MANUAL METAL BAR BENDING

MACHINE
 INTRODUCTION
 CURRENT SCENARIO
 COMMON PROBLEMS
 SOLUTIONS
 DESIGN
 WORKING
 CONSTRUCTIONAL DETAILS
 SPECIFIACATION OF COMPONENTS
 FRABRICATION PROCESS
 APPLICATIONS
 ADVANTAGES
 My project is to design and construct a
bending machine.
 This machine is used to bend steel into curve
or other curvature shape.
 The size of the machine is very convenient
 for portable work
 . It is fully made by steel. Moreover it is easy
to be carried and used at any time and any
place.
 Various type of bending machines are used
for bending.
 Majority of the machines are manually
operated and operating force is magnified
using mechanical advantage from an
appropriate lever system.
 Not suitable for small scale industeries.

 Labor cost is more.

 Time consuming in terms of setting of

operation setup.

 Defects in the form of angular deformation

and wrinkles are seen and quality is not good.
 The bending force is generated is quite large
with a minimum human effort.

 Loading is done by operating handle of the

jack which carries the bending action
resulting into a safe and damage free bending
operation.
 Design consists of application of scientific
principles, technical information, imagination
for development of new and improved
machine or mechanism to perform specific
function with maximum economy and
accuracy. It consists of two parts
1. System Design
2. Mechanical design
 System selection based on physical
constraints.
 Arrangement of various component.
 Man machine interaction.
 Servicing facility.
 Height of machine.
 Weight of machine.
 Fabricated parts.

 Parts to be purchased.
 The Hydraulic Jack is a device used for lifting heavy
loads by the application of much smaller force. It is
based on the Pascal’s law, which states that intensity
of pressure is transmitted equally in all directions
through a mass of fluid at rest.

 The working principle of a hydraulic jack may be

explained with the help of Fig. shown below. Consider
a ram and plunger, operating in two cylinders of
different diameters, which are interconnected at the
bottom, through a chamber, which is filled with some
liquid.
The pipe is inserted between the pulleys and the Hydraulic
jack pulley as shown in figure. The Bending Force is applied
with hydraulic Jack when the handle is operated. Thus pipe is
bent.For desired diameter of bending curve the pulleys are
changed or altered.
 In the constructional part of the project work, a
base frame structure is fabricated using Mild
Steel bars.
Frame : A f lat platform is formed on the top of this
base structure. On this platform two mounting
points are fixed. These mounting points are kept
very robust in nature as they have to withstand
huge lateral forces during working of the device.
Set of combination of two numbers of affix able
meshing pulleys of various diameters are
fabricated or machined.
 Pedestal Bearing : A It is a supporting element in
the metal bender,its another function is to rotate the
rod.
 Circular Shaft : It is the main element of the
metal bender which is is rotating as well as it is
bending the piece of metal rods.
Hydraulic Jack : Hydraulic jack with Semi
Circular pulley as shown in figure is fixed on
the frame in between two pulleys and below
it by calculating working distance . Provision
for Adjustment of jack should be there to
achieve any type of shapes and curvature.
 Springs: Quick retraction springs are attached
to hydraulic jack upper end for easy and fast
retraction of jack shaft.Springs should be
designated in such way that it will not add
more pressure or force for upper movement
of the hydraulic jack.
Componenets Specifications

Frame pipe 2*2 inch

Circular Shaft Diameter 30 mm

Hydraulic Jack 3 tones

Bearings Diameter 30 mm

Spring Helical
 1) Frame Cutting
 2)Frame Welding
 3) Lathe work on shaft
 4)Frame Allignment
 5)Mounting of shaft and Bearings
 6) Mounting of spring and jack
 7) Handle Welding
 Used in automobile industry.
 Agricultural work components fabrication.
 Gym equipment's.
 Boat and swimming pool furnishings.
 Exhausts.
 Handles.
 Road signs and posters.
 Fuel pipes for diesel engines.
 Hydraulic ram force reduces human effort in
operation.
 Portable.
 Simple construction.
 Low cost.
 Less needs for maintenance.
 No extra skill is required for operating this
system.
THANK YOU