Sample Project-1 Report NILESH

Sheet Rounder Machine
SUBMITTED IN
PARTIAL FULFILLMENT
DIPLOMA
IN
MECHANICAL ENGINEERING
PREPARED BY:
DHOBI NILESH 216450319028

PADHIYAR AAYUSH 216450319079
VASAVA CHIRAG 216450319025
PATEL PRIT 216450319056
RANA HARDIK 216450319011
SOLANKI ADITYAKUMAR 216450319042
Diploma in Mechanical
GUIDED BY
MRS UJWALA S.
2023-2024
Department Of Mechanical Engineering

Shri K.J. Polytechnic Bharuch
Bharuch – 392001, Gujarat, India
2023-2024 KJP BHARUCH

CERTIFICATE
This is to certify that Enrolment No: _________________________

Mr./Ms.______________________________________________________________
____________________________________________________________________
From Shri K.J.Polytechnic, Bharuch Institute has completed
Mechanical Engineering Project-I Report of Semester-V having
title________________________________________________________________
______________________________________________________________________
(Project Id: _____________) in a group consisting of _______students
under the guidance of the Faculty Guide__________________________
_____________________________ in the academic year:_________________
The mentor from the industry for the project, if any:
Name:
Industry:
Contact Details:
Institute Guide Industry Guide Head of Department
DEPARTMENT OF MECHANICAL ENGINEERING

BHARUCH-392001, GUJARAT, INDIA

MECHANICAL ENGINEERING DEPARTMENT
INSTITUTE VISION AND MISSION STATEMENTS
INSTITUTE’S VISION STATEMENT
Is an Excellent Institute in Technical Education Committed to Fulfill the

Needs of Industry and Society.
INSTITUTE’S MISSION STATEMENTS
• To Provide a Conducive Environment for Qualitative Learning and

Nurture Teamwork.
• To Foster the Skills of Employability, Innovation and

Entrepreneurship among Students.
• To Bridge the Gap between Curriculum and Needs of Society.
DEPARTMENT VISION AND MISSION STATEMENTS
MECHANICAL DEPARTMENT’S VISION STATEMENT
• To become an excellent department in technical education

developing competent diploma mechanical engineers to meet the
needs of industry and society.
MECHANICAL DEPARTMENT’S MISSION STATEMENTS
• To impart quality education through innovative practices to enhance

technical skills in students.
• To provide conducive environment through industry interaction,
expert lecture and technical workshop to enhance skills of
employability, innovation and entrepreneurship in students.
• To inculcate soft skills and ethical values in students by organizing
events, extra-curricular and Co-curricular activities to adapt to the
needs of industry and society.

COURSE OBJECTIVE AND COURSE OUTCOMES
COURSE OBJECTIVE: This course is designed to develop the ability in the

student identify and estimate element of cost in various engineering processes.
This will also be helpful in budgeting and analysis.
COURSE OUTCOMES (CO): At the end of this course, the students should
be able to
COURSE CO’s CODE COURSE OUTCOMES

CODE
C4351904.1 Conduct the visit and/or survey to search
the problem.
Select the problem and outline the conceptual
C4351904.2
model of its solution.
4351904
C4351904.3 Modify the conceptual model of a solution
based on safety, quality, cost or sustainability
C4351904.4 Prepare plans and estimates for the solution
and Project-I report.

PROJECT RUBRICS
Subject: PROJECT-I (4351904) SEM: 5th
Project Title: - sheet rounder machine
Group No: - 3
Project Mentor: - Mrs. Ujwala Salunkhe
Group Leader: - Dhobi Nilesh R.
TOTAL
CRITERIA(RUBRICS) EXCELENT GOOD AVERAGE POOR
MARKS
5 4 3 2
Logbook 5
5 4 3 2
Literature Survey 5
Concept development 10 7.5 5 2.5
10
and finalization of topic
Drawings, plans and 10 7.5 5 2.5
10
estimates
5 4 3 2
Budget Analysis 5
Presentation 5 4 3 2
5
Report write-up 5 4 3 2
5
Conclusion, Future 5 4 3 2
5
Scope
TOTAL MARKS
Faculty’s Sign

DECLARATION
We here by declared that the work, which is being presented in the report, entitled
“Sheet Rounder Machine” in partial fulfillment for the award of “Diploma
engineering” in department of Mechanical Engineering at SHRI
K.J.POLYTECHNIC. Is a record of our own investigations carried out under
the guidance of VIDYA SAGAR SINHA Department of Mechanical
Engineering. We not submitted anywhere the matter presented in this project for
the award for any degree.

