Index Copernicus Value-63.45 Improvement in Design and Fabrication of a Portable Pipe Bending Machine Authors Avirat P. Kshar 1, Avantika P. Kshar 2 1 Department of Mechanical Engineering, Veermata Jijabai Technological Institute (VJTI), Mumbai 2 Department of Mechanical Engineering, Government Polytechnic, Amravati Email- aviratkshar999@gmail.com, ksharavantika@gmail.com ABSTRACT The expansion of nation and economy depends on the achievement in advancement of science and technologies. So, innovating a machine which is easy to use and that cannot tolerate with their accuracy without affecting prize of machine is the prime motto of any design engineer. All over the world the sources of energy are reduced for that we can find new source of energy. In India, there are many industries which are engaged in production of manually operated pipe bending machines. The paper deals with manufacturing of fixed die and lever operated manually pipe bending machine. This manufacturing technique would reduce the size of a conventional bending machine for portable works. Keywords-Manufacture, Machining, Bend, Design. 1. INTRODUCTION In modern days, all area of industries are going to like automated, economically and accurate machinery.there are many types of pipe bending machine are available in market like hydraulic pipe bending machine, pneumatic pipe bending machine, manual pipe bending machine, etc. The utility model discloses a full-automatic pipe bending machine. Whole machine is supported by a base with four supporting legs which has enough strength to carry the weight and force of machine. Two parallel shafts are clamped on base by clamps which carry the lower pulley. Pulley is driven by dc motor with chain drive mechanism. Here two guide ways are used for guide the working pulley for up & down linear motion. Pulley gets that motion from lead screw. Lead Screw is working as a nut and bolt mechanism. The lead screw is get rotary motion from upper dc motor. Guide way and lead screw are fitted between two horizontal supporting plates, which are fitted on frame by the help of the two vertical parallel supporting plates. Production efficiency is improved, the production cost is reduced, and the application range is world. In various fabrication works as well as in architectural work pipes are used in artistic ways. To bend this pipe into this artistic form, it is not easy thing to be done manually. Using a particular machine specially developed for bending of pipes helps to draw pipes in required curvatures making the process faster and easier. With this consideration we have designed this machine with the maximum quality and low in cost. 2. LITREATURE REVIEW We searched on various pipe bending machine designs and also pointed out the various defects and difficulties which arise due to changes in dimensions and material considerations. For proper material selection we carried out a market survey. We visited market for the material of machine. There we bought square pipes of side 25 mm. Then we cut the square pipes as per the requirement. We then searched for the pedestal bearings in the market. We also bought shafts of BRITE BAR. The dies which required for bending are made on lathe machine. At first we got a blank of mild steel of required diameter of which pipe is to be bent. We then grooved it over the circumference. After that Avirat P. Kshar, Avantika P. Kshar IJMEIT Volume 05 Issue 08 August 2017 Page 1683
we drilled a hole of the size of which bearings we used. The entire market survey and design changes were for the following designs of bending machines, 1. In April 2013, Prof. Nilesh Nirwan and Prof A. K. Mahalle, Department of Mechanical Engineering, G. H. Raisoni College of Engineering, Nagpur devised a Portable Rolling Pipe Bending Machine meant for reliability, easy conveyance and good quality purpose. But there are some difficulties like that is can t be used for mass production and slow in process due to hand operated devices. 2. In November 2012, Prof. A. Pandiyan, Department of Mechanical Engineering, Saveetha School of Engineering, Chennai devised a Zig- Zag Pipe Bending Machine which is used for making zig-zag profile pipe. It is operated by hydraulic bottle jack. This Bending Machine is only used for zig - zag profile,so not used for other bending operation. 3. In September 2011, Prof. N. N. Jadeja, Department of Mechanical Engineering, GEC, Bhavnagar has devised a manually operated pipe bending machine for use in small industries. This machine is a low cost machine. It has low accuracy of bending and force is not uniformly distributed over whole length of pipe, so this bending machine is not preferable. For all such problems and errors in bending we manufactured a bending machine which solved all the above problems and improved the efficiency of bending machine and also the cost reduced in all terms. 3. DESIGN PROCEDURE DESIGN FEASIBILITY & EVALUATION DESIGN DEVELOPMENT FINAL DESIGN SELECTION DETAILED DESIGN PROTO-TYPE & TESTING PRODUCTION 4. CONSTRUCTIONAL COMPONENTS The machine consists of following components: 4.1 Frame: Frame consists of base that supports the entire arrangement. Over which is attached vertical members. 4.2 Roller: There are three rollers. Rollers are used to bend the pipe. Pipe passes through these rollers and bends at specific angle. It is made of Mild Steel. It is supported by shaft which is fixed in bearing. NEED FOR DESIGN PROBLEM STATEMENT& ANALYSIS DESIGN IDEAS & ALTERNATIVES Fig 1- Machined Roller of Pipe Bending Machine Avirat P. Kshar, Avantika P. Kshar IJMEIT Volume 05 Issue 08 August 2017 Page 1684
