risk to accident.
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• Interaction

There was a lot of interaction scene going on at the workshop area. First of all, the driver
was interacting with the workshop manager explaining him about the fault in the vehicle.
Then the workshop manager told him to fill the form for the repairing of the vehicle. Then
the workshop manager told the mechanic to repair the brakes in the vehicle. The driver
was talking to the mechanic telling him about the brake problems in his vehicle and
asking for the solution. Most of the drivers were complaining about the smooth braking
problem in their vehicle, and the frequency of oiling the brake mechanism, for better working.

• Objects

There were so many objects at the workshop. The first object we saw was new vehicles.
There were other old vehicles also. At the backside there were towing vehicles and
damaged police vehicles. Also, there was a petrol filling station for the fueling of
vehicles. Oil barrels were kept at a side of the service station which were used for the
oiling in vehicles.

• Users

There are so many users for the mechanical brakes but the main user is a driver. He is the
one who drives the vehicle daily and knows about the problem in his vehicle. Another user
is the workshop manager, who tests the vehicle after being repaired. The mechanic drives
the car again and again while repairing the car. The people working with machines
operating on mechanical brakes on daily purpose. The supervisor checks the car that it is
properly serviced or not.
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• AEIOU Summary

The AEIOU summary contains all the points regarding the AEIOU sheets.

ACTIVITIES

1) Boarding
2) Identification
3) Safety
4) Packing
5) Checking
6) Shipping
7) Loading
8) carrying

ENVIRONMENT

1) Warm Air
2) Polluted
3) Noisy
4) High Temperature
5) Toxic
6) Dusty

INTERACTION

1) Supervisor to workers(maintenance)

2) Owner to student (instruction)

3) Teacher to student (teaching)

4) Owner to labors (cleaning)

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OBJECTS

1) Safety Tools
2) Milling Machine
3) Vehicle Engines
4) Heavy machine
5) Modern Models

USERS

1) Government
2) Private Industries
3) Different Factories
4) Shipping Companies
5) Common People
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 Snapshot of AEIOU Summary

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Selected User and Its Stake Holders

Activities Of Users and Its Stake Holders

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Story Telling

HAPPY

Once I was driving a car, I saw a bags and I stopped because he looked tense . and
then I understand that he was looking for taxi and I great a ride to him for his help . he
thanked me later for that and it made me happy.

HAPPY

It was a regular day . I was working on plant and suddenly plants stop working . I
was worried for a major issue and then my college told me that it was just a power cut. It
made me happy

SAD

Once I was during a car . I saw a car whose overtaking me and after sometime a terrible
read accident took place in front of my car and a person was so badly injured it made me very sad

SAD

It was a regular day . I am walking ,towards road and after sometimes I saw a car full of
lpg gas battles bumped at bumper and same of lpg bottle were dropping road and I saw a
terrible accident in front of my eyes and made just sad
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SNAPSHOT OF EMPATHY MAPPING

Date
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CHAPTER 4. IDEATION CANVASS

Explanation Of People and Their Activities

There were passengers travelling in Buses and Rickshaw, pedestrians waling, Students
going to school and collages, job workers, Road sweepers sweeping roads.

1) Identification
2) Safety
3) Boarding
4) Unloading
5) Checking

Understanding about Situation/Context and Location

1) Toxic
2) Safety
3) Traffic
4) Factories
5) On road
6) Shipping company
7) Industry
8) Accidentals
9) Infectious
10) Radioactive
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Relevant and Irrelevant Props

There were so many things nearby road. The road sweepers sweeping roads. Peoples going to
their jobs. Customers purchasing at shops. Shop owners opening their shops. People riding on
bicycle. Students waiting for the bus. Repairing and reconstruction of roads by workers. Traffic
police trying to execute the traffic situations. We can say it Very Noisy, busy and fast paced
environment.

PEOPLE

1) Labour
2) Workers
3) Public
4) Industries
5) Factory

Props/Tools/Objects/Equipment

1) Milling Machine
2) Vehicle Engine
3) Safety Tools
4) Heavy Machine
5) Modern Machine
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CHAPTER 5: PRODUCT DEVELOPMENT CANVASS

Description of Final ProblemStatement

The final problem that came by surveying is failure of mechanical brakes in cars. Another
problem is the less efficiency of brakes.

