Group-D1

Project Title: Design of Pipe

Bending Machine

Project Guide: Prof. Dr. Raju Ladhwe

1
Group Members -

Name MIS
Omkar Fulkar 111910067
Omkar Harihar 111910068
Onkar Jadhav 111910069
Paridha Talmale 111910070

2
 INDEX

Sr. No Title Page No.

1 Introduction of the Machine 4
2 List of Components 4
3 List of Materials 4
4 Spur & Bevel Gears 5
5 Pillow Bearing Calculation 6
6 Shaft dimensions 6,7
7 Shaft Tolerance calculation, limits & fit 7,8
8 Bending force calculation 8,9
9 Handle Dimension & Torque generated 10
10 Dimensions of V block 10
11 Pulley/Die Dimension 11,12
12 Thrust Ball Bearing (SKF Catalog) 13-17
13 Deep Groove Ball Bearing (SKF Catalog) 20
14 Spur Gear Calculations 21,22
15 Bevel Gear Calculations 22,23
16 C-Clamp Calculation 24
17 Square key Calculation 24,25
18 Results Table 26
19 References 27

3
Introduction:
This machine is used to bend steel into a curve or other curvature shape.
This pipe bending machine is manually operated but less human effort is
required. This machine uses spur gear and bevel gears For power
transmission.

List of Components:
1. Handle
2. Bevel Gear
3. Spur Gear
4. Pulley
5. V Block
6. C clamp / oscillating handle
7. Thrust bearing
8. Deep Groove ball bearing
9. Pillow bearing block
10. Shafts
11. Shaft key
12. Pipe to be bended

Materials used:
1. Handle - Cast Iron
2. Bevel Gear - Alloy Steel
3. Spur Gear - Alloy Steel
4. Die/Pulley - Steel
5. V Block - Cast Iron
6. C-Clamp - Cast Iron
7. Thrust Ball Bearing - Stainless steel
8. Deep Groove Ball bearing - Stainless steel
9. Pillow bearing Block - Cast Iron
10. Shafts - Carbon Steel
11. Shaft key - Carbon Steel
12. Pipe - Steel

4
Spur Gears:
Spur gears are a type of cylindrical gear, with shafts that are parallel and
coplanar, and teeth that are straight and oriented parallel to the shafts.

Spur gears are used in mechanical applications to increase or decrease the

speed of a device or multiply torque by transmitting motion and power from
one shaft to another through a series of mated gears.

The teeth of a spur gear have an involute profile and mesh one tooth at a
time. The involute form means that spur gears only produce radial forces
(no axial forces).Spur gears are typically used for lower speed applications,
although they can be used at almost any speed.

Spur gears are generally seen as best for applications that require speed
reduction and torque multiplication.

Bevel Gears:
A bevel gear is a toothed rotating machine element used to transfer
mechanical energy or shaft power between shafts that are intersecting,
either perpendicular or at an angle. This results in a change in the axis of
rotation of the shaft power.
Aside from this function, bevel gears can also increase or decrease torque
while producing the opposite effect on the angular speed.

The gear transmitting the shaft power is called the driver gear, while the
gear where power is being transmitted is called the driven gear. The
number of teeth of the driver and driven gear are usually different to
produce a mechanical advantage. The ratio between the number of teeth of
the driven to the driver gear is known as the gear ratio.

5
DESIGN CALCULATIONS :

Pillow Bearing block:

Material - cast iron or cast steel

Two horizontal shafts passing through these blocks-

Dia = 30mm
Length = 400mm
6
Shaft 2 —> passing through the center of the die or pulley
Dia = 50mm
Length = 50mm

Material:
Carbon Steel
—-------------------------------------------------------------------------------------------------
Shaft Tolerance Calculation:
Fit: Interference Fit
1) Shaft passing through bevel gears

