final third year project report (joseph stynes x00105837)

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INSTITUTE OF TECHNOLOGY TALLAGHT

DUBLIN Department of Mechanical Engineering

Title: Third year project - The manufacturing of a manually

operated pyramid type slip rolls

Project supervisor : Tom Healy

Student Name: Joseph Stynes

Student No: X00105837

Date of Submission: [28/04/2015]

Declaration

I hereby declare that this is my original work produced without the help of any third party.

Signed:

Date:

Lecturer Feedback

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1 Table of Contents

INSTITUTE OF TECHNOLOGY TALLAGHT DUBLIN ....................................................................... 0

1 Table of Contents ............................................................................................................... 2

Chapter 1 Introduction .......................................................................................................... 5

1.1 Project description ....................................................................................................... 5

1.1.1 Justification ......................................................................................................... 5

1.1.2 Deliverables ......................................................................................................... 5

a. Product scope................................................................................................................. 5

1.1.3 Design specifications........................................................................................... 5

1.1.4 Desirable features................................................................................................ 5

1.1.5 Criteria of excellence .......................................................................................... 6

b. Project objectives .......................................................................................................... 6

c. Project plan.................................................................................................................... 6

2 Investigation....................................................................................................................... 8

2.1 What is metal forming? ............................................................................................... 8

2.1.1 Examples of compressive forming....................................................................... 8

2.1.2 Examples of tensile forming .............................................................................. 10

2.2 History of metal forming ........................................................................................... 12

2.3 Pyramid style roller operating principle (concept design 1) ..................................... 12

2.4 Spring adjusted pyramid style roller operating principle (concept design 2) ........... 13

2.5 Three roll initial pinch style roller operating principle (concept design 3) ............... 13

2.6 Weighting of proposed designs ................................................................................. 14

2.7 Selection of chosen design according to weightings criteria .................................... 14

2.8 Testing of selected design ......................................................................................... 14

2.9 Concept design one ................................................................................................... 15

2.10 Concept design two................................................................................................ 16

2.11 Concept design three.............................................................................................. 17

3 Concept development....................................................................................................... 18

3.1 Selection of preferred design and calculation of critical dimensions ........................ 18

3.2 Factors that are crucial in the design of..................................................................... 18

3.3 Theoretical mathematical calculations ...................................................................... 19

3.4 Conclusions of simple bending theory calculations .................................................. 21

3.5 Calculating the velocity ratio for a screw jack .......................................................... 21

3.6 CREO 3D CAD Assembly drawings ........................................................................ 23

3.6.1 Box section sub assembly .................................................................................. 23

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3.6.2 Idle end plate sub assembly ............................................................................... 24

3.6.3 Gear end plate sub assembly .............................................................................. 25

3.6.4 Hand crank sub assembly................................................................................... 26

3.6.5 Final complete assembly .................................................................................... 27

3.6.6 Final machine assembly part drawing................................................................ 28

Bill of materials and manufacturing plan................................................................................. 29

3.7 Bill of materials ......................................................................................................... 29

3.8 Manufacturing plan ................................................................................................... 30

4 Testing and evaluation of manufactured artefact ............................................................. 31

4.1 Testing the functionality of the manufactured artefact ............................................. 31

4.2 Testing calculations ................................................................................................... 31

4.2.1 Test 1.................................................................................................................. 31

4.2.2 Test 2.................................................................................................................. 31

4.2.3 Test 3.................................................................................................................. 32

4.2.4 Test 4.................................................................................................................. 32

4.2.5 Test 5.................................................................................................................. 32

4.2.6 Test 6.................................................................................................................. 33

4.2.7 Test 7.................................................................................................................. 33

4.2.8 Table of results for practical testing of slip rolls ............................................... 34

4.2.9 Photo image of the final fabrication................................................................... 35

4.2.10 Discussion of functional testing results ............................................................. 36

5 Progress of project ........................................................................................................... 37

5.1 Progress and working to set deadlines ...................................................................... 37

5.1.1 Design using CREO Parametric......................................................................... 37

5.1.2 Sourcing of materials ......................................................................................... 37

5.1.3 Manufacturing of components and final assembly ............................................ 37

5.1.4 Final testing of the functional capabilities and limits of the machine ............... 38

6 Conclusions ...................................................................................................................... 39