ACKNOWLEDGEMENT
It gives me immense pleasure to express my sense of sincere gratitude towards

respected guide Mrs. Ujwala Salunkhe (Lecturer, Mechanical Engineering) for his
constant encouragement and valuable guidance during the preliminary work in project.
I would like to thank our Head of the Department Mr. N . B . V A S A V and

Principal Mr. S.M. MISTRY, who provided me opportunity to do this dissertation.
I also express my sincere thanks all staff members and those who have directly or
indirectly helped me in successfully completion of the dissertation.

ABSTRACT
A sheet rolling machine, also known as a plate rolling machine, roll bending machine,
or plate bending machine, rolls sheet metal into a round or conical shape. It uses a set
of rollers to bend the metal into a cylindrical shape. Cones and other curved shapes
can also be made using this machine. Sheet rolling machines are used to roll out thin
sheets of metal for a variety of industrial purposes. Here are some things to consider
when buying A plate rolling machine is a machine that will roll different kinds of sheet
metal into a round or conical shape. It can be also called a “roll bending machine”,
“plate bending machine” or “rolling machine”.

CONTENT
Acknowledgements
Abstract
Table of contents
1. Introduction
1.1 Features of sheet rounder machine

1.2 Problem Statement
1.3 Objectives
1.4 Scope
2 About frame
2.1 Fabrication
2.2 Body Parts
3 Manufacturing Processes
4 Materials
4.1 Factor of Safety
4.2 General design principles
5 2D drawing
6 Advantages and disadvantages
7 Future Scopes
8 Conclusions
9 References

INTRODUCTION
Sheet metal fabrication plays an important role in the metal manufacturing world
(Cloutier, 2000). Sheet metal is used in the production of materials ranging from
tools, to hinges, automobiles etc. Sheet metal fabrication ranges from deep
drawing, stamping, forming, and hydro forming, to high-energy-rate forming
(HERF) to create desired shapes (Cloutier, 2000). Fascinating and elegant shapes
may be folded from a single plane sheet of material without stretching, tearing or
cutting, if one incorporates curved folds into the design (Martin et al., 2008). Shape
rolling of sheet metal is the bending continually of the piece along a linear axis.
This causes alteration of the original form of the sheet as it passes through a
pathway of series of rollers. Such work tool as shape rolling machine is found to
be very useful in manufacturing processes for used parts in various industries like
inner and outer panels and stiffeners in automotive and agricultural industries,
small metal workshops to roll round and conical profiles for stoves, cylinders (flue
pipe, water pipes), basic machine elements with curved surfaces, buckets, bins,
gear box cover, mud guards, drinkers and feeders for poultry, feed mixers etc. and
also in food cans and civil engineering applications. A wide range of these products
should satisfy tight tolerances compared to desired geometry.
1.1 Features of sheet rounder machine
• Low initial cost
• Low tooling cost
• Easy & Quick setting
• Enormous versatility
• Accurate repetition & bending
• User friendly
• Easy maintenance
• Standard spares, hence easy availability

1.2 Problem Statement
Sheet metal/plate rolling machines are extremely dangerous, especially because it

is not generally practicable to have the rollers guarded with a solid structure (e.g.
fixed guard). Often the operator's hands are caught and drawn into the counter-
rotating rollers, usually during the initial feeding of the work piece. A large number
of incidents involving sheet metal/plate rolling machines have resulted in
amputations and other serious injuries, with a large proportion of them being
associated with the operator wearing gloves. Additionally, it is not uncommon for a
person walking past the machine to slip, trip or fall and find that their hands have
been caught in the machine.
1.3 Objectives
The following are the objectives of the work:

a. To make a bending machine to bend metal sheets up to 8 mm.
b. To make on simple working principle.
c. To reduce the time for operation.
d. To make in minimum cost.
1.4 Scope
• Fabricating/Rolling
• Boilers, Pressure Vessels
• Storage Tanks, Silos
• Tubes and Pipelines
• Pumps, Burners and Filters
• Heating and Ventilation
• Wind Towers, Power Generation

