MDP2130 11/27/2023 Machine Design Project

SHEET ROLLING MACHINES

PROGRESS REPORT

What are sheet rolling machines?

Sheet rolling machines are machines which are used mainly to roll metallic sheets by bending
them, several desired shapes can be done especially cylindrical ones, such as tanks and pipes,
pressure vessels are also made by this operation and cones also.
We are considered in rolling thin sheets (0.5 mm – 7mm) which most of available sheet
rolling machines are capable of rolling.
Principles and Mechanisms:-

As we know we must bend sheets by using rollers of various dimensions, main operation is
to stick the sheet inside a lower roller... an upper roller then is pushed down compressing the
sheet to do the bending job, then lower and upper rollers are rolled in opposite directions to
move the sheet forward and backward, rollers must roll with same velocity and opposing
directions so we must use gears to transmit motion from one roller-which connected to
power source – to the other roller.
Rollers are simple cylinders which are made from materials that have a higher tensile
strength than the rolled sheets …

Fig 1.1

The top roll is positioned in a fixed manner and does not move during the bending process, two bottom rolls
positioned in a triangular or pyramid arrangement. These rolls are adjustable, allowing for the bending of the
metal sheet.

Sheets also must have certain properties, it is important to have a suitable ranges of ductility,
hence we can roll stainless steel / carbon steels / and aluminum...Etc.
Rolling is a cold forming operation which changes material properties … as the thickness is
reduced, the strength of the material is increased, and it is also obvious that rolling thicker
sheets must be harder to do.
We must concern studying bending moment during analysis, failure can occur in the upper
roller so it must be studied as a
simply supported shaft.
In operation of fabricating pipes for example , after rolling
sheets … leading edges must be welded together perfectly
to avoid any leakage that may occur during the motion of Sheet metal is used in the production of
the fluid , those pipes are welded by using several materials ranging from tools, to hinges,
techniques such as / SAW – MIG – TIG – SMAW. automobile, boilers, pressure vessels, road
tankers, storage tanks, silos, tubes and
Also pre-bend operation is important to achieve more
pipelines, pumps etc.
précised works.
Plate Bending Roll History and Development
The sheet metal rolling machine is one of the eight major forging machines. Its development
has been experienced from mechanical to hydraulic and then to CNC.
1) Five Development Trends
There is a growing demand for the 3 roll plate rolling machines to process large thick plates,
high strength plates and composite plates.
The large 4 roll plate rolling machine has the characteristics of good forming precision and
short remaining straight edge, which makes it become the development direction.
The small CNC plate bending machine for processing extra-long thin plate is the
development demand of the oil tank truck industry.
Providing customers with complete sets of equipment not only to provide a single coil
machine is also a future development direction.
Another important development direction is to form a flexible production line processing
unit based on CNC automatic plate rolling machine.
2) Analyze from two perspectives
– From the production
The development trend of the plate rolling machine is to the economy and adaptability.
– From the direction
It is also developing in the direction of improving the utilization efficiency of the driving
device.
3) Rolling machine automation: Automatic Feeding
Plate automatic feeding technology is specially used to solve the feeding problem of the plate
rolling machine.
Therefore, this must fully meet the basic requirements of the feeding action of the bending
rolls and have the following characteristics.
In our project we can consider designing the Pyramid type machines, these machines
have three rolls arranged in a pyramid configuration. The top roll is fixed, and the two
bottom rolls are adjustable. This design allows for the bending of thicker sheets and is
commonly used for the production of large-diameter pipes.

Fig 1.2
Pyramid Type – Sheet Rolling Machine

Why Pyramid Type?

The manufacture of cylinders with different curvatures requires rolling machines with three
or four rolls. A three roll bending machine is usually used for the rolling process. Three steps
can be used to break down the roll bending procedure in its entirety:

1. Placing the plate or blank sheet in place

2. Repositioning the central roller

3. The plate being fed.

Components:
Top Roll (Fixed): The top roll is positioned in a fixed manner and does not move during
the bending process. Its primary function is to apply downward pressure on the metal sheet.
 Bottom Rolls (Adjustable): There are two bottom rolls positioned in a triangular or
pyramid arrangement. These rolls are adjustable, allowing for the bending of the metal sheet.
The adjustment of the bottom rolls determines the final shape of the bent workpiece.