Description of Problem Solution

Product development canvas can give to insights to these problems when creating a
product, factors such as product, factors experience, product functions, product features,
and components. it is a simple but powerful tool that helps you create a product with a
great user experience and the right features.

Explanation of Product Components, Functions and Features.

COMPONENT

1) Pneumatic actuator

2) Pneumatic pipes

3) Air control valve

4) Mounts and joints

FEATUERS

1) Low initial cost

2) Easy and quick setting

3) Easy maintenance
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FUNCTION

1) Make big and right angles

2) Curved folds
3) Shape metals in required shape and size

Discussion on Product Experience

1) Easy to use
2) Eco friendly
3) Sustainable
4) Easy to operate

Discussion of Reject, Redesign and Retain Parameters

As per the need of our final product we have rejected, redesigned and retained some of
the components of the type. They are as follows:

1) Affordable
2) Easy to run
3) Efficient
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20
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CHAPTER 6. MIND MAPPING

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CHAPTER 7. LEARNING NEEDMATRIX

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CHAPTER 8. REVERSE ENGINEERING

1. Pneumatic Cylinder

Pneumatic cylinder(s) (sometimes known as air cylinders) are

mechanical devices which use the power of compressed gas to produce a force in a
reciprocating linear motion. Like hydraulic cylinders, something forces a piston to
move in the desired direction. The piston is a disc or cylinder, and the piston rod
transfers the force it develops to the object to be moved. Engineers sometimes
prefer to use pneumatics because they are quieter, cleaner, and do not require
large amounts of space for fluid storage. Because the operating fluid is a gas,
leakage from a pneumatic cylinder will not drip out and contaminate the
surroundings, making pneumatics more desirable .

2. Solenoid Valve
A solenoid valve is an electromechanically operated valve. The valve is controlled
by an electric current through a solenoid. In the case of a two-port valve the flow is
switched on or off; in the case of a three-port valve, the outflow is switched
between the two outlet ports. Multiple solenoid valves can be placed together on a
manifold. Solenoid valves are the most frequently used control elements in fluidics.
Their tasks are to shut off, release, dose, distribute or mix fluids. They are found in
many application areas. Solenoids offer fast and safe switching, high reliability, long
service life, good medium compatibility of the materials used, low control power
and compact design.
 P a g e | 27

3. Air Compressor
A solenoid valve is an electromechanically operated valve. The valve is
controlled by an electric current through a solenoid. In the case of a two-port valve
the flow is switched on or off; in the case of a three-port valve, the outflow is
switched between the two outlet ports. Multiple solenoid valves can be placed
together on a manifold. Solenoid valves are the most frequently used control
elements in fluidics. Their tasks are to shut off, release, dose, distribute or mix
fluids. They are found in many application areas. Solenoids offer fast and safe
switching, high reliability, long service life, good medium compatibility of the
materials used, low control power and compact design.

4. Air Pipe
A pipe is a tubular section or hollow cylinder, usually but not necessarily of
circular cross section, used mainly to convey substances which can flow liquids and
gases (fluids), slurries, powders, masses of small solids. It can also be used for
structural applications; hollow pipe is far stiffer per unit weight than solid
members.

5. Rods
Thermo-mechanical processing, also known as thermo mechanical treated bars’
(TMT), is a metallurgical process that integrates forging, rolling and/or work
hardening with heat-treatment into a single process.

6. Pressure Gauge
Pressure regulators, commonly called pressure- reducing valves, maintain
constant output pressure in compressed-air systems regardless of variations in input
pressure or output flow. Regulators are a special class of valve containing integral
loading, sensing, actuating, and control components. Available in many configurations,
they can be broadly classified as general purpose, special purpose or precision
 P a g e | 28

CHAPTER 9.DIACHRONIC AND SYNCHRONIC ANALYSIS

Understanding about Diachronic Analysis

The evolution of brakes has been impressive, and has included many new technologies
throughout the years. In all new developments to the brake system, the number one priority is to
improve auto safety and efficiency.

Since the earliest automobiles, several methods of braking have been used. As the history of
brakes progressed, each new system was built using the concepts used to design its predecessor.

Brake system evolution began in the 19th century, and continues today. The types of braking
systems that have been used over the years include:

• Wooden block brakes

The earliest brake system applied the physical principles used to design brakes today;
however, the system consisted only of wooden blocks and a single lever used by the

driver to apply the brake. This form was used on vehicles with steel-rimmed wheels, including
horse-drawn vehicles and steam-driven automobiles.

