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TITLE PAGE

DESIGN AND FABRICATION OF A PNEUMATIC PIPE BENDING MACHINE

BY

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EE/H2013/01430
DEPARTMENT OF ---
INSTITUTE OF ---

DECEMBER,2018

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APPROVAL PAGE

This is to certify that the research work, "design and fabrication of a pneumatic pipe bending machine" by ---, Reg. No. EE/H2007/01430 submitted in partial fulfillment of the requirement award of a Higher National Diploma on Electrical and Electronics Engineering has been approved.

By
Dr. ---                                           Dr. ---
Supervisor                                                  Head of Department.
Signature……………….                           Signature……………….        

……………………………….
Dr. ---
External Invigilator

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DEDICATION
This project is dedicated to Almighty God for his protection, kindness, strength over my life throughout the period and also to my --- for his financial support and moral care towards me.Also to my mentor --- for her academic advice she often gives to me. May Almighty God shield them from the peril of this world and bless their entire endeavour Amen.

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ACKNOWLEDGEMENT

The successful completion of this project work could not have been a reality without the encouragement of my --- and other people. My immensely appreciation goes to my humble and able supervisor mr. --- for his kindness in supervising this project.
My warmest gratitude goes to my parents for their moral, spiritual and financial support throughout my study in this institution.
My appreciation goes to some of my lecturers among whom are Mr. ---, and Dr. ---. I also recognize the support of some of the staff of --- among whom are: The General Manager, Deputy General manager, the internal Auditor Mr. --- and the ---. Finally, my appreciation goes to my elder sister ---, my lovely friends mercy ---, ---, --- and many others who were quite helpful.

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In line with the growth in the recent technologies, there is large opportunity present in the piping sector. As the part of the piping industry the demand of the customer being changes day by day. The manual pipe bending machines are not able to fulfill the raising demands of the market in quality, quantity as well as cost prospective.
Particularly in this machine, we have used the compressed air to perform the bending operation. This makes the machine or the process much more efficient over the manual operated bending machine. Radius of the bend can be obtained within the limits of this machine. The machine is very useful for the Aluminum and copper pipes.
The machine is designed to bend a pipe of aluminum, MS and copper type of metallurgical grade. The aluminium and copper pipe up to 22 mm OD and 1.5 mm thickness and MS pipe up to 20 mm OD and 0.5mm thickness has been designed by this machine.

 

 

TABLE OF CONTENTS
COVER PAGE
TITLE PAGE
APPROVAL PAGE
DEDICATION
ACKNOWELDGEMENT

ABSTRACT
CHAPTER ONE
1.0      INTRODUCTION
1.1      BACKGROUND OF THE PROJECT

• AIM OF THE PROJECT
• OBJECTIVE OF THE PROJECT
• PROJECT MOTIVATION
• APPLICATION OF THE PROJECT
• ADVANTAGES OF THE PROJECT
• SIGNIFICANCE OF THE PROJECT
• LIMITATION OF THE PROJECT

CHAPTER TWO
LITERATURE REVIEW

• REVIEW OF THE RELATED STUDIES
• TYPE OF BENDING MACHINES

CHAPTER THREE
3.0     CONSTRUCTION METHODOLOGY
3.1      MATERIAL SELECTION
3.2      MACHINE’S COMPONENTS
3.3      DESCRIPTION OF THE MACHINE’S COMPONENTS USED
3.4      COMPONENTS SPECIFICATIONS
3.5      CALCULATIONS

3.6    PNEUMATIC FITTINGS
3.7    PROJECT WORKING

3.8    MACHINE BLOCK DIAGRAM
3.9    MACHINE DIAGRAM

CHAPTER FOUR
TESTING AND RESULT ANALYSIS

• DESIGN PROCEDURE AND TESTING ANALYSIS
• ASSEMBLING OF SECTIONS
• TESTING OF SYSTEM OPERATION
• RESULTS AND DISCUSSION
• SAFETY MEASURES WHEN USING PNEUMATIC CONTROL SYSTEMS

CHAPTER FIVE

• CONCLUSION
• RECOMMENDATION
• REFERENCES

 

 

 

 

CHAPTER ONE
1.0                                                        INTRODUCTION
1.1                                         BACKGROUND OF THE PROJECT
Pipe bends are critical components in piping systems. In the manufacturing process of pipe bends it is difficult to avoid thickening on the intrados and thinning on the extrados. The cross section of the bend also becomes non circular due to bending process. The acceptability of pipe bends is based on the induced level of these shape imperfections.
Now-a-days in industries especially in automobile and other industries the automatic plate bending machines are widely used. Earlier the bending machines where operated manually. So the output of machine was very less. Now the technique of bending operation of the component is changed.
Once the plate is loaded the operator should not only use once push button to start the machine, but he has operated two push buttons so that both the hands of the operator are engaged. This arrangement is made in order to avoid injuries to operators. The main aim of this project is to have the complete know how of pneumatic devices, sensors etc. by which the manually operated press or any machine can be converted into a semi or fully automatic unit. In this project the bending machine is a semi-automatic bending machine, in which the loading and unloading of the component is done manually and the bending of the rod is done pneumatically.
The main objective of this paper is to implement the Pneumatic rod bending machine in the construction sites with less cost compared to the existing bending machines, and increasing the productivity of the stirrups. The bending machine is one of the most important machine tool in sheet metal work shop. It is primarily designed for bending. The bend has been made with the help of punch which exerts large force on the work clamped on the die. The bending machine is designed in such a way that, it works automatically. The automation strategy, when implemented is believed to result in reduced cycle time, costs and improved product quality. Other possible advantages are repeatability, increased productivity, reduced labor and integration of business systems. Automation is achieved with the help of Electro pneumatic system.

