SKMM 3523 COMPONENT DESIGN

ENGINEERING DESIGN PROJECT

THREE ROLLER STEEL PLATE BENDING
MACHINE
GROUP 7
LECTURERS NAME: ENCIK KHAIRUL ANWAR HANAFIAH
NAME MATRIX NO PHOTOS

NOORFARAHAIN BINTI MD A13KM0176

SHANI Hain2340@gmail.com
03-25

NUR NABILAH BINTI A13KM0180

MOHAMMAD MUSTAFA nabilahnurmustafa@gmail.com
03-26

NURUL ZAHIRAH BINTI A13KM0187

MOHD ZAN nurulzahirah@yahoo.com
03-28

OOI TZE XIONG A12KM0133

Otx93@yahoo.com
03-29

1
TABLE OF CONTENT

BIL TOPIC PAGE

1.0 INTRODUCTION 3-4
2.0 PROBLEM STATEMENT 5
3.0 DESIGN ANALYSIS 6-7
3.1 SHAFT ANALYSIS 8-10
3.2 BEARING ANALYSIS 11-13
3.3 GEAR ANALYSIS 14-16
4.0 RESULT AND DISCUSSION 17-18
5.0 CONCLUSION 19-21
6.0 REFERENCES 22
7.0 APPENDICES

2
1.0 INTRODUCTION

In three roller steel plate bending machine sheet is bend with the help of load acting

on upper roller. Three roller sheet bending machine mainly consist of following parts, 3

rollers (upper roller and 2 bottom rollers), motors, gears, power screw, and frame. Bending

operation is done by applying load (force) with the help of upper roller, which is movable.

Motor is used in steel plate bending machine for providing power transmission. Gear drives

are used for minimize the rpm transferred from motor to the machine. Spur gears are used in

3 roller sheet bending machine. Frames is a fixed rigid support used for supporting the

machine and also prevent machine from vibrations.

Figure 1.1: Three roller plate rolling sequence for fixed bottom roller gap

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The entire process of three roller plate bending machine can be divided into three:

1) Positioning of blank plate

2) Lowering of the centre of roller

3) Feeding of the plate

First the flat plate is fed into the bending machine by two rotating bottom rollers. It is fed

until the plate is properly positioned. Then the centre of the roller displaced downward causes

bending of the plate. Two bottom rollers rotate continuously so that the plate also bent

continuously.

This machine can produce variety of bending size which are useful in different

industrial such as cylindrical tank industries. It also useful in domestic application.

Significantly this machine reduces the efforts required to bend plate to a large extent.

Bending load from the top roller required to bend the plate is the function of various

parameters:

1) Plate thickness

2) Plate width

3) Plate material property

4) Centre to centre distance between bottom two rollers

5) Displacement of top roller and etc.

4
Figure 1.2: ROUNDO 3- Roll Plate Bending Machine

2.0 PROBLEM STATEMENT

Proposed simple machine that can capable to bend a plate based on the design requirement

and specification given.

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3.0 DESIGN ANALYSIS
3.1 SHAFT ANALYSIS
When a steel plate of 1.52 m 1.22 m is bent with a bending radius, R = 0.2 m,

3
Second moment of inertia of the plate is, = where h = 0.005 m, b = 1.22 m
12

Therefore get I = 1.27 x 108 4

According to Table A-20 inside Shigleys Mechanical Engineering Design book material
chosen is AISI 1015 HR steel is chosen and its properties as shown below

Yield strength, Sy = 190 MPa

Ultimate strength, Sut = 340 MPa

Young Modulus, E = 205 GPa

The force acting on the roller from the bending plate is, 3
=
48
9 8
4 EI 4(20510 )(1.2710 ) = (34.26k) (1.52)^3/(205109 )(1.27108 )48
W = = 34.26 KN
Rb (0.2)(1.52)
=96.28 mm

= 0 = + 34.26

Since RA and RB are similar,

34.26
RA = RB = = 17.13 kN
2

Then, alternating moment, Ma can be calculated which is,

Ma = 17.13 (1) = 17.13 kNm

6
For calculate alternating stress, consider = 1 since no fillet occur on the shaft for midrange

For midrange stress, = 0 , it is because no torque on the upper roller shaft so no power can
be transmit to the shaft.