4.4 Pedestal Bearing: We used six bearings which are fixed to square bars with help of nuts and bolts. Bearing used are of M20 size. They are tilted at some angle for adjustment. For locking of bearing Allen key is used as bearing is not self-locking. For lubrication purpose GREASE NIPPLE is provided. Fig 2- Actual Pedestal Bearing 4.3 Shaft: There are three shafts used on this machine. They are also made up of mild steel. It supports rollers. It is fixed in bearing and rotates freely which in turn rotates the rollers. Fig 4- Handle for the Machine 4.7 Lifting And Lowering Mechanism: This unit consists of two plates which are welded to the assembly one at the top and the other at the middle section of the assembly. A screw enters from the top through a nut which welded at upper plate and then enters into the hole made at lower plate and the washers which are also welded to plate. Fig 5-Mechanism for lifting and lowering roller Fig 2- Machined (Turning) shaft 4.5 Sprockets: Two sprockets are used for rotation of the shaft. Sprockets are welded to the shaft and chain is mounted over the sprockets. Fig 3- Sprocket Wheel 4.6 Handle: Handle is used for rotating the sprockets and thus the rollers. 5. WORKING AND SPECIFICATIONS This machine works on the principle that pipe enters from one side through the rollers and load is applied from the top and further rotation results in bending of pipe from the other side. The machine has three rollers through which pipe passes. At one roller handle is connected at the back side through sprocket. When pipe is fed at one side, handle is rotated and pipe moves further. When pipe comes in contact to the middle roller load is applied from the top. Then handle is rotated further and pipe bend through the another roller at other side at specific angle. The following are the specifications of the machine to be manufactured, Avirat P. Kshar, Avantika P. Kshar IJMEIT Volume 05 Issue 08 August 2017 Page 1685
Fig 6- Actual Bending Machine 1. HANDLE Length - 35cm Width - 12cm 2. ROLLER Diameter 9cm Thickness 1.9 cm 3. SHAFT Length 30 Cm Diameter 2 cm 4. BEARING Diameter 2 cm 5. BODY Length 38 Cm Width - 15 Cm Height - 55 Cm 6. NUT Inner Diameter-1cm Outer Diameter-1.1cm 7. SPROCKETS AND CHAIN Distance between Shaft Centre 20cm Number of teeths 28 8. BASE Length- 50cm Width- 30cm 9. NUTS, BOLTS AND WASHERS- 12 6. ADVANTAGES Simple in construction Compact in size. Ease in operation. Clean system. Easy to maintain. Economical. Less skilled labor can operate the machine. The machine should be rigid. Continuous lubrication is not required. 7. DIADVANTAGES Load has to be applied manually. Less efficient than hydraulic machine. More effort is required. The die is replaced according to the variance in diameter in pipe. Precautions to be taken while operating the machine. 8. APPLICATIONS Building Constructions Windows, Trusses. Automotive- Exhaust, Seat Frames, Stabilizer. Cycle, Motor-Cycle Frames. Refrigeration Pipes Electrical Appliances Irrigation System Boiler Tubes 9. COST ANALYSIS Sr.No Material Quantity Cost 1. Pedestal Bearing 6 1110/- 2. Roller 3 1500/- 3. Shaft 3 200/- 4. Sprockets 2 500/- 5. Chain 1 100/- 6. Handle 1 130/- 7. Nuts, Bolts & Washers 12 100/- 8. Paints and Accessories -- 300/- 9. Machining cost -- 400/- 10. Lead Screw 20/- 11. Main Body 850/- Total (Rs)= 5210/- Avirat P. Kshar, Avantika P. Kshar IJMEIT Volume 05 Issue 08 August 2017 Page 1686
10. CONCLUSION The main objective of producing the pipes through bending was achieved by the designed concept of bending machine, which proved to be efficient in many factors. The factors included reduction in the cost, proper space utilization, compact design and construction & were the prime goals of the determined concept. Moreover the benefits of the bending machine for use of the workshop practices was achieved. This manually operated bending machine replaced the use of hydraulic machine which caused increase in cost due to the employment of oil as a energy source to impart the required force. Also the oil leakages and the surrounding working conditions were improved by simply eliminating these factors. The machine in overall aspect proves to be efficient and an alternative to the conventional hydraulic machine. REFERENCES 1. YANG Hea, LI Henga, ZHANG Zhiyonga, ZHAN Meia, LIU Jinga, LI Guangjunb.,Advances and Trends on Tube Bending Forming Technologies, 2012. 2. Mohan Krishna S.A., experimental design and fabrication of a portable hydraulic pipe bending machine International Journal of Development Research Vol. 4, Issue, 12, pp. 2681-2684, December, 2014 pp. 2681-2682. 3. J.K.Gupta,A Text Book of Machine Design, 1 st edition, S.Chand Publication 7. 4. P.N Rao, Manufacturing Technology, Second Edition, tata McGraw Hill Avirat P. Kshar, Avantika P. Kshar IJMEIT Volume 05 Issue 08 August 2017 Page 1687