1.2                                                   AIM OF THE PROJECT
The main aim of this project the manually operated press can be converted into a semi or fully automatic machine. In this project the loading and unloading of the component is done manually and the bending of the plate is done automatically

1.3                                             OBJECTIVE OF THE PROJECT
This project is developed to study about the automation in process of pipe bending machine industries. Mainly preferable for small industries. The purpose of this project is listed below:

• To increase the accuracy of product.
• To reduce the time consumption.
• Less machine setup time is required.
• To produce curve and curvature shaped bend pipe.
• Pipe should be bent in 90 degree.

1.4                                                  PROJECT MOTIVATION
The Reasons to design Bending machine for pipe bending is because there is no proper bending machine to bend a metal pipe for small scale. The bending machine found in the market comes from variety of types. There are bending machine such as press brake bending machine, roll bending machine, three roll bending machine. Moreover the design for the bending machine for pipe bending machine for pipe bending is to bend a metal pipe. It produces pipe metal bending with desire degree of bending except90 degree. Other reason and regarding to the bending machine design, the bending machine in the market come with big size and the bending machine expansive. The requirement of operation of bending machine is simple. Thus it is not suitable to purchase existing bending machine to be used for simple bending machine operation. Moreover, the machine is heavy sans use up a lot of small space.

1.5                                         APPLICATIONS OF THE PROJECT

• Angle bending
• Metal folding
• U hook
• Marine tube
• Heat exchanger
• Scroll bending

1.6                                          ADVANTAGES OF THE PROJECT High effectiveness: Many factories have equipped their production lines with compressed air supplies and movable compressors. There is an unlimited supply of air in our atmosphere to produce compressed air. Moreover, the use of compressed air is not restricted by distance, as it can easily be transported through pipes. After use, compressed air can be released directly into the atmosphere without the need of processing. High durability and reliability: Pneumatic components are extremely durable and cannot be damaged easily. Compared to Electromotive components, pneumatic components are more durable and reliable. Simple design: The designs of pneumatic components are relatively simple. They are thus more suitable for Use in simple automatic control systems. High adaptability to harsh environment: Compared to the elements of other systems, compressed air is less affected by high Temperature, dust, corrosion, etc. Safety: Pneumatic systems are safer than electromotive systems because they can work in inflammable environment without causing fire or explosion. Apart from that, overloading in pneumatic system will only lead to sliding or cessation of operation. Unlike electromotive components, pneumatic components do not burn or get overheated when overloaded. Easy selection of speed and pressure: The speeds of rectilinear and oscillating movement of pneumatic systems are easy to adjust And subject to few limitations. The pressure and the volume of air can easily be adjusted by a Pressure regulator. Environmental friendly: The operations of pneumatic systems do not produce pollutants. The air released is also processed in special ways. Therefore, pneumatic systems can work in environments that demand high level of cleanliness. One example is the production lines of integrated circuits. Economical: As pneumatic components are not expensive, the costs of pneumatic systems are quite low Moreover, as pneumatic systems are very durable, and the cost of repair is significantly lower than that of other systems.

1.7                                         SIGNIFICANCE OF THE PROJECT
The bending machine is one of the most important machine tool in sheet metal work shop. It is primarily designed for bending. The bend has been made with the help of punch which exerts large force on the work clamped on the die. The bending machine is designed in such a way that, it works automatically. The automation strategy, when implemented is believed to result in reduced cycle time, costs and improved product quality. Other possible advantages are repeatability, increased productivity, reduced labor and integration of business systems. Automation is achieved with the help of Electro pneumatic system.
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.

1.8                                           LIMITATION OF THE PROJECT
i. In this paper the wiring is very much complicated, if any troubleshoot occurs then the fault cannot be easily found.
ii. In this project the bending machine is a semi-automatic bending machine, in which the loading and unloading of the component is done manually and the bending of the rod is done pneumatically.

1.9                                                         PROJECT ORGANISATION
The work is organized as follows: chapter one discuses the introductory part of the work,   chapter two presents the literature review of the study,  chapter three describes the methods applied,  chapter four discusses the results of the work, chapter five summarizes the research outcomes and the recommendations.

CHAPTER ONE: The complete chapter one of “design and fabrication of a pneumatic pipe bending machine” is available. Order full work to download. Chapter one of “design and fabrication of a pneumatic pipe bending machine”consists of the literature review. In this chapter all the related work on“design and fabrication of a pneumatic pipe bending machine” was reviewed.

CHAPTER TWO: The complete chapter two of “design and fabrication of a pneumatic pipe bending machine” is available. Order full work to download. Chapter two of “design and fabrication of a pneumatic pipe bending machine” consists of the literature review. In this chapter all the related work on “design and fabrication of a pneumatic pipe bending machine” was reviewed.

CHAPTER THREE: The complete chapter three of “design and fabrication of a pneumatic pipe bending machine” is available. Order full work to download. Chapter three of “design and fabrication of a pneumatic pipe bending machine” consists of the methodology. In this chapter all the method used in carrying out this work was discussed.

CHAPTER FOUR: The complete chapter four of “design and fabrication of a pneumatic pipe bending machine” is available. Order full work to download. Chapter four of “design and fabrication of a pneumatic pipe bending machine” consists of all the test conducted during the work and the result gotten after the whole work

CHAPTER FIVE: The complete chapter five of “design and fabrication of a pneumatic pipe bending machine” is available. Order full work to download. Chapter five of “design and fabrication of a pneumatic pipe bending machine” consist of conclusion, recommendation and references.

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