7 Appendix (Piece Part Drawings)...................................................................................... 40

7.1 Box section long ........................................................................................................ 40

7.2 Box section short ....................................................................................................... 41

7.3 Tapped threaded flat bar............................................................................................ 42

7.4 Bottom locking block ................................................................................................ 43

7.5 Top locking block...................................................................................................... 44

7.6 Idle end plate ............................................................................................................. 45

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7.7 Gear end plate............................................................................................................ 46

7.8 Brass roller guide ...................................................................................................... 47

7.9 Brass guide retaining ring ......................................................................................... 48

7.10 Top block threaded round ...................................................................................... 49

7.11 Body of threaded rod ............................................................................................. 50

7.12 T bar turning handle............................................................................................... 51

7.13 Top roller ............................................................................................................... 52

7.14 Front feed roller ..................................................................................................... 53

7.15 Back feed roller...................................................................................................... 54

7.16 Intermediate gear shaft .......................................................................................... 55

7.17 Intermediate gear shaft disc .................................................................................. 56

7.18 Front feed roller key .............................................................................................. 57

7.19 Back feed roller key ............................................................................................... 58

7.20 Intermediate shaft key............................................................................................ 59

7.21 Sealed roller bearing .............................................................................................. 60

7.22 Spur gear ................................................................................................................ 61

7.23 Hand crank boss..................................................................................................... 62

7.24 Hand crank handle ................................................................................................. 63

7.25 M16 x 2mm Threaded bar section ......................................................................... 64

7.26 M12 x 1.75mm CSK Hex head bolt ...................................................................... 65

7.27 M12 x 1.75mm Cap head bolt ............................................................................... 66

7.28 M16 x 2mm Hex head bolt .................................................................................... 67

7.29 M8 x 1.25 Hex head bolt ....................................................................................... 68

8 Works Cited ..................................................................................................................... 69

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Chapter 1 Introduction

1.1 Project description

The aim of the project is to design and manufacture a sheet metal forming device that must

roll sheet metal with a maximum thickness of 4mm into an arc forming a complete circle of no smaller than 60 mm in diameter. The slip rolls must be manually operated as opposed to electrically or hydraulically powered. To successfully complete this project it will be crucial

to utilise all the facilities that the institute has available such as the design software like CREO and the manufacturing facilities such as the lathes, milling machines, CNC etc. Skills

in metal fabrication, welding, and machining will be crucial in successfully completing this project.

1.1.1 Justification

To form metal plates or sheets into the required radii a machine of this type is required. The

use of heavy plate rollers and sheet metal rollers have extensive application right across industry from the fabrication of bespoke exhaust systems for the motorcycle racing industry to the shipbuilding industry. To form sheet metal into the required diameter for the

fabrication of rolled tubular sections or conicular sections with welded seams, a machine such as the design proposed would be the preferred method of forming as opposed to segmented

forming on a press brake.

1.1.2 Deliverables

Completed artefact: A functioning manually operated sheet metal rolling machine

Project report

Project logbook

Detailed 3D CAD drawings as well as piece part drawings including exploded view of

finished assembly

Presentations (Both Christmas and Easter)

Poster show

a. Product scope

1.1.3 Design specifications

The completed sheet metal rolling machine must be portable. It must be no more than 0.75 metres in length at maximum. It must not be more than 0.3 metres in height at maximum. Its

weight is difficult to quantify at this early stage. The machine must be constructed using mild steel as the main fabrication material. It must be fully adjustable so as to allow the forming of straight tubular sections as well as conicular sections. It must feature a quick release

mechanism on the top roller so as to allow the rolled section to be removed from the rollers once it has been formed.

1.1.4 Desirable features

It would be desirable for the rollers to roll a piece of 2mm thick sheet steel at least 0.5 metres

in length or a piece of 4mm thick sheet at least 0.25 metres in length into a complete circle without approaching the limits of the machines capability. It would be desirable to include in the design multiple lubrication points on the machine so as to lubricate all moving and

rotating parts which will aid in extending the life of the machine, minimising eventual wear. It would be desirable to limit the mass of the completed machine to 50 kg.

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1.1.5 Criteria of excellence

The completed machine will be tested using the following criteria to ascertain whether the

degree of excellence in manufacturing and functionality has been achieved.