Working Principle:

Inserting the Sheet:

The metal sheet to be rolled is inserted between

the adjustable bottom rolls.

Adjusting the Rolls:

The operator adjusts the position of the bottom rolls

based on the desired curvature and shape of the final product.

Bending Process:
As the metal sheet passes through the rolls, the adjustable bottom rolls move towards
each other, creating a bending force on the sheet.
Forming the Cylinder or Cone:
The sheet is gradually formed into a cylindrical or conical shape as it passes through the
rolls.

Removing the Bent Workpiece:

Once the desired shape is achieved, the bent workpiece is removed from the machine.

After all there are numerous factors that led us to select this type of machines to
design.
Advantages:
1. Versatility: Pyramid type rolling machines are versatile and can be used for a variety of
applications, including the production of cylindrical and conical shapes.

2. Suitability for Thick Materials: These machines are often suitable for bending thicker metal
sheets compared to some other rolling processes

3. Flexibility in Bending: The adjustable bottom rolls provide flexibility in achieving different
bending radii and shapes.

Additionally, we had no trouble obtaining sufficient machine data because the

collage's work shop included these kinds of equipment, making it simple to view the
components in person.

Fig 1.3
Side of reviewing Rolling machine in the workshop
Design Consideration
To achieve bending, the work material must be
subject to two major forces; frictional force which

causes a no slip action when the metal and roller

come in contact and a bending force acting

against the forward speed and the torque applied

to move the material.

At least, two rollers are involved in flat rolling

depending on the thickness and the properties of

the material while three or multiple roller system

is required in shape rolling.

A work material under bending load is subjected

to some forms of residual stress and deformation

as it bends. The outer bend radius of the material

undergoes tensile plastic deformation while the

material at the inner bend radius undergoes

compressive plastic deformation. The width

along the bend radius will reduce in length based

on Poisson’s ratio, and if the end radius is too

small, the plastic deformation at the outside of

the bend will result in a fracture.

Thoughts and discussions
In principle, we agree that we have to find the pressing force applied on the sheet which
resulting from the upper roller , if we took a side view to see the whole sheet length we can
observe that this type of loading is similar to simply supported bars ( as the two lower rollers
could be assumed to be roller supports and the upper one is the concentric load ) , so we
took a snapshot at the moment of first bending of the sheet .

Then how to calculate this pressing force?

Too many thoughts were swimming around our minds, we need a design procedure
to get some real numbers, so our initial idea was to assume that the adjusting screws were
the source of this loading, we can liken this process to screw jacks and assume we are
lowering some sort of load which is assumed to be the upper roller weight .., calculations
were made as follows:

Fig 2.1 – screw calculations

 Fig 2.2 – screw calculations

Conclusion:
However, after some team discussions and additional research, we discovered that this idea
is insufficient for following reasons:
- Choosing a material such as mild steel could be a wrong decision because we need higher
strength and hardness
- When calculating the torque of the screws, we based our calculations on the upper roller
weight, but eventually we had to neglect this thought because – considering the universal
testing machine as an example – when applying the compression load, all the pressing bar
can do is to deliver this force from another source, in conclusion: the upper roller must
deliver the pressing force from another source which could be the torque applied by the
workman.
- According to design principles, we must base our calculations on the application, which
forces us to take into account the sheet that will be formed.
 To avoid above problems, we did another calculations steps based on the application
(maximum sheets to be formed), dimensions of the sheet were assumed to be as follows:
Thickness(t)= 0.5 _ 7 mm
Length(L)= 2000 mm
Width(b)= 1000 mm
R(max radius of curvature)= 200
I=28583.33
Pressing force = 4 EI/RL
Steel sheet-E= 205 Gpa = 205×10^3 Mpa
Pressing force = 58595.8 N

Observation: Because the sheet thickness is assumed to be 7 mm, which is too high
for a basic rolling machine—even one that is motorized—we can see that this force is
a little bit excessive.

Next step?

We returned back to the workshop, this time with a vernier calliper to measure basic
dimensions so we can be sure we are on the right track. We also had a primary drawing for
the parts on the solid works, assuming some parts dimensions, because we needed more
creative minds to help us come up with the final solution.
 Fig 2.3 – assembled rolling machine drawing

Eventually…
Other assumptions were made to have more realistic dimensions.