• Mechanical drum brakes

Considered to be the foundation of the modern braking system, the mechanical drum brake was
developed in 1902 by French manufacturer Louis Renault, but had been invented earlier by
Gottlieb Daimler. Daimler had theorized that anchoring a cable- wrapped drum to the vehicle’s
chassis could be used to stop momentum, thus creating the first concept of the drum brake.

• Expanding internal shoe brakes

Before the expanding internal shoe brake was invented, all brake systems had been fastened
outside of the vehicle. Those systems were vulnerable to the elements, collecting dust and
water, and being affected by fluctuations in temperature all of which made the brake less
effective. The internal shoe brake was the first to be fixed inside the vehicles frame, an important
innovation in the history of braking systems.
 P a g e | 29

• Hydraulic brakes
In 1918, the concept of a four-wheel brake system using hydraulics was first proposed by
Malcolm Loughead. The system used fluids to transfer force to the brake shoe when a pedal was
pressed. This braking system was adopted in nearly every vehicle by the late
1920's.

• Disc brakes
The disc brake was invented long before becoming popular. William Lanchester patented
the disc brake in 1902; the system was not popular until the auto industry began to boom in the
mid-20th century. The rise of disc brakes as a popular option is attributed to the increasing
weight and speed capabilities of vehicles, which caused hydraulic brakes to become less
efficient in distributing heat. The first system to use disc brakes integrated both disc and
hydraulic functions and was introduced in the Chrysler Imperial.

• Anti-lock brakes
The anti-lock brake system, better known as ABS, was created to assist previous braking
systems to prevent the brakes from locking up while in use. ABS works by sensing when a lock
is about to occur and igniting a system of hydraulic valves to reduce the pressure of a brake on a
single wheel. The system revolutionized the way brake’s function and is useful in providing more
control for the modern driver.

Understanding about SynchronicAnalysis

1) Your foot pushes on the brake pedal.

2) As the pedal moves down, it pushes a class 2 lever (a kind of simple machine),
increasing your pushing force.
3) The lever pushes a piston (blue) into a narrow cylinder filled with hydraulic brake
fluid (red). As the piston moves into the cylinder, it squeezes hydraulic fluid out of the end
(like a bicycle pump squeezes out air).
4) The brake fluid squirts down a long, thin pipe until it reaches another cylinder at the wheel,
which is much wider.
5) When the fluid enters the cylinder, it pushes the piston in the wider cylinder (blue)
with greatly increased force.
6) The piston pushes the brake pad (green) toward the brake disc (gray).
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7) When the brake pad touches the brake disc, friction between the two generates heat (red
cloud).
8) The friction slows down the outer wheel and tire, stopping the car.
 P a g e | 31

CHAPTER 10.SCAMPER TOOL

SUBSTITUE:
We substituted cables from mechanical brakes to fluids and pipes in
Hydraulic brakes.

COMBINE:
For some vehicle types can combine both the technologies in one vehicle to provide
more safety.

ADAPT:
We can also provide cables to ensure more safety and for emergency
stopping and for parking, from the mechanical brakes.

MODIFY:
Instead of the braking pad applying friction on the rim, we can apply it on rotor,
bringing the bike to a stop.

MAXIMIZE/MINIMIZE
We can select the type of brake fluid, which has a higher boiling point and has a
better level of lubricity that can prevent oil leaks

PUT TO OTHER USE

Many other vehicles use hydraulic brakes such as cranes and lifts or
elevators, airplanes, mining vehicles,
the uses and application for hydraulic brakes are endless and all use similar systems
and components

ELIMINATION
Hydraulic breaks eliminate the use of cables as compared to traditional brakes,
which decreases the risk of failing of to a great extent.

REVERSIBILITY AND REARRANGEMENT

The direction of rotation of which can be reversed, one of the pump gears being rotationally
driven by a drive motor and being rotationally coupled to the other gear viathe tooth
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CHAPTER 11:DESIGN CALCULATION

A. Material Selection

To prepare any machine part, the type of material should be properly selected, considering
design, safety .The selection of material for engineering application is given by the following
factors:-

1) Availability of materials
2) Suitability of the material for the required components
3) Suitability of the material for the required components.
4) Cost of the materials

The machine is basically made up of mild steel. The reasons for the selection are Mild steel is
readily available in market .It is economical to use and is available in standard sizes. It has
good mechanical properties i.e., it is easily machinable .It has moderate factor of safety,
because factor of safety results in unnecessary wastage of material and heavy selection. Low
factor of safety results in unnecessary risk of failure. It has high tensile strength. Low
coefficient of thermal expansion. The materials of the sheets to be cut are taken as aluminum
and plastic as they are replacing many metals in the present scenario because of their
distinguished properties and features.