Minimum & maximum diameter (60mm - 300mm) of rolled tubular sections

The mass of the final assembly is desired to be within 50 kg if possible

The manual winding handle and the adjustment features must be ergonomic in design

There must be a smooth rotation of the rolls so as to achieve an accurate forming of the required dimensions.

Ease of manufacturing different constituent components

Value for money – keeping the costs as low as is permissible is obviously desirable

b. Project objectives

Develop a project plan to illustrate how the project will be managed

Develop a literature survey on the fundamentals of machine design and the principles

of mechanics of machines

Develop a complete set of CAD drawings for the machine design and its constituent

components

Develop a test procedure to ascertain whether the machine meets structural and

mechanical specifications

Develop a test procedure to ascertain whether the machine performs as designed

Complete all work within the time allocated for the completion of the project

Develop a project report, presentation, and poster

Display and demonstrate the functioning machine

c. Project plan

The project plan will be set out on a week to week basis whereby specific tasks will be earmarked for completion within a specific timeframe. This will undoubtedly change slightly

throughout the duration of the project due to unforeseen circumstances such as delays in delivery of materials and components from vendors or delays in manufacturing time in the

workshop or possible design changes, every effort will be made to avoid this happening. Any changes to agreed schedules will be avoided if at all possible, however any changes to schedules will be communicated to the project supervisor at the earliest opportunity. The

project plan will be laid out in tabular form in a “Gantt chart” using MS Project. The Gantt chart will clearly illustrate the specific tasks assigned to each week of the project and the individual tasks completion dates.

The Gannt chart is illustrated on the following page.

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2 Investigation

2.1 What is metal forming?

Metal forming is a process whereby metals are plastically deformed into the required shape

and dimensions by a force exerted on the material. The force required to deform the material into the required shape must exceed the yield strength of the material, if the force exerted on the material does not exceed the yield strength of the material then the material would return

to its original dimensions because it is within the elastic region. Yield strength will vary between different metals. The amount of deformation that the material will experience will be

dependent on the force applied to the material. There are many types of metal forming and they usually fall into two main categories, compressive forming and tensile forming.

2.1.1 Examples of compressive forming

Rolling - Where the material is passed through two or more rollers either to roll the material into a circular shape or to progressively change the shape of the material by passing it through a whole series of rollers with different

dimensions and patterns which will form the material into parts or components with definite geometry.

Figure 2-2 Hydraulically powered 4 roll roller (1)

Folding (In a brake press) – This process consists of a flatbed die with multiple dimensions on the block for folding different thicknesses of materials

which runs the length of the press. The die block on an industrial size brake press will have a mass of several thousand kilos and will we secured in place

on a machined bed by multiple bolts. A multitude of different shapes and dimensions of blades will be used to fold the material at definite angles or to progressively fold a piece of material into an arc. The blade is secured to the

machine by bolts and is connected to the top half of the machine which moves vertically up and down by way of hydraulic rams which exert tremendous

force onto the material to plastically deform it. See Figure 2-2 Hydraulically powered brake press.

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Figure 2-2 Hydraulically powered brake press (2)

Forging – Cold forging is done by placing a material on a flat bed or in a female die and the material is then subjected to one off or repeated exertion of force usually by a hydraulically powered male die which forges the material

into the required shape. Hot forging is usually carried out on larger thicker sections which require great amounts of heat to enable the material to be

forged into the required shape. The material is usually hammered into the required shape by a hydraulically powered drop hammer, often requiring reheating to allow the material to be continually hammered into shape. See

Figure 2-3 Hydraulically powered drop hammer .

Figure 2-3 Hydraulically powered drop hammer (3)

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Extruding – This is done by pushing, under great pressure, white hot material

(in the case of steel) through a definite dimensioned die to give the required shape and dimensions. This is how seamless pipe, for example, is produced. Also complex shaped angles and channels are produced in this manner. See

Figure 2-4 Hot extruded steel section .

Figure 2-4 Hot extruded steel section (4)

2.1.2 Examples of tensile forming

Stretching – This is done by exerting a tensile load on a material along the

longitudinal axis so as to elongate the material and make it longer. This is done usually in the manufacture of steel wire and steel cables. See Figure 2-5 Representation of drawing/stretching process

Figure 2-5 Representation of drawing/stretching process (5)

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Expanding – This is usually performed by exerting a force, in the case of pipes or

round tubular sections, internally outwards so as to expand the pipe and increase its circumference, which in turn will decrease the wall thickness of the tubular section. See Figure 2-6 Induction heating of large diameter pipe section .