Therefore,

32 32(1)(17.13 x103 )
= = = 5.17107. Pa
3 (0.153 )

Therefore safety factor,

Sy 190 x 106
= = = 3.68
5.17107

To calculate endurance limit of shaft,

Se = 0.5Sut = 0.5 340106 = 170 MPa

Se = kakbkckdkekfSe

where ka = aSutb

Based on Table 6-2 which is table for surface modification factor inside Shigleys Mechanical
Engineering Design book and given the parameter of properties for AISI 1015 HR steel for
hot-rolled surface finish that needed are shown below

a = 57.7 MPa

b = -0.718

So,

ka = aSutb = (57.7)(340)-0.718 = 0.8782

By consider kb = kc = kd = ke = kf = 1, then get

Se = kakbkckdkekf Se = (0.8782)(170)= 149 MPa

Then, fatigue safety factor using modified-Goodman criterion is

1 1
nf = = 5.17107 = 2.88

( + Sut ) ( 6 +0)
149 10

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 3.2 BEARING ANALYSIS

Bearing for bottom roller

F is from force that act on the gear which can be calculate as from equation gear inside
Shigleys Mechanical Engineering Design textbook page 699 equation (13-36) which is
60000
equation transmitted load, =

60000 (7.5)
Therefore, get Wt = = = 3.37 kN
(85)(500)

Calculate the forces acting on the shaft,

Based on y-x axis,

+ve = 0

Fsin20 (2.5) RDy (2) = 0

(3.37103 ) sin 20 (2.5) - RDy (2) = 0

RDy = 1.44 kN

Based on z-x axis,

+ve = 0

Fcos20 (2.5) RDz (2) = 0

(3.37103 ) cos 20 (2.5) - RDz (2) = 0

RDz = 3.958 kN

Then get reaction forces that react, RD,

RD = (1.44)2 + (3.958)2 = 4.21 kN = FD

8
Thus, find value for C10 that can get from Shigleys Mechanical Engineering Design textbook
page 570 equation (11-9) which is

1

C10 = af FD [ 1 ]
1
( +( 0 )ln( ) )

and consider the bearing use is ball bearing with RD = 96% af = 1, a = 3, b = 1.483 , = 4.459
60 ( )( )
and0 = 0.02 while to calculate value of is = where LD = 30 kh and nD
106
= 500 rpm

60 (30000)(500)
Then, = = 900. Therefore,
106

1
900
C10 = (1) (4.21x103 ) [ 1 ]3 = 50.1 Kn
1 1.483
(900+( 4.439)ln(0.96) )

Therefore, ball bearing that can be used is any bearing that greater than specification get which
is 02-60mm ball bearing.

Chosen bearing for upper roller is 02-80mm ball bearing.

Bearing for upper roller

We consider the force react on upper roller is the reaction force because the shaft does not get
force from bending plate. The used reaction force get from the shaft analysis which is

34.26
RA = RB = = 17.13 kN and consider it equal to FD.
2

Then the equation C10 get to use inside from Shigleys Mechanical Engineering Design
textbook page 567 equation (11-3)

60 ( )( ) 1
C10 = FD [ ]
106

and consider the bearing use is Cylindrical roller bearing with a = 10/3, b = 1.5, = 4.48,

0 = 0, LD = 60 kh and nD = 500 rpm.

9
Then,

1
60 (60000)(500) (10)
C10 =(17.13 x 103 ) [ ] 3 = 162 kN
106

Therefore, cylindrical roller bearing that can be used is any bearing that greater than
specification get which is 02-90mm cylindrical roller bearing.

Chosen bearing for upper roller is 02-150mm cylindrical roller bearing.

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3.3 GEAR ANALYSIS

Wt

The material used is AISI 1020 Steel-Rolled. According to Table A-20 inside Shigleys
Mechanical Engineering Design textbook,the properties of material is shown below

Yield strength, Sy = 390 MPa

Ultimate strength, Sut = 470 MPa

Young Modulus, E = 205 GPa

Pitch diameter of the gear, d = 280mm with 36 teeth. Therefore from equation (13-2) inside
Shigleys Mechanical Engineering Design textbook page 668 the module, m=d/N

Then, m= 0.28 / 36 = 7.77x103

For diametral pitch, P it can get from equation (13-1) same page with equation (13-2) above:

P=N/d = 36/280 = 0.129

For the speed of gear rotation, used n = 500 rev/min which is equal to 8.333 rev.