TABLE 1: Specifications

SHEET METAL MATERIAL ALUMINIUM

THICKNESS .5 mm

LENGTH OF CUT 25 mm

Max. SHEAR STRENGTH 30 N/mm2

OF ALUMINIUM
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B. Force Calculation for cutting operation

Force required to cut the Sheet = L×t×ፘmax for sheet of 0.5 mm thickness, Force
required = 25×0.5×30= 375 N This is the force required to cut the sheet metal,
however the initial force required to cut the sheet is more and it is 10% to 20%
than we calculated, Therefore, max force required to cut the sheet = 431.25N
Now we have chosen 12-volt DC Air Compressor that develops a pressure of
10.34 bar (150psi).

B. Design of a cylinder for cutting operation

Since the max force required to cut the sheet = 431.25 N

And pressure applied by 12-volt compressor =10bar
Therefore,
Force applied by the cylinder,
F = ( /4) × d2 ×p
431.25= ( /4) × d2 ×(10/10)
d=23.43 mm
For safety , we have taken the cylinder of diameter 24 mm.

C. Force Calculation for bending operation

Force required to bend the Sheet Metal = (L × K × ut × t) / (w)

Where, ut = Ultimate Tensile Strength of Aluminum(400N/mm2

K = Die opening Factor (1.33 for V-Bending)
w = Width of Die Opening, For value of K=1.33, w=16t

Force required = (25 × 1.33 × 300 × 0.5) / (16 ×0.5) = 623.44 N

This is the force required to bend the sheet metal, however the initial force
required to cut the sheet is more and it is 15% than we calculated. Therefore, max
force required to cut the sheet = 716.96
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E. Design of a cylinder for bending operation

Since the max force required to cut the sheet = 716.96 N
And pressure applied by 12-volt compressor =10 bar
Therefore,
Force applied by the cylinder, F = ( /4) × d2 ×p
716.96= ( /4) × d2 ×(10 /10)
d=30.21 mm
For safety , we have taken the cylinder of diameter 30 mm.

F. DC Motor
A stepper motor is an electromechanical device which converts discrete electrical pulse
into discrete mechanical movements. The shaft or spindle of a stepper motor rotate at equal
angle of increment called steps when electrical command pulses are applied to it in the proper
sequence. The sequence of the applied pulse is directly related to the direction of rotation of
motor shaft and its speed directly related to the frequency of input pulses and total radiation
at a stretch is directly related to the number of input pulse applied. Stepper motors with steps
of 12, 24, 72, 144, 180 and 200 per revolution are available resulting in angle of the shaft
increments of 30°, 15°, 5°, 25°, 2° and 1.8° per step. Special micro-stepping circuitry is
sometimes provided to allow many more steps per revolution and these circuitries offer
10,000 steps per revolution or even more.
G. Specification of DC Motor
• Length : 80mm
• Torque : 1.5kg.cm
• Shaft Diameter: 6mm
• Weight : 130.00g
• Supply Voltage: 12V
• Speed = 3.5 RPM

FUTURE SCOPE:
Operation for making rod bend is tedious and required continuous manual work to
perform the bending operation. This will minimize human efforts for less physical exertion of the operator.
Adverse effect of repetitive work on human health is 22inimizing. Reduce the wastage of stirrup and this
will reduce the cost of stirrup making activity. There is a scope to design the stirrup with safety standards
and with ergonomic considerations which will help to avoid the incidents during manually stirrup making.
There is a scope to improve the stirrup making efficiency and production capacity of stirrup by using human
powered flywheel motor of stirrup making. The currently available machines are motor power (electrical
supply) operation machines and hydraulic type machine which cannot work where non availability of
electricity. This research presents a new urge as method to bend the given rod of 10, 12 mm diameter with
the help of human power as a energy source for performing the job .
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CHAPTER 12. SECONDARY RESEARCH AND REFERENCES

Prior –Art Search

Anything can be prior art. The sources of prior art include patents, published
patent applications, periodicals, books, and products. However, the most common prior
art used by Examiners at the United States Patent and Trademark Office (USPTO), by
far, are previously granted patents and patent publications. A prior art search involves
searching various publicly available sources to find out whether an invention has been
previously described or detailed in other references (i.e., prior art).