Figure 2-6 Induction heating of large diameter pipe section (6)

Recessing – This is done by stamping an impression into a material or punching a hole. This exerts a tensile force onto the material which stretches to the new

dimensions to create an indented impression in the material. See Figure 2-7 Stamped recessed metal car panel.

Figure 2-7 Stamped recessed metal car panel (7)

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2.2 History of metal forming

The history of modern metal forming can be traced all the way back to Leonardo Da Vinci

with his ingenious design of what can be said is the first ever sheet metal rolling device that was used to flatten sheets of tin and lead and to change their shape by adjusting the height of

the top roller which would alter the radius of the rolled sheet. (8). However, sticking to contemporary technology there are a few principle design types of sheet and plate metal rolling/forming machines. These principal designs are (9)

Pyramid style 3 roll rolling machine

Initial pinch style 3 roll rolling machine

Initial pinch style 4 roll rolling machine

Shoe type with two powered rollers

2.3 Pyramid style roller operating principle (concept design 1)

The principal of operation of a pyramid style three roll rolling machine is a set of three rollers fixed in a pyramid shape. The bottom rollers are both gear driven so as to aid in the pulling of the work through the rollers. The bottom two rollers are located upon a parallel axis fixed at

either end and have a gear located at one end of each shaft with one gear located between the two shafts connecting the other two gears on the other shafts and are intermeshed so as to ensure that the rotation of the bottom rollers is in the same direction. The top roller is an idler

and moves freely, it is dependent on the friction between the sheet metal being rolled and the top roller itself once it has been lowered down onto the bottom two rollers which are both

driven rollers, to prevent slip. The top roller is adjustable vertically by raising or lowering a threaded section by the manual turning of a sliding T handle, to which the threaded section is fixed, through a drilled and tapped block at each end of the rolling machine body. The

threaded section is secured to the top roller by threading the rod through the block and into a brass sliding bush with a rectangular slot cut out of the bush, which houses a retaining ring.

Once the threaded section has been inserted through the block and into the bush then a piece of tube (20 mm OD, 16mm ID) ,which acts as the retaining ring, will be placed over the end of the threaded section in the rectangular slot and will be TIG welded in place to securely

connect the threaded section to the roller, this is done to both ends of the roller. The drilled and tapped top block made from mild steel flat stock will also have two counter bored holes

drilled into the block so as to secure the top block to the main machine body with two hex head cap screws on either block. These cap screws can be released quickly so as to release the top roller and take out the finished rolled section from the machine. This proposed design for

this project will be manually driven with the aid of a hand crank which will be directly connected to the shaft of the front feed roller. The hand crank will be pushed forward rotating

the first gear in a clockwise direction which rotates the second gear in an anti-clockwise direction which in turn rotates the third gear in a clockwise direction, thus maintaining the same rotational direction of the feed rollers.

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2.4 Spring adjusted pyramid style roller operating principle (concept design 2)

This design operates on the same principle as the conventional three roll rolling machine

whereby you have three rollers, two bottom driven rollers located on a parallel axis which are gear driven and one free moving top roller. The difference in the operating principle of this

design is how the work is secured in the rollers by the adjustment of the top roller and how it is raised and lowered onto the work. Instead of using a sliding T handle type design to raise and lower the threaded section, a fixed T handle fashioned from a large nut with two equal

lengths of round bar welded either side of the nut would raise and lower the top roller. There would be a stiff spring fitted along the length of the threaded section which would aid in the

securing of the work between the bottom feed rollers and the top roller. The spring would be secured between the base of the large nut and the top of the rectangular brass sliding bush and would pass through a drilled hole in the top block. The threaded section would be secured to

the shaft by passing the bottom of the threaded section into the rectangular slot cut into the rectangular bush and a tubular retaining ring would be TIG welded to the end of the threaded

section. With the application of an increasing force applied to the spring by rotating the handle clockwise, this would then lower the top roller onto the work piece.

