1. DESIGN AND FABRICATION OF
BENDING MACHINE

2. ABSTRACT
• 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.

3. INTRODUCTION
• To build this machine many equipment or
machine is used. By using all this equipment,
process for making the project is faster and
easier. I had also learned a proper method for
operating all this machine and equipment.
Choosing component material is very important,
because it will affect the overall cost of the
machine and the product quality. With this
consideration, I had design this machine with the
maximum quality and low in cost.

4. TYPE OF BENDING MACHINES
• TUBE BENDING
• CIRCLE BENDING
• BAR BENDING
• CHENNEL BENDING
• SQUARE BENDING

5. TUBE BENDING:
The Forming Roller method of tube bending is recommended
for all large bends. where the centerline radius is at least 4
times the outside diameter of the tube. It can also be
successfully employed for bending pipe or heavy wall tubing
to smaller radii and is the most practical method of bending
very small diameter tubing. The Forming Roller and Radius
Collar must be grooved to exactly fit the tube and the tube
must not be allowed to slip during the bending operation as
even a slight amount of slippage will cause distortion.

7. CIRCLE BENDING:
This operation is somewhat involved by the fact
that most materials “spring back” after they have
been formed. To compensate for this, it is often
necessary to use a Radius Collar having a smaller
diameter than that of the circle required. Actual
size can best be determined by experiment, as the
“spring back” varies in different materials.
Material should be precut to exact length before
forming.

9. • CHANNEL BENDING:
The same general bending rules which cover the forming of
channel with
“flanges out” also apply when it is formed with “flanges in.”
Since it is necessary to compress the flanges as they are bent
inward, the operation shown below requires considerably more
bending pressure than when forming with the “flanges out”, and
it is recommended that the largest possible radius be used to
allow for compression of the material. if a sharp 90 bend is
desired, it can be obtained by cutting a notch out of the channel
flanges before forming around a special Zero
Radius Block as illustrated . It is sometimes possible to make a
circle in channel by using a segment of a Radius Collar similar .
By following the procedure outlined on, the circle can be formed
in three operations. To form channel with the flanges facing
upward it is necessary to first fill it with Cerro bend or some
other commercial filler as it is not possible to support the flanges
in this position with a radius Collar.

11. • SQUARE BENDING:
Forming zero radius bends around square, rectangular,
or other multisided blocks employs the same principle
used in scroll bending. Forming Nose “leads” material
between corners of the block. Any number of zero
radius bends can be obtained in one operation by this
method in all types of solid materials. Both centered
and off-center square eye can also be formed by
following the same procedure outlined on. This method
of bending is limited by the size of the square block and
the ductility of the material. In general, when squares
larger than 1” are needed, they should be formed in
progressive operations using the zero radius block.

13. WORKING

14. WORKING
The rod to be bent is placed in between the
two Jigs mounted on the circular plate. The motor
is attached with the circular plate. The power from
the motor is transfered which rotates the circular
plate in anticlockwise direction.one Jig is connected
to the motor and the other Jig is rotated due to the
rotation of circular plate. The rod will be fixed since
the fixed rod lies on the other side . since the rod is
kept in between the two Jigs, the rod would bent.

15. CALCULATION

16. calculated shear stress τ = 458 N/mm2
wkt , (σb÷y) = (Mt÷I)
y = (d÷2) = (10÷2) = 5mm
moment of inertia I = (π÷64)×d4
I = (π÷64)×104 = 490.87 mm4
σb= 89×103×5/490.87
bending stress σb = 906.66 N/mm2
substitute all the values in the above relation.

17. 906.66/10 = M/490.87
M = 44500 N mm
WL/4= 44500
W = 44500×4/100
L = length of the rod = 200 mm
W = 1780 N =182 kg
Polar moment of Twist
J = (π÷32)d4
= (π÷32) ×104
J = 981.74 mm4
Common angle of Twist
Θ = (T×L÷Cs×J)
Cs = modulus of rigidity
= 8.4×104 N/mm2
Θ = (90×103×100/8.4×104×981.74)
Θ = 0.109 rad
Θ = 0.109×(180÷π)
Θ = 6.25°

18. APPLICATIONS
• ANGLE BENDING
• METAL FOLDING
• U HOOK
• MARINE TUBE
• HEAT EXCHANGER
• SCROLL BENDING

19. ADVANTAGES
• Easily operated.
• Simple construction.
• Low cost.

20. SPECIFICATION
MOTOR
• MOTOR POWER -0.5hp
• SPEED -40rpm
CIRCULAR DISC
• DIAMETER -20mm
• THICKNESS -2.5mm
jigs -2 no
BATTERY -12v