 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:

1. W: Load on the Sheet (N)

2. 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.
3. 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.

4. R: Radius of curvature (mm)

5. 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 0.200 %) 450 – 475 MPa 65300 – 68900 psi
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 = 1250 mm Length = 2000 mm

Let: Radius of curvature = 200 mm
I = b h^3 /12 = (1250x5^3)/12= 13021 mm^4
Substituting in (1): W= (4x197x10^3 x 13021) / (200x2000)
Then: W=25651.37 N
W=25.7kN
--Consider the Upper roller simply supported: (Let: roller length = 900mm)
 ROLLER MATERIAL: ST 52 - CARBON STEEL MATERIA L GROUP - CARBON
STEEL
 Alloy - ST 52
 Equivalent Grades - DIN 1.0060

MECHANICAL PROPERTIES
 Elongation % - 13
 Tensile Strength MPa - 630
 Yield Strength (0.2%) MPa - 310
 Shear Strength MPa - 380
 Hardness Brinell - 180
PHYSICAL PROPERTIES
 3
Density g/cm - 7.9
 Melting Point (±50) °C - 1470
 Thermal Conductivity W/mK - 53
  Electrical Conductivity %IACS - 6.8
COMPOSITION
 Fe - 99.88
 S - 0.055
 P - 0.055
All data is obtained from {2}

 Calculations of the Upper roller diameter (d):

the stress that the upper roller is subjected to will be calculated by using:

σ = My /Ix

Where:

σ – Bending Stress in N/mm^2

M – Moment of Neutral Axis Nmm

y – Perpendicular distance to neutral axis in mm

Ix – Moment of inertia around Neutral axis in mm^4

For a circular cross section:

σx = (32M)/ π d^3)

σx = (32x5771.55825x10^3)/ π d^3)

Now calculating the principal stresses using the relation:

σ1 = σx , σ3=0

Applying Tresca:
Assuming safety factor (ns)=2

(32x5771.55825x10^3)/ π d^3) = 310/2

We find that the diameter of the upper roller (d)=72.386 mm

Therefore, since 72.386 mm is enough to get the work done it is safer to choose a larger diameter

Let the diameter be (d)=80mm.

To obtain an additional diameter number that is close enough to the real one, additional final
calculations were performed.

W= 21354

sigma bending of sheet = 2562.48 MPa

deflection required = 1667 mm

FS=1.5

so working load = 32031 N

max bending happening on the upper shaft = working load x 1250 (shaft length) = 40x10^6 N.mm

on the lower shaft there are bending AND torque

torque due to friction = (o.8) x 32031/2 because there are two shafts = 12812.4

and main torque = 32031 x D/2

applying principle stresses

we get that D of upper shaft = 109.5 mm

Take D= 120 mm

Also lower rollers are subjected to bending and torque, doing similar calculations will lead to obtain the
lower rollers diameters which can be iterated in ranges of 50 mm to 120 mm, but let us say that it
could be 100mm for symmetry and function.
 In the end, we can now be content with our computations to guarantee
performing the function without worrying about our components failing.
We can use chains to transfer torque from the motor to the gear system, which
essentially consists of an intermittent gear ensuring that the lower rollers rotate in the
same direction. However, we still need to calculate the power needed for the motor
and the transition system.
Some upgrading ideas came up to our minds , as making the adjusting of the upper
lower from on component assuring the two screws moving with the same lead , this
idea can be done using shafts connecting between the two screws and worm gears
connected to the shafts.
References :
Shigleys mechanical engineering design
{1} Development of a Motorized Sheet Metal Rolling Machine Olunlade Bankole Adeoye1 , Ogundola Jide1 , O. Odiba1* and Obaje Onuche1

{2} Raw Materials (zriha.com)

papers
Design and Fabrication of Three Roll Metal Bending
Machine
Design of three-roll bending machine
tool and research on compensation
algorithm
Force Analysis of Metal Sheet in Bending
Operation on Sheet Bending Machine
Development of a Motorized Sheet Metal Rolling
Machine
https://www.engineeringtoolbox.com/friction-coefficients-d_778.html

Sheet Rolling Machine

MDP2130
Submitted to Dr.Mohamed Elshazly