2.5 Three roll initial pinch style roller operating principle (concept design 3)

The initial pinch style rolling machine can have either three rolls or four rolls, there are designs that incorporate more rollers but by and large the initial pinch style design uses either a three roll or four roll configuration. (9) The design consists of the top roller and front feed

roller situated one directly above the other, and running parallel. The second bottom roller is adjustable. It is adjustable by means of a sliding T handle directly connected to a threaded section which is secured to a rectangular bronze bush with a square slot in the bush. The

threaded section is secured by TIG welding a tubular retaining ring to the end of the threaded section which will secure it to the brass sliding bush which is in turn connected directly to the

shaft. This is secured in place by means of a mild steel flat stock top block with two counter bored holes to accommodate hex head cap screws which will secure it to the main body of the machine. This roller is called the “pinch” roller and is fully adjustable so as to adjust the

radius of the material being rolled. It is horizontally parallel with the front feed roller if it is negatively adjusted to the fully out position. When the pinch roller is positively adjusted it

will be raised at 30 degrees off the vertical thereby altering the bend radius of the material being rolled. The top roller is vertically adjustable by raising and lowering a threaded section through a drilled and tapped top block made of a piece of mild steel flat stock. The threaded

section is connected to the shaft by inserting the end of the threaded section into the brass bush. The threaded section is secured to the brass bush by inserting a tubular retaining ring

into a square slot in the bush. The retaining ring is then TIG welded to the bottom of the threaded section which securely fixes the threaded adjuster to the bush enabling the shaft to be raised and lowered. The top roller is easily removed by unscrewing two hex head cap

screws in each top block, this allows for the removal of the top roller and the removal of the finished rolled section. The top roller and front feed roller are gear driven with the pinch

roller being an idle roller which moves freely. The cranking handle is connected directly to the end of the front feed roller and a spur gear is secured to the end of the shaft. The cranking handle is rotated in a forward clockwise direction which pulls the material into the roller

which in turn rotates the second parallel gear anti-clockwise, this then rotates the third gear situated directly above the second gear in a clockwise direction, this then finally rotates the

last gear of the top roller in an anti-clockwise direction which maintains the same rotational direction of the bottom feed roller and the top roller. (10)

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2.6 Weighting of proposed designs

Certain criteria will be used so as to choose the most suitable design for this project, they will

be scored on a scale of one to ten. One being poor and Ten being very good. The selection criteria will be chosen based on importance to selection design and not what is personally

desirable. They will be listed in the table below.

TABLE OF WEIGHTINGS

Design Cost Mass Safety Time

to

man.

Ability

to

man.

Number

of man.

processes

Avail.

of

mat.

Suitability

for use

Final

score

1 5 5 5 6 8 6 8 6 49

2 5 6 5 5 8 5 7 4 45

3 3 4 3 4 6 4 5 8 37

2.7 Selection of chosen design according to weightings criteria

After careful selection of the chosen design by adhering to the weightings criteria it has been decided that design concept 1 was the design that was chosen for further development and

manufacture. Although this is only a concept design and will of course be subject to subtle changes by the time final specifications have been calculated and finalised and final detailed

CAD drawings have been drawn up.

2.8 Testing of selected design

No testing is possible at this early stage.

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2.9 Concept design one

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2.10 Concept design two

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2.11 Concept design three

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3 Concept development

3.1 Selection of preferred design and calculation of critical dimensions

Having selected the preferred design for the sheet metal slip rolls the task at hand is now to fine tune the design and engineer the design around available materials and available standard components. The preliminary design has been completed, however the exact dimensions of

available components such as spur gears and bearings are as of yet unknown. So this, as can be imagined, prohibits any exact calculations at this stage of dimensions for measurements of

feed roller centres and the distance between the axes of the spur gears in mesh. However the dimensions for length of rollers, width & height of end plates as well as plate thickness, and length & width of box section frame have all been finalised. Other component dimensions

such as the turning handles for the threaded sections which raise and lower the top roller, the brass sliding guides, the threaded section which connects the turning handles to the brass

guides, and all the threaded fasteners that are to be used, have all been finalised.

3.2 Factors that are crucial in the design of

There are a multitude of factors to be taken into consideration when finalising the exact design for this machine type. These factors would vary depending on scale of design,

however there are certain factors that remain constant regardless of scale. These factors would include –

Maximum width of sheet to be rolled – (500.00 mm in this case)

Maximum thickness of material to be rolled – (4.00 mm in this case)

Material type to be rolled – (2.00 mm mild steel in this case)

Yield strength of material to be rolled – (Approximately 210 MPa in this case)

The bending force that can be applied to the material by the downward force exerted

by the top roller over a distance no greater than 600.00 mm.