Two Research paper with conclusion by Prince Kachhadiya

1. TITLE:

FABRICATION OF PNEUMATIC ROD BENDING MACHINE AND CUTTING

MACHINE
AUTHOR:
Mr. Pratik K. Channa, Mr. Ajay S. Tiwari , Mr. Prakash V. Mahadole , Mrs.
Mrunal M. Salwan, Mr. Akshaya M. Adana, Mrs. Diksha A. Yelekar
DATE OF PUBLISH: March-2020
CONCLUSION: From this project work we conclude that Pneumatic bending machine is very
cheap as compared to hydraulic bending machine. We can increase the bending thickness by
arranging the high-pressure compressor. This machine can also be used where electricity problems
occur. This type of bending machine uses compressed air. So, when electricity problem occurs, we
can change our electric compressor to IC-Engine installed compressor. This type of bending machine
is very useful to small scale bending industries because they can’t afford the expensive hydraulic
bending machine. In this machine the manually controlled press is converted into automatic machine.
So, we can save maximum operating time and the output will also increase compared to manual. In
this project the humans have to only load and unload the TMT bars. It can be also called as semi-
automatic type bending machine. This machine can also be converted into fully automatic machine so
the loading and unloading will be done automatically. For making automatic one should have to be
fully knowledgeable in this particular field. By doing so the existing old machines can be modified
and made automatic by which the initial cost, to procure new automatic machines may be minimized.
Thus, there is a lot of scope in this area (automation). We can achieve many types of shapes by using
many types of fixtures in bed. This system is easily handled by any worker. The worker doesn’t have
to be someone knowledgeable. Because of its cheap and simple design this machine can be sell
everywhere with ease. Advance bar bending machine use for mass production. By using advance bar
bending machine increases production rate and reduce Labour cost. With the bending machine the
manual usage and cycle time is reduced. They are compact in size and reliable.
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2. TITLE: Design and Fabrication of Pneumatic Rod Bending Machine

AUTHOR: Mr. S.Suresh,M.E,1 Narasigaperumal.V 2 Ram Kumar 3 Sathish Kumar’s 4 Nitish

Kumar’s 5

DATE OF PUBLISH: ETEDM - 2021 Conference Proceedings

CONCLUSION: Useful to small scale bending from this project we conclude that
Pneumatic bending machine is very cheap as compared to hydraulic bending machine. We can
increase the bending thickness by arranging the high-pressure compressor. This machine can also be
used where electricity problems occur. This type of bending machine uses compressed air. So, when
electricity problem occurs, we can change our electric compressor to IC-Engine installed
compressor. This type of bending machine is
very industries because they can’t afford the expensive hydraulic Bending
machine.
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Two Research paper with conclusion by Jay kalavadiya

1. TITLE:
Developing a Semi-Automatic Pneumatic Bar Bending Machine

AUTHOR:
Bapuji V S, Devaraj G R, Girish S, Ramesh M C, Dr. Sridhar S

DATE OF PUBLISH: 2020

CONCLUSION: The main idea of this work is to provide ease and comfort to patients while
taking appointment from doctors and it also resolves the problems that the patients have to face
while making an appointment. The android application Mr.Doc acts as a client whereas the database
containing the doctor's details, patient's details and appointment details is maintained by a website
that acts as a server.

2.TITLE: DESIGN AND FABRICATION OF PNEUMATIC BAR BENDING

MACHINE

AUTHOR: Thokale Manoj, Kotwal Satish, Kotkar Rahul, More Suyog, Pawase Mahesh.

