I.

CALCULATIONS:
(A) Design the upper roller.
(B) Design of the lower roller.
(C) Dynamic analysis.
(D) Power calculations.
(E) Summary of the calculations.

_Roll bending process is an important metal forming process used to produce cylindrical sections for
various applications. 3-roller bending is one such process. For this process it is important to evaluate
the maximum force acting on the rollers during the rolling process for designing the rolling machine.

(A) Design the upper roller:

1. Calculations of the force applied by the press roll (upper roller):

The force applied by the press roll represents the load applied on the Metal sheet, which can be
calculated using the expression: {1}

W = 4EI/ RL -------------- (1)

Where:

W: Load applied on the Sheet (N)

E: Modulus of Elasticity (MPa)

(E) is the modulus of elasticity of the material of the sheet. It is a material property that characterizes
the stiffness of the material. It describes how much the material will deform under a given load.

I: Moment of Inertia of the Sheet (mm^4)

(I) represent the moment of inertia of the sheet. It is a measure of the distribution of material around
the neutral axis of the sheet. A larger moment of inertia indicates more resistance to bending.

R: Radius of curvature (mm)

L: Length of the Sheet. (mm)

_ Desired Sheet metal to be bended specifications:

Material: The most metal to deal with would be 205 stainless steel (UNS S20500) which is a versatile
metal commonly used to produce food-grade equipment and components. It has become
increasingly popular for its impressive corrosion resistance, excellent heat conductivity, sanitary
qualities and easily maintained surfaces. 205 stainless steels might be found in commercial baking
ovens, braising pans, steamers, conveyor toasters, dry kettles and many other kitchen appliances
used in cooking establishments. This metal also finds applications outside of the food industry, such
as large-scale construction projects where its tensile strength is beneficial.
Table (1): --- {2}

Properties Metric Imperial

Tensile strength 790 – 830 MPa 115000 – 120000 psi
Yield strength (@strain 450 – 475 MPa 65300 – 68900 psi
0.200 %)
Elastic modulus 197 GPa 28572 ksi
Poisson’s ratio 0.27-0.30 0.27-0.30

Elongation at break 40% 40%

Hardness, Rockwell B 100 100

Therefore, (E = 197x10^3 MPa or N.mm2)

Dimensions: Thickness = 5 mm

Width = 1000 mm Length = 2000 mm

Let: Radius of curvature = 200 mm
I = b h^3 /12 = (1000x5^3)/12= 10416.7 mm^4
Substituting in (1): W= (4x197x10^3 x 10416.7)/(200x2000)
Then: W=20521N
W=20.5 KN

--Consider the Upper roller simply supported: (Let the total length of the roller=1250mm)
_Roller specifications:

Roller Material: ST 52 - Carbon Steel Material Group - Carbon Steel

Alloy - ST 52
Equivalent Grades - DIN 1.0060

Table (2): --- {3}

MECHANICAL PHYSICAL COMPOSITION

PROPERTIES PROPERTIES

Elongation % - 13 Density g/cm3 - Fe - 99.88

7.9 S - 0.055
P - 0.055

Tensile Strength Melting Point

MPa - 630 (±50) °C - 1470

Yield Strength Thermal

(0.2%) MPa - 310 Conductivity
W/mK - 53

Shear Strength Electrical

MPa - 380 Conductivity
%IACS - 6.8

Hardness Brinell -
180

2. Calculations of the stresses that the upper roller is subjected to:

The maximum bending the roller is subjected to = 20521 x 1250 (roller length)

= 25.65125x10^6 N.mm

σx = (My/I)

For circular cross section

σx = (32M/ π d^3)

∴ σx = (32x 25.65125x10^6 / π d^3)

Now calculating the principal stresses using the relation:

Neglecting the shear stress

σ1 = σx , σ3=0

σ1 = (32x 25.65125x10^6 / π d^3)

Applying Tresca:

Assuming safety factor (ns)=1.5

(32x 25.65125x10^6 / π d^3) = 310/1.5

We find that the diameter of the upper roller (d)=108.129 mm

Therefore, since 108.129 mm is enough to get the work done it is safer to choose a bigger diameter

Let the diameter be (d)=120mm.

(B) Design of the lower roller:

1. Calculations of the stresses that the lower roller is subjected to:

Lower roller is subjected to torque due to: (1) Their function of moving the sheet. (2) Friction.

(1) Load Torque = (w /2) x d1, where (d1: the lower roller diameter)

Load Torque= (20521/2) x d1

(2) Torque due to friction force:

For steel surfaces, the coefficient of friction is μ = 0.8

Friction force = μ x N = μ x (W/2) =0.8 x (20521/2) = 8208.5 N

∴ Torque due to friction force = 8208.5 x d1

∴ Total Torque = [( 20521/2) x d1] + [8208.5 x d1] = 18469 d1 N.mm

𝜏=(Tr/J)

For circular cross section

𝜏xy= (64 T/ π d^3) 𝜏xy= (64 x 18469 d1/ π d1^3) = (64 x 18469 / π d1^2)

Lower roller is also subjected to bending stress: it is the same as the bending stress the upper roller
is subjected to, but it is distributed over the 2 lower rollers

σx = (32x 25.65125x10^6 / π d^3) / 2 = (130.641 x10^6) / d^3 Mpa

Now calculating the principal stresses using the relation:

σ1 =

σ3 =

Applying Tresca:

We find that the diameter of the lower roller (d1) =75 mm

Therefore, since 75 mm is enough to get the work done it is safer to choose a bigger diameter

Let the diameter be (d1) =100mm.

(C) Dynamic analysis:

In the upper roller the force oscillates between 0 and 20521 N so

Calculations of the mean and alternating stresses:

σa = σm = (136x10^6)/12^3 Mpa

Calculations of the endurance Limit:

From tables and graphs we get the modification factors

Se= (0.5 x 630) Kf= 4.51(630)-0.265 Ks= 1.189(10)-0.112 Kr= 0.82 Kt= 1

Se=Kf.Ks.Kr.Kt. se= 4.51(630)-0.265 x 1.189(10)-0.112 x 0.82 x 1 x 1 x (0.5 x 630) = 194 Mpa

using Soderberg’s and Kf equals 0.7 we get a safety factor equals = 1.85 which means that both will
be safer under oscillating load

(D) Power calculations:

From the previous analysis it is now clear that the total torque required for this machine is

T= (18469 x d1) = 18469 x 100 T= 1846900 N.mm

(E) Summary of the calculations:
Name of Entity Required Properties Chosen Material Dimensions
Bending Roller
Tensile Strength ST 52 - Carbon Steel Length=1250mm
Hardness, Resilience Material Group
Carbon Steel Diameter=120mm
Alloy - ST 52

Lower Rollers
Tensile Strength ST 52 - Carbon Steel Length= 1250mm
Hardness, Resilience Material Group
Carbon Steel Diameter=100mm
Alloy - ST 52

Bearing Corrosion Resistance White Metal, Bearing

Thermal Steel
Conductivity
Hardness
Base Frame / Support Tensile Strength
Frame Machinability Cast iron
Resilience Hardness
Availability

Refrences:

{1} Development of a Motorized Sheet Metal Rolling Machine Olunlade Bankole Adeoye1, Ogundola Jide1, O.
Odiba1* and Obaje Onuche1

{2} Stainless Steel Grade 205 (UNS S20500) (azom.com)

{3} Raw Materials (zriha.com)