2. ABOUT MS FRAME
Building frames: Mild steel is used to build frames for tents. It's also used in the construction
of small and large structures, including warehouses, buildings, bridges, and railway stations.
Car bodywork parts: Mild steel is a popular choice for car bodywork parts.
Utensils and pipes: Mild steel can be crafted into useful items like utensils or pipes.
Fig- 1: frame

2.1 Fabrication
Fabrication is the building of overall structures by cutting, and assembling processes.

It is a value added process that involves the creation of machine parts, and structures
from various raw materials. The raw materials we used.
For fabrication with their dimensions are as follows:
1. MS hollow pipe.
2. MS square hollow pipe.
3. Solid rod.
2.2 Body Parts
1. Basic frame :

2. ROLLER :-
Prepare Surface:*Ensure the surface where you'll be using the roller is clean and
smooth.
Select Roller Type: Choose the appropriate roller based on your task, whether it's
a paint roller, dough roller, or any other type.
Load Material: If applicable, load the material onto the roller. For paint rollers, dip
it into the paint tray and roll to evenly distribute the paint.
Apply Pressure: Use consistent pressure while rolling. Too much pressure can lead
to uneven results, and too little may not achieve the desired effect.
Roll in Sections: Work in small sections, rolling back and forth to cover the entire
area evenly.
Fig- 2: roller

3. MANUAL HANDEL :-
Some good handling techniques include:
• Keeping your shoulders level and facing in the same direction as your hips
• Turning by moving your feet instead of twisting and lifting at the same time
• Keeping your head up when handling
• Looking ahead not down at the load once it is held securely
Manual handling training can help minimize the risk of injury by addressing the safe
and proper techniques for performing tasks.
Fig.-3: HANDEL

3 Manufacturing Processes
1. Welding Process :
Welding is a fabrication process whereby two or more parts are fused together by
means of heat, pressure or both forming a join as the parts cool. Welding is usually
used on metals and thermoplastics but can also be used on wood. The completed
welded joint may be referred to as a weldment. Welding is a fabrication or sculptural
process that joins materials, usually metals or thermoplastics, In addition to melting
the base metal, a filler material is typically added to the joint to form a pool of molten
material (the weld pool) that cools to form a joint that, based on weld configuration
(butt, fillet, etc.),
FIG.WELDING PROCESS
2. Drilling process:
We have used drilling machine for drilling holes in the rectangular cross
section. We also used the machine to drill the holes in the top plate according to the
projections of rectangular cross section.
FIG.VERTICAL DRILLING MACHINE

3. Grinding process :-
We used the grinding machine to cut the hollow mild steel pipe for providing
ventilation to driving bearing also to reduce the weight. We used the grinding
machine to cut the circular bars according to the dimensions.
FIG. Grinding Process
4. Cutting Process :-
Cutting processes applied for cutting of metal rods, M S hollow pipes, different metal
rodsused in project.
FIG. Cutting Process

4 Materials
o MS HOLLOW PIPE.
o MS SQUARE HOLLOW PIPE.
o THICK PLATE.
o BEARING.
o SOLID ROD.

4.1 Factor of Safety
Safe work procedures should be written to cover such things as inspection and
maintenance, cleaning, safe operation of the machine, emergency situations,
reporting faults and defects immediately. Of particular importance, as part of safe
work procedures, is to ensure:
• Use of gloves with fingertips and the wearing of loose fitting clothing are prohibited.
• Work pieces are held far enough back from the edge being fed into the rollers to
allow for in feed speed.
• The area around the machine is well-lit and free of materials which may cause
slips, trips and falls.
4.2 General design principals
Following basic shearing operation on a sheet metal, components can be rolled to give
it a definite shape, Bending of parts depends upon material properties at the location
of the bend. To achieve bending, the work material must be subjected to two major
forces; frictional force which causes a no- slip action when metal and roller came in
contact and a bending force acting against the forward speed and the torque applied
to move the material.
Fig 4. Shape rolling mechanism
At least two rollers are involved in flat rolling depending on the thickness and properties
of material while three or multiple roller system is required in shape rolling. A work
material under bending load is subjected to some form of residual stress and
deformation as it bends. Materials at the outer bend radius undergo tensile plastic

deformation while the material at the inner bend radius undergoes compressive plastic
deformation.
Fig- 5: Shape rolling mechanism

2D DRAWING:
Fig- 6: roller

Fig- 7: sheet rounder machine

ADVANTAGES AND DISADVANTAGES
• Advantages of sheet rounder machine.
1. Cost-effective.
2. Simple to use.
3. Less weight.
4. Little tooling.
• Disadvantages of sheet rounder machine.
1. Less precise: manual bending machines are not as precise as automatic bending
machine.
2. Time consuming: manual bending machines require manual labor.
3. Incorrect bending radius: an incorrect bending radius can cause damage to
tooling and result in inaccurate bending.