H7/p6 designation
D = 50 mm so in range 30-50mm
H7 basic size= 50 mm
a) For hole, H7
Tolerance grade T7, H type hole
So tolerance= 0.023mm
H type hole, so hole basis system
Fundamental deviation of hole = lower deviation = 0
Lower limit = base size + fundamental deviation
Lower limit = 50 + 0
= 50 mm
Upper limit = lower limit + tolerance
= 50 + 0.023
Upper limit =50.023 mm
Hole dimension 50^(+0.023,+0.000) mm

b) For shaft of p6
Tolerance grade, 6p type shaft
So tolerance = 0.0156mm
Lower deviation = IT7 + 0 = 0.023mm
Upper deviation = Tolerance + Lower deviation = 0.0156 + 0.023
= 0.0386mm
Shaft dimensions = 50^(+0.0386,+0.023) mm
2) Shaft passing through pillow bearings

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H7/r6 designation
D = 30 mm so in range 18-30mm
H7 basic size= 30 mm

a) For hole, H7
Tolerance grade T7, H type hole
So tolerance= 0.03mm
H type hole, so hole basis system
Fundamental deviation of hole = lower deviation = 0
Lower limit = base size + fundamental deviation
Lower limit = 30 + 0
= 30 mm
Upper limit = lower limit + tolerance
= 30 + 0.03
Upper limit =30.03 mm
Hole dimension 30^(+0.03,+0.000) mm

b)For shaft of r6
Tolerance grade, 6r type shaft
So tolerance = 0.013mm
Lower deviation = 0.53mm
Upper deviation = Tolerance + Lower deviation = 0.013 + 0.53
= 0.543mm

Shaft dimensions = 30^(+0.543,+0.530) mm

—---------------------------------------------------------------------------------------------------------

Bending Force Calculation :

Pipe to be bent:
Dimensions:
Max Outer Dia, D = 50mm = 5cm
Thickness = 2t = 1 cm
t = 0.5 cm = 5mm
Inner Dia, d = D - 2t = 5 - 1 = 4cm = 40mm
Material:

8
Mild Steel

Allowable bending stress (σb) = 300 N/mm^2 ……..(PSG data book)

Sut = 420 MPa
Syt = 350 MPa
Fos = 3 ………………(for steel pipes)

Permissible tensile Stress:

σ = Syt / Fos = 350 / 3
= 116.67 N/mm^2

Flexural formula
𝑀/𝐼=σ/𝑌

Bending moment is given by

M=F×L

𝐹 = (𝜎 × I) /(𝐿 × 𝑌)

Where, I= Moment of inertia

Y= Distance between C.G. and baseline
L= Length of pipe

𝐼 = 𝜋 (𝐷^ 4 − 𝑑^ 4 )/64
= 3.14 * (50^4 - 40^4) / 64
= 1.81 * 10^5 mm^4

Y = D/2 =25mm

Assume length of pipe 500mm

F = (300*1.81*10^5)/(500*25)
= 4344 N
F = 4.34 kN

9
Dimensions of Handle -
Vertical length = 150mm
Horizontal length = 170mm
Material - Cast iron

Syt = 300 N/mm^2

Fos = 2
Permissible Stress = 150 N/mm^2

Assume max force applied by human on the handle is about 120N

Torque generated = force applied * horizontal distance
= 120 * 170
= 20400 N-mm

V Block

Material - Cast iron

10
dmax = 50mm
Hence, a = 63mm
b = 50mm
c = 50mm
dmin = 5mm

Die Calculation
A die is located on the vertical shaft and is connected with the bevel gear
pair. This die is fixed. The C clamp is attached to the die and holds the V
block, where the pipe is inserted.

Pulley/Die -
Material -Mild Steel
Center bearing hole dia = 49.8 - 50mm
B = 30mm
A = 600mm

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12
Thrust ball bearing -

A thrust ball bearing consists of a row of balls running between two rings—
the shaft ring and the housing ring. Thrust ball bearing carries thrust load in
only one direction and cannot carry any radial load.
The use of a large number of balls results in high thrust load carrying
capacity in smaller space.

The balls and the inner and outer races are made of high carbon
chromium steel (SAE 52100 or AISI 5210).
It contains 1 per cent carbon and 1.5 per cent chromium. The balls and
races are through-hardened to obtain a minimum hardness of 58 Rockwell
C.

The cages are made from stampings of low carbon steel.

The rollers are made of case hardened steels (AISI 3310, 4620 or 8620).
They are case carburized to obtain a surface hardness of 58 Rockwell C.
It should be noted that balls are through hardened, while the rollers are
case hardened.

