Department of Mechanical EngineeringRKGIT , GHAZIABAD

Under the supervision of Mr. Ved prakash

By:Sumit SahgalSujeet SinghAnmol Kumar

Vibhanshu kr. Tripathi

FABRICATION OF HYDRAULIC BENDING MACHINE

INTRODUCTION

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. In various fabrication works as well as in architectural work pipes are used in artistic ways. To bend these pipes into these artistic forms is not easy thing to be done manually. Using a particular machine specially developed for bending of pipes helps.

CURRENT SCENARIO OF PIPE BENDING MACHINE

Various type of pipe bending machines are used for pipe bending. Majority of the machines are manually operated and operating force is magnified using mechanical advantage from an appropriate lever system.

COMMON PROBLEMS WITH THESE SYSTEMS

• Tremendous amount of human effort is necessary.

• Labor cost is more.• Time consuming in terms of setting of

operation setup.• Defects in the form of angular

deformation and wrinkles are seen and quality is not good.

SOLUTION IS HYDRAULIC PIPE BENDING MACHINE• The bending force is generated is quite

large with a minimum human effort.• Loading is done by operating handle of

the jack which carries the bending action resulting into a safe and damage free bending operation.

DESIGNDesign consists of application of scientific principles, technical information, imagination for development of new and improved machine or mechanism to perform specific function with maximum economy and accuracy. It consists of two parts1. System Design2. Mechanical design

System Design System selection based on physical constraints. Arrangement of various component. Man machine interaction. Servicing facility. Height of machine. Weight of machine.Mechanical Design Fabricated parts. Parts to be purchased.

WORKING PRINCIPLE The Hydraulic Jack is a device used for lifting heavy loads by the application of much smaller force. It is based on the Pascal’s law, which states that intensity of pressure is transmitted equally in all directions through a mass of fluid at rest. The working principle of a hydraulic jack may be explained with the help of Fig. shown below. Consider a ram and plunger, operating in two cylinders of different diameters, which are interconnected at the bottom, through a chamber, which is filled with some liquid.

WORKINGThe pipe is inserted between the pulleys and the Hydraulic jack pulley as shown in figure. The Bending Force is applied with hydraulic Jack when the handle is operated. Thus pipe is bent. For desired diameter of bending curve the pulleys are changed or altered.

CONSTRUCTION DETAILS OF PIPE BENDING MACHINEIn the constructional part of the project work, a base frame structure is fabricated using Mild Steel bars. Frame : A flat platform is formed on the top of this

base structure. On this platform two mounting points are fixed. These mounting points are kept very robust in nature as they have to withstand huge lateral forces during working of the device. Set of combination of two numbers of affix able meshing pulleys of various diameters are fabricated or machined.

Supporting Pulley: The peripheral cross sectional area of pulleys in pairs in any set is kept same either semicircular or half square depending on the pipe to be bent like circular or square cross section. Other pipes can also be bent but for that special pulleys have to be made.

Hydraulic Jack: Hydraulic jack with Semi Circular pulley as shown in figure is fixed on the frame in between two pulleys and below it by calculating working distance . Provision for Adjustment of jack should be there to achieve any type of shapes and curvature.

Springs: Quick retraction springs are attached to hydraulic jack upper end for easy and fast retraction of jack shaft. Springs should be designated in such way that it will not add more pressure or force for upper movement of the hydraulic jack.

Hydraulic Jack: Hydraulic jack with Semi Circular pulley as shown in figure is fixed on the frame in between two pulleys and below it by calculating working distance . Provision for Adjustment of jack should be there to achieve any type of shapes and curvature.

Springs: Quick retraction springs are attached to hydraulic jack upper end for easy and fast retraction of jack shaft. Springs should be designated in such way that it will not add more pressure or force for upper movement of the hydraulic jack.

APPLICATIONS Used in automobile industry. Agricultural work components fabrication. Gym equipment's. Boat and swimming pool furnishings. Exhausts. Handles. Road signs and posters. Fuel pipes for diesel engines.

ADVANTAGES

• Hydraulic ram force reduces human effort in operation.

• Portable.• Simple construction.• Low cost.• Less needs for maintenance.• No extra skill is required for operating this

system.

THANK YOU