7 FUTURE SCOPE
Sheet bending machines are often used in combination with bolts, rivets, or a welding
process. They have many applications, including in industrial equipment, household
appliances, furniture, and automotive. A sheet rolling machine compresses raw metal
into a thinner and more uniform shape. This is an essential step in the production of
sheet metal. A manually operated sheet rolling machine can be used in any machine
parts that have sheet rollers.

8.Conclusion
The shape rolling machine is very efficient in rolling curved sections.

The machine is cost effective based on the materials of production and
simplicity of the design of component parts. Operational mode meets
the level of technical knowhow of the artisans.

References
1) https://youtu.be/cJYWbbxgnjg?si=ze83pkhFmD8MnPBE
2) https://www.researchgate.net/publication/275642320

WORK ALLOCATION MATRIX

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Sheet Rounder Machine

DHOBI NILESH 216450319028

Department Of Mechanical Engineering

2023-2024 KJP BHARUCH

This is to certify that Enrolment No: _________________________

Institute Guide Industry Guide Head of Department

DEPARTMENT OF MECHANICAL ENGINEERING

2023-2024 KJP BHARUCH

INSTITUTE VISION AND MISSION STATEMENTS

INSTITUTE’S VISION STATEMENT

Is an Excellent Institute in Technical Education Committed to Fulfill the

INSTITUTE’S MISSION STATEMENTS

• To Provide a Conducive Environment for Qualitative Learning and

• To Foster the Skills of Employability, Innovation and

• To Bridge the Gap between Curriculum and Needs of Society.

DEPARTMENT VISION AND MISSION STATEMENTS

MECHANICAL DEPARTMENT’S VISION STATEMENT

• To become an excellent department in technical education

MECHANICAL DEPARTMENT’S MISSION STATEMENTS

• To impart quality education through innovative practices to enhance

2023-2024 KJP BHARUCH

COURSE OBJECTIVE: This course is designed to develop the ability in the

COURSE CO’s CODE COURSE OUTCOMES

2023-2024 KJP BHARUCH

Subject: PROJECT-I (4351904) SEM: 5th

Project Title: - sheet rounder machine

Project Mentor: - Mrs. Ujwala Salunkhe

Group Leader: - Dhobi Nilesh R.

2023-2024 KJP BHARUCH

2023-2024 KJP BHARUCH

It gives me immense pleasure to express my sense of sincere gratitude towards

I would like to thank our Head of the Department Mr. N . B . V A S A V and

2023-2024 KJP BHARUCH

2023-2024 KJP BHARUCH

1.1 Features of sheet rounder machine

4.1 Factor of Safety

4.2 General design principles

2023-2024 KJP BHARUCH

1.1 Features of sheet rounder machine

• Low initial cost

• Low tooling cost

• Easy & Quick setting

• Accurate repetition & bending

• Standard spares, hence easy availability

2023-2024 KJP BHARUCH

Sheet metal/plate rolling machines are extremely dangerous, especially because it

The following are the objectives of the work:

2023-2024 KJP BHARUCH

2023-2024 KJP BHARUCH

Fabrication is the building of overall structures by cutting, and assembling processes.

For fabrication with their dimensions are as follows:

2.2 Body Parts

2023-2024 KJP BHARUCH

2023-2024 KJP BHARUCH

Some good handling techniques include:

• Keeping your head up when handling

• Looking ahead not down at the load once it is held securely

2023-2024 KJP BHARUCH

FIG.VERTICAL DRILLING MACHINE

FIG. Grinding Process

FIG. Cutting Process

2023-2024 KJP BHARUCH

o MS SQUARE HOLLOW PIPE.

2023-2024 KJP BHARUCH