Therefore, the pitch-line velocity is from equation (13-34) inside Shigleys Mechanical
Engineering Design textbook page 699. As shown below,

V =

Then, V = (0.28)(8.333) = 7.33 /

11
The velocity factor from equation (14-6b) inside Shigleys Mechanical Engineering Design
textbook page 731:

6.1+ 6.1+7.33
KV = = = 2.202
6.1 6.1

Transmitted load, on the gear can be calculate from equation inside Shigleys Mechanical
Engineering Design textbook page 699 equation (13-36) which is transmitted load,

60000
=

60000 (7.5)
Therefore, get Wt = = = 3.37 kN
(85)(500)

The gear having 36 teeth and face,F=0.02m. Based on Table 14-2 inside Shigleys Mechanical
Engineering Design textbook page 730, the Lewis form factor Y for gear with 36 teeth is 0.384.
Then substitute in equation (14-8) page 731 as follows:

(2.202)(3.37 103 )
= = = 124
(0.02)(7.77x103 )(0.384)

The next step is to estimate the size factor kb. From Table 13.1 inside Shigleys Mechanical
Engineering Design textbook page 688, the sum of the addendum and dedendum is

1 1.25 1 1.25
l= + = + = 17.44
0.129 0.129

The tooth thickness t is given in Figure 14-1(b) inside Shigleys Mechanical Engineering
3
Design textbook page 729 as t = (4) when x = from equation (14-3). Therefore,
2

3(0.384)
x= = 4.465m t = (4(17.44)(4.465)) = 17.65mm
2(0.129)

We have recognized the tooth as a cantilever beam of rectangular cross section, so the
equivalent rotating beam diameter must be obtained from equation (6.25) inside Shigleys
Mechanical Engineering Design textbook page 297:

1 1 1
de =0.808()2 = (0.808)( )2 = 0.808[(20)(17.65)]2 = 15.18mm

then equation (6-20) page 296 gives kb as

kb = (d/7.62)0.107 = (15.18/7.62)0.107 = 0.929

12
The load factor kc from equation (6-26) page 298 is unity. With no information given
concerning temperature and realibility we will set kd = ke = 1 and ka = 0.935

In general, a gear tooth is subjected only to one way bending. Exceptions include idlers gears
and gears used in reversing mechanisms. We will account for one way bending by establishing
a miscellaneous-effects Marin factor kf.

Since a Gerber locus runs in and among fatique data and Goodman does not, we will use kf =
1.66. The Marin equation for the fully corrected endurance strength is

Se = kakbkckdkekfSe

Se = 0.5Sut = 0.5 470106 = 235 MPa

Se = (0.935)(0.929)(1.66)(235) = 338.85 MPa

For stress, start with determine the fatique stress concentration factor kf. For a 20 degree full
depth tooth the radius of the root filler is denoted rf where ,

0.300 0.300
rf = = = 2.33
0.129

From figure A-15-6 at the appendix of Shigleys Mechanical Engineering Design textbook.
2.33
Get , = = 17.65 = 0.132

And since D/d is infinity , we approximate with D/d = 3 giving Kt = 1.7. From figure 6-20 page
303 inside Shigleys Mechanical Engineering Design textbook get q = 0.70. Therefore, from
equation (6-32) same page as above parameter used.

Kf = 1 + q(Kt -1) = 1+(0.7)(1.7-1) = 1.49

For a design factor, = = Kf , therefore

338.85
FS = = 1.83
(1.49 124)

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 3.4 BOLT ANALYSIS

RC RB

RD RA

Reference
point

Consider the net weight of the machine is 3500 kg and use a bolt from grade 4.6 with safety
factor 3. So, from Table 8.11 page 427 inside Shigleys Mechanical Engineering Design
textbook for properties bolt with grade 4.6 are the size range inclusive is between M5-M36.
And the minimum proof strength of this bolts grade is 225 MPa.

Fc

C B

FD
FC
FB
FB
D
A

FD FA
FA
The shear reaction that passes through the center of the body is

V = 3500 X 9.81 = 34335 N

The distance from centroid to the center of each bolts is equal which is
1
RA = RB = RC = RD = (0.492 + 0.992 )2 = 1.1 m

14
1) Bolt in shear

The primary shear load per bolt is

34335
F = = 8583.75 N
4

Since the Rn are equal, the secondary shear forces are equal and based on equation (8.57) page
448 inside Shigleys Mechanical Engineering Design textbook

34335(990)
F = = = 7725.38 N
4 4(1100)

The primary and secondary shear forces are plotted to scale and the resultant obtained by using
the parallelogram rule. The magnitudes are found by analysis to be

FA = FB = 15.07 kN

FC = FD = 6.29 Kn

15.07
The maximum forces are on FA and FB, therefore = ( )

2) Bolt in tensile

M = 34335 X 990 = 33992 kN.mm,

lA = lD = 10mm lB = lC = 990mm

Tension of bolt measured from axis of rotation, U

33992(10 ) 3
U=
1 1+2 2 +
= 2(10)+2(990) = 17.34 N/mm

Fmax = Ulmax therefore for calculated force due to bending is

FA = FD = 17.34 X 10 = 173 N

FC = FB = 17.34 X 990 = 17.17 kN

Maximum bending stress occurs on the bolt which is far from the axis of rotation.