Calculation:

The expression for the equivalent dynamic load is written as,

P = XVFr + YFa

13
where, P = equivalent dynamic load (N)
Fr = radial load (N)
Fa = axial or thrust load (N)
V = race-rotation factor
X and Y are radial and thrust factors respectively and their values
are given in the manufacturer’s catalogs.

When the bearing is subjected to pure thrust load Fa ,

P = Fa

The relationship between the dynamic load carrying capacity, the

equivalent dynamic load, and the bearing life is given by,

where, L10 = rated bearing life (in million revolutions)

C = dynamic load capacity (N)
p = 3 (for ball bearings)
p = 10/3 (for roller bearings)

For all types of ball bearings,

For all types of roller bearings,

The relationship between life in million revolutions and life in working hours
is given by

14
where, L10h = rated bearing life (hours)
n = speed of rotation (rpm)
The forces acting on the bearing are calculated by considering the
equilibrium of forces in vertical and horizontal planes.

The forces determined by these equations are multiplied by a load factor to

determine the dynamic load carrying capacity of the bearing.

15
16
d = 50mm
b = 70-78 mm
H = 22mm
C (dynamic load) = 49.4kN
Co (static load) = 116kN
Pu (Fatigue load limit) = 4.3kN
A = 0.069
Ref. Speed = 3400 rpm
Limiting speed = 4500 rpm
Mass = 0.37kg
Designation = 51210
d1 = 78mm
D1 = 52mm
r1,2 = 1mm
da min = 67mm
Da max = 61mm
ra max = 1mm

Therefore, (Ref loads table for formula)

Fam (Minimum axial load) = 0.069 (4500/1000)^2 = 1.39 kN
Assume L10h = 10,000 hrs
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L10 = (60*4500*10000)/10^6 = 2700 hrs

49.4 = P (2700)^(⅓)

P = 3.55 kN
= 3550 N
= Fa (Axial Force)

Single direction thrust ball bearings

• consist of a shaft washer, a housing washer and a ball and cage
assembly (fig. 4)
• can accommodate axial loads and locate a shaft axially, in one direction
only.

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19
Deep Groove Ball Bearing:

20
Spur Gear Calculations:
Assume Gear ratio of 1:3
Teeth on pinion, Zp = 22
Teeth on gear, Zg = 66

Permissible bending stress σb = 116.67N/mm^2

Yp = 0.0484 - 2.87/22 = 0.3535
Yg = 0.0484 - 2.87/66 = 0.4405

σbYp = 41.242
σbYg = 51.393

As σbYp < σoYg, pinion is weaker than gear in bending failure Hence it is
necessary to design the pinion for bending.

Bending strength

Fb = σb. b. m. p
Assume face width, b=lom.

Fb = 116.67 X 10 m X m X 0.3535
Fb = 412.428 m² N - D

Effective Load:

Feff = ka km Ft/Kv

Ft=2Mt/dp.

Mt=20400 N-mm

Ft= 2 X20400/22m
=1854.54/m

Feff = ka km Ft/kv

Assume service factor Ka=2

21
Kv = 6/(6+v)

np= 30 rpm.

V=piX22m X30/(60*1000) = 0.03455 m m/s.

On solving we get m = 3

Dimensions of gear pair

dp = mZp = 3 (22) = 66mm

dg=mZg = 3 (66) = 198 mm
CD = (dp+dg)/2 = (66 +198)/2 = 13.2 mm.
ha = 1(3) = 3 mm
ht= 1.25 (3)=3.75mm

Ft= 1854.54/3 = 618.18 N

Feff = 618.18 [ 6 + 0.03455 (3)] /3

Feff=1257.718 N
Fb= 412.428 (3) ² = 3711.852N
Fb =3711.852 N

Available Factor of safety Fb = Fs. Feff

Fs= 3711.852/1257718

= 2.9512 > 2

Design for gear pair is safe against bending failure

Bevel Gear Calculation:

Consider Gear ratio: 1:4.
Teeth on pinion, Zp=22

Teeth on gear, Zg = 88.