DATE OF PUBLISH:2017

CONCLUSION: Now a days the world is focusing into automation. Each and every work of
human is reduced by a machine, but few areas like construction the usage of machines for bending
rods for stirrups which are used to withstand loads in beams and columns are not done by machine
because the cost of machine is high and need skilled labours to operate it. In this paper is aimed to do
bending operation for stirrups using pneumatic and named as pneumatic rod bending machine. The
main objective of our paper is to implement the pneumatic rod bending machine in the construction
sites with less cost compared to the existing bending machines, and increasing the productivity of the
stirrups. Pneumatic rod bending machine consist of Pneumatic cylinder, Compressor, Hoses, Pulley,
cutting blades, Fixture, Electronic circuits, Switches and wiring .The rod is bent by the Pneumatic
cylinder piston with holding the rod in the fixture. The main advantage of our paper is the square
shape of the Stirrups is bent continuously without repositioning the rod in the machine.
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Two Research paper with conclusion by Prajapati Jagadish

1.TITLE: DESIGN AND FABRICATION OF PNEUMATIC BAR BENDING

MACHINE

AUTHOR: Thokale Manoj1, Kothwal Satish2, Kotkar Rahul3, More Suyog4, Pawase
Mahesh5

DATE OF PUBLISH: Mar -2017

CONCLUSION:
In latest attempt a successful solution for the manual stirrup making is obtained.

By using various fixtures in the table, we can ably achieve different shapes
and sizes of the stirrups.
The system can be handled by any operator very easily.
Since it is cheap and simple design this machine can be sell to anywhere
across the nation.

Advance bar bending machine use for mass production. By using advance
bar bending machine increases production rate and reduce Labour cost.

2.TITLE: Pneumatic Shearing and Bending Machine

AUTHOR: Vishal Tambar, Nilkanth Rane, Omkar Savant, Pankaj Yadav

DATE OF PUBLISH: April 2015

CONCLUSION: Now we know that Pneumatic Shearing machine is very cheap as compared to
hydraulic shearing machine. The range of the cutting thickness can be increased by arranging a high-
pressure compressor and this machine is advantageous to small sheet metal cutting industries as they
do not have rely on the expensive hydraulic shearing machine
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Two Research paper with conclusion by Prajapati Jitendra

1.TITLE: Design and Fabrication of Pneumatic Punching and Bending Machine

AUTHOR: Girish Gharat , Aniket Patil, Harshal Mhatre, Sandesh Satvi

DATE OF PUBLISH:2015

CONCLUSION: This project has met its objective to produce a Frame

Pneumatic Press and its function are limited to V-Bending and Punching. We designed a
pneumatic press which costs less than that available in the market. We are very good at what we
have done and had fun doing it. Our pneumatic press is useful to do metal forming operations and
as it is a 2-ton capacity press. We can do simple operations like bending, punching. which is very
useful and helpful to do small works at our college. We chose a simple c-frame press which
occupies less space which any one can operate. We tested our project by producing a V-bend and
punching the sheet metal. As our project is based on manufacturing of pneumatic punching and V-
bending, further modifications can be done and increase its applications.

2.TITLE: Review Paper on Design and Development of Metal Bending Machine

AUTHOR: A. D.Zope, R.R.Deshmukh, D.R.Mete, V.S.Mane

DATE OF PUBLISH: 18th March 2017

CONCLUSION: To bend metal sheet and pipe in one system. To operate the system
hydraulically. To ease the operation in small scale industries.
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Two Research paper with conclusion by Modi Karan

1.TITLE: A REVIEW PAPER ON AUTOMATIC PNEUMATIC BAR BENDING MACHINE

AUTHOR: Ranjeet D Patil, Akshaya M Jadhav, Prashant N Mundhfane, Anil P Throat

DATE OF PUBLISH: 15th -16th March- 2018

CONCLUSION: The manually controlled press is converted into automatic machine by which
maximum operating time will be saved. Thus the output will be more. In this project the human
intervention is for loading and unloading the bar. It may be called as semiautomatic machine. This
machine can be converted into a fully automatic machine where loading
and unloading of the bar can be pass automatically. To conclude, this project is made keeping
in mind that any manually operated machine can be converted to automatic machines by using
pneumatic, electrical and electronic devices . Thus, there is a lot of scope in this area
(automation).

2.TITLE: DESIGN OF AUTOMATIC PNEUMATIC SHEET METAL AND PAPER

CUTTING machine

AUTHOR: SACHIN S RAJ, S.MANICKAM, M.MEGANATHAN,

G.NANDHAKUMAR, M.PUSHPARAJ, Dr N.BALAKRISHNAN

DATE OF PUBLISH:2017-2018

CONCLUSION:

The pneumatic is more efficient in the technical field,

Quick response is achieved,
Simple in construction,
Easy maintenance and repair,
Cost of unit is very less,
No fire hazard problem due to overloading,
Continuous operation is possible without stopping.
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