Nowadays for construction works bending of metal sheet is necessary for constructions. Bending of such metal sheet is done manually by setting angle plates. This wastes lot of labour (man) power and time. It is proposed to replace the manual work and reduce time taken for bending by designing an alternative machine to replace the manual work which works by the principle of hydraulic system and indexing mechanism. This will reduce the time taken for bending operation and more than one metal sheet can be bent at a same time. Bending can be done with required dimensions and accuracy is maintained during the entire operation. By changing the dimensions of the die required bents are made on the metal sheet. Along with the ease of operation use of hydraulics also makes it more precise, economical and compact. The entire machine is easily portable and having nice aesthetics as well.

TABLE OF CONTENTS
COVER PAGE
TITLE PAGE
APPROVAL PAGE
DEDICATION
ACKNOWELDGEMENT
ABSTRACT

CHAPTER ONE
INTRODUCTION
1.1    BACKGROUND OF THE PROJECT

• OBJECTIVE OF THE PROJECT
• ADVANTAGE OF THE PROJECT
• APPLICATION OF THE PROJECT
• PURPOSE OF THE PROJECT
• SCOPE OF THE PROJECT

CHAPTER TWO

• LITERATURE REVIEW
•      OVERVIEW OF METAL BENDING
•       TYPES METAL SHEET BENDING
•     PROCESS OF BENDING
•     REVIEW OF THE RELATED STUDY
•     HISTORICAL BACKGROUND OF THE STUDY

CHAPTER THREE
SYSTEM DESIGN

• MACHINE ACCESSORIES
• DESIGN CONSIDERATION
• DESIGN OF BENDING MACHINE
• CALCULATION
• LIMITATIONS SAFETY & MAINTENANCE

CHAPTER FOUR

• TESTING AND RESULTS
• PARTS OF BENDING MACHINE
• MECHANICAL RATINGS AND SERVICE FACTORS
• MOTOR CONSTRUCTION
• PEDESTAL BEARING

CHAPTER FIVE

• CONCLUSION
• REFERENCES

 

CHAPTER ONE

1.0 INTRODUCTION

1.1                                       BACKGROUND OF THE PROJECT

Sheet metal fabrication plays an important role in the metal manufacturing world. Sheet metal is used in the production of materials ranging from tools, to hinges, automobiles etc. Sheet metal fabrication ranges from deep drawing, stamping, forming, and hydro forming, to high-energy-rate forming (HERF) to create desired shapes. Fascinating and elegant shapes may be folded from a single plane sheet of material without stretching, tearing or cutting, if shape rolling of sheet metal is the bending continually of the piece along a linear axis. This causes alteration of the original form of the sheet as it passes through a pathway of series of rollers. The present invention relates to plate bending machines of the type which operates with rolls. Such machines involve certain well-known difficulties in respect of bending plates into conical shape. The invention has for its object to remedy this drawback and to enable, by including auxiliary means, the bending of conical mantles and the like.
The main characterizing feature of the plate bending machine according to the invention resides in that it comprises a pin which is adapted, during the bending operation, to be moved into engagement with one of the rolls in a substantially radial direction so as to serve as an abutment for one edge of the blank to be bent.
In a plate bending machine, a frame, two parallel cylindrical rolls rotatable mounted in side frame and adapted to be driven in the same direction, a third cylindrical roll situated substantially in the median plane between the two first-mentioned rolls and freely rotates, mounted in side frame in adjustable bearings permitting side third roll to be inclined relatively to the two first-mentioned rolls for producing conical bends, a tubular support mounted in fixed relation to said frame adjacent one end of said third roll and substantially perpendicularly to its axis, and a pin slid-ably mounted in said tubular support and movable into engagement with the periphery of said third roll to serve as an abutment for the edge of a plate when producing a conical bend.

     1.2                        OBJECTIVES OF THE WORK

  The following are the objectives of the work:

• To make a bending machine to bend metal sheets up to 8 mm.
• To make on simple working principle.
• To reduce the time for operation.
• To make in minimum cost.

  1.3                                                    ADVANTAGES OF THE PROJECT

• Reduction of man power employed.
• Improved output.
• Increased safety.
• Easy handling & movement of machine.
• Easy access to all areas.
• Quick response is achieved.
• Easy maintenance and repair.
• Low investing cost.
• Continuous operation is possible without stopping.
• Compact size and less floor space is used
• All movements are pneumatically operated.
• Can be stored easily
• Clean and non – pollutant
• Transportable over long distances
• High speed operation
• Relatively low cost to produce
• Largely insensitive to temperature
• Technology can be easily learned

    1.4                       APPLICATIONS OF THE PROJECT

This device found application in the following places:

• for Paper cutting
• For sheet cutting
• For stamping operating
• For bending operation
• Fabricating/Rolling
• Boilers, Pressure Vessels
• Storage Tanks, Silos
• Tubes and Pipelines
• Pumps, Burners and Filters
• Heating and Ventilation
• Wind Towers, Power Generation

1.5                                                       PURPOSE OF THE PROJECT
The purpose of this project is to therefore design a simple, easily operated pneumatic sheet metal bending machine that is sturdy and strong. A pressure of 8-10 bar is enough for operating the unit. The pressurized air passing through the tubes to the cylinder, forces the piston out whose power through the linkage is transmitted to the punch.

1.6                                                          SCOPE OF THE PROJECT
Sheet metal bending is one of the most widely applied sheet metal forming operations. The understanding of the bending mechanics is aimed at obtaining two kinds of information important for industrial applications. The first one is the springback prediction for die design and shape control. The second is an estimation of the bend force for selection of press capacity, strength analysis and design of dies.
The bending machine is designed in such a way that, it works automatically. The machine is designed by observing the factors to improve the efficiency and to reduce the cycle time by producing quality output. Automation of machine is achieved with the help of pneumatic system. This involves the design of an efficient system which reduces the human effort and help to increase production output.

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