22
tanYp=Zp/Zg=22/88 = 0.25

Yp=tan^-¹ (0,25) = 14.036°

Yg = 90 - Yp = 90-19.036
Yg = 75.964°

Formative teeths on pinion & Gear

Zp’= Zp/cos(14.036) = 22/cos(14.036) = 22.677

Zg’= Zg/cos(75.964) = 88/cos(75.964) = 362.89

Yp’= 0.484-2.87/22.677
Yp ‘= 0.3574

Yg’=0.484-2.87/362.839
Yg’ =0.4760

σb=116.67 N/mm²

σbYp’=116.67X 0.3574= 41.697

σb Yg’ = 116.67X0.4760 = 55.534

As σbYp’ <σb Yg' pinion is weaker than gear in bending. Hence it is necessary to
design the pinion for bending..

Bending strength.
AO= 45.3541m mm
Fb = 325.07m^2 N

Torque generated = 20400 Nm

On calculation we get m= 2.96 = 3

Dimensions of gear

dp=mZp= 3*(22) = 66mm

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dg=mZg = 3*(88) = 264 mm

A0 = 45.3541(3) = 136.0623 m

ha = 1(3) = 3mm.
hf = 1.25 (3) = 3.75mm

Ft = 694.8 N

Feff = 1413.60 N

Fb= 2925.63 N

Available factor of safety

Fb= Fs. Feff

Fs = 2925.63/1413.60 = 2.07>2

Design for bevel gear pairs is safe against bending failure.

C-Clamp Calculation:

W = 392.4 N……………………………...weight of Die

A=b*t………………………………………..Assume b=2t
e = 400mm………………..........................Considered
Factor of Safety = 2
Syt = 300 N/mm^2

24
Permissible Stress = 150N/mm^2………..From data book-for Cast Iron and by
……………………………………………….Calculation

Calculation:
σ = W/A = 392.4/2t^2
σ b = 6We/tb^2 = (6*392.4*400) / 4t^3
σ + σ b = Permissible Stress
392.4/2t^2 + (6*392.4*400) / 4t^3 = 150

Solving the above equation we get,

t=11.6mm =12mm
Hence, b=2t = 2*12 = 24mm
Length = 400mm
Height = 85mm

—---------------------------------------------------------------------------------------------------------
Square key Calculation:

T = 20400 Nmm
P = 64kW
N = 30 rpm
Syt = 460 N/mm^2 (Steel 50C4)
fs = 3
D = 30mm

Syc =Syt = 460 N/mm^2

σc = Syc/fs = 153.33 N/mm^2
Ssy= 0.5Syt = 230 N/mm^2
Tau = Ssy/fs = 76.67 N/mm^2

b = h = D/4 = 7.5 = 7mm

L = 2T/Tau*D*b = 25mm = 2.5 cm

Dimension of Key = 7x7x25

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 Results Table:

Components Materials Dimensions

Spur Gears Alloy steel 15 Cr 3 Mo 55 Zp = 22, Zg = 66, m=3, dp =
66mm, dg =198mm, ha=3mm,
hf=3.75mm

Bevel Gears Alloy steel 15 Cr 3 Mo 55 Zp = 22, Zg = 88, m=3, dp =

66mm, dg = 264mm, ha=3mm,
hf=3.75mm

Frame Mild Steel

Thrust Ball Bearing Stainless Steel d = 50mm, b = 70-78 mm,

H = 22mm, Mass = 0.37kg
Designation = 51210
d1 = 78mm, D1 = 52mm
r1,2 = 1mm, da min = 67mm
Da max = 61mm,
ra max = 1mm

Deep Groove Ball Bearing Stainless Steel d = 50mm, D=90mm, B= 20mm

C- frame Cast Iron t=12mm, b=24mm, L=400mm,

H=85mm
Die Steel Dia = 600mm, Width = 30mm
Handle Cast Iron L= 150mm, H = 170mm

Shaft 1 Carbon Steel D=30mm,

Shaft 2 D=50mm
Square Key Carbon Steel Square key, 7mmx7mmx25mm

Bolts Steel M10x40mm, M16x100mm

Pipe Steel D = 50mm

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REFERENCES:

https://www.skf.com/binaries/pub12/Images/0901d196802809de-
Rolling-bearings---17000_1-EN_tcm_12-121486.pdf

SKF bearings catalog

V.B Bhandari
PSG Databook

27