Therefore maximum stress due to bending occur at bolt at position C and B

17.17
= ( )

15
Based on distortion energy theory, DET

1
= ( 2 + 3 2 )2

17.17 2 15.07 2 1
= (( ) + 3( ) )2

31.24
=( )( )

Factor safety is 3.

n=

31.24 225
So, =
3

At = 416mm

From Table 8-1, get the nominal major diameter for the bolt in mm which is M30 X 3.5

16
3.5 WELDING ANALYSIS

Figure 3.5: Diagram showing the weld geometry

The primary shear stress is

A= 1.414hd

= =1.414(0.01)(1.0)

=0.014142
45
= = 3.18 MPa X=1
0.01414
Y= 0.5

The distance from centroid to the center of each pont is

1
2
RA = RB = RC = RD = (0.5 + 12 ) 2 = 1.12 m

Find the value of J using case 2 in Table 9-1 in Shigleys Mechanical Engineering Design
textbook.

(32+ 2)
J=
6

(1)(3(2)2+ (1)2)
J=
6

17
 = 2.167 4

= M=FL= (45K) (0.75) = 33750 N.m

(33750)(1.12)
= = = = = 17.4
2.167

Figure 3.5.2: Free body diagram

=(318017.426.57)2 +(17.426.57)2

=3172.25MPa

=(3180+17.426.57)2 +(17.426.57)2
=3642.35MPa

=
=

= =

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4.0 RESULT AND DISCUSSION

In designing a three roller bending machine it is required to calculate the force for bending.

From this force the machine parameters and motors power are decided. There are factors that

should be considered while calculating this force. Some of the factor are:

1) Material properties

2) Width and thickness

3) Bending radius

Table 4.1: Required Design Specification

Minimum bending radius 200mm

Plate range Maximum 5mm thickness

Plate movement speed Maximum 1meter/min

Motor powered Safe(not under or overpowered)

Machine size Capable to bend a steel plate up to 4 X 5 feet

Table 4.2: Machine Design Specification

Specification Name Value

Distance between bottom roller 510mm
Diameter of bottom roller 80mm
Diameter of upper roller 150mm
Speed of motor 500 rpm
Power of motor 7.5 KW

19
Table 4.3: Material Specification

Specification Name Value

Material to bend AISI 1015 HR
Max dimension to be rolled 4x5 feet
Youngs Modulus 205 GPa
Ultimate tensile strength 340 MPa
Yield strength 190 MPa
Bending stress 5.17107. Pa
Deflection of sheet at mid span to obtain 96.28 mm
required radius

In designing a bearing it is required to calculate the transmitted load,. From this force the

forces acting on the bearing decided. There are factors that should be considered while

calculating this force. Some of the factor are:

1) Desired life

2) Desired speed

3) Desired radial load

Table 4.4: Bearing Design Specification

Specification Name Value

Bore diameter for upper roller 80mm
Bore diameter for bottom roller 150mm
Type of bearing upper roller Deep groove ball bearing
Type of bearing bottom roller Cylindrical roller bearing

20
In designing a gearing it is required to calculate the transmitted load,. From this force the

forces acting on the gear decided. There are factors that should be considered while calculating

this force. Some of the factor are:

1) Desired life

2) Desired speed

3) Desired radial load

Table 4.5: Material Specification

Specification Name Value

Material to bend AISI 1020 Steel-Rolled
Max dimension to be rolled 4x5 feet
Youngs Modulus 205 GPa
Ultimate tensile strength 470 MPa
Yield strength 390 MPa

Table 4.6: Gear Design Specification

Specification Name Value

Bore diameter for upper roller 80mm
Bore diameter for bottom roller 150mm
Type of bearing upper roller Deep groove ball bearing
Type of bearing bottom roller Cylindrical roller bearing

All the structural members have been sized to support the specified load with a safety factor
ranging from2.0 and 4.0.

21
5.0 CONCLUSION

Instead of using the high cost software to analyse the force and power of motor to design

bending machine we can design our own bending machine by referring the theories regarding

bending machine. All the parameters related to the bending theories like bending force, bend

radius, material thickness and etcetera are calculated and analyse in our project. The analysis

are made until the suitable design specification is reached.

6.0 REFERENCES

1. Mr. Nitin, Mr Prafulla Force Analysis of Metal Sheet in Bending Operation on Sheet

Bending Machine

2. Adsul A. n, Chavan Review of theories regarding material Bending

3. Catalogue ROUNDO 3-Roll Plate Bending Machines Type P-S

4. Shigleys Mechanical Engineering Design Textbook

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APPENDICES

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