The allowable radial and axial load of the shaft bearings

The gears to be used and the gearing calculations

The theoretical velocity ratio (VR) of the adjustable screws used to raise and lower the top roller.

Velocity ratio - 𝑽𝑹 = 𝟐𝝅 𝒙 𝑳𝒆𝒏𝒈𝒕𝒉 𝒐𝒇 𝒆𝒇𝒇𝒐𝒓𝒕 𝒂𝒓𝒎

𝑷𝒊𝒕𝒄𝒉 𝒐𝒇 𝒔𝒄𝒓𝒆𝒘

Efficiency (η) - η = 𝑴𝒆𝒄𝒉𝒂𝒏𝒊𝒄𝒂𝒍 𝒂𝒅𝒗𝒂𝒏𝒕𝒂𝒈𝒆

𝑽𝒆𝒍𝒐𝒄𝒊𝒕𝒚 𝒓𝒂𝒕𝒊𝒐 𝒙 𝟏𝟎𝟎 % where MA =

𝑳𝒐𝒂𝒅 (𝑵)

𝑬𝒇𝒇𝒐𝒓𝒕 (𝑵) and

VR = 𝑫𝒊𝒔𝒕𝒂𝒏𝒄𝒆 𝒎𝒐𝒗𝒆𝒅 𝒃𝒚 𝒆𝒇𝒇𝒐𝒓𝒕 (𝒎)

𝑫𝒊𝒔𝒕𝒂𝒏𝒄𝒆 𝒎𝒐𝒗𝒆𝒅 𝒃𝒚 𝒍𝒐𝒂𝒅 (𝒎)

Simple bending theory - 𝜎

𝑌=

𝑀

𝐼

Second moment of area of a rectangular plate - 𝐼 =𝑏𝑑3

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3.3 Theoretical mathematical calculations

To demonstrate the fluctuation in magnitude of the forces required to bend materials of

different thicknesses over varying lengths, a few simple calculations will be carried out on materials of varying dimensions to illustrate this clearly.

F

0.6 m Direction of rolling

0.08 m = Bottom feed roller centres F/2 F/2

Bottom feed roller centres = 80 mm (0.08 m)

Maximum width of sheet to be bent (b) = 600 mm (0.6 m) Maximum thickness (d) to be bent over the maximum length = 2 mm (0.002 m) Yield strength of mild steel = 210 MPa (or N/m2)

TEST 1

Y = 0.5 x d - so - Y = 1 mm (0.001 m)

𝐼 =𝑏𝑑3

12 Therefore 𝐼 =

(0.6)(0.002)3

12= 400 x 10-12m4

𝜎

𝑌=

𝑀

𝐼 Therefore

210𝑥106𝑁/𝑚2

1𝑥10−3𝑚=

𝑀

400𝑥10−12𝑚4

(400𝑥10−12𝑚4) x

210𝑥106𝑁/𝑚2

1𝑥10−3𝑚= 𝑀 so M = 84 Nm

Maximum bending moment =

𝐹

2𝑥 0.04 𝑚 = 0.02 F

100𝑁𝑚

0.02 = F Therefore F = 4200 N

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TEST 2

b = 300 mm (0.3 m) d = 2 mm (0.002m)

Y = 0.5 x d- so - Y = 1 mm (0.001 m)

𝐼 =𝑏𝑑3

12 Therefore 𝐼 =

(0.3)(0.002)3

12= 200 x 10-12m4

𝜎

𝑌=

𝑀

𝐼 Therefore

210𝑥106𝑁/𝑚2

1𝑥10−3𝑚=

𝑀

200𝑥10−12𝑚4

(200𝑥10−12𝑚4) x

210𝑥106𝑁/𝑚2

1𝑥10−3𝑚= 𝑀 so M = 42 Nm

Maximum bending moment = 𝐹

2𝑥 0.04 𝑚 = 0.02 F

42𝑁𝑚


TEST 3

b = 300 mm (0.3 m) d = 4 mm (0.004 m)

Y = 0.5 x d - so - Y = 2 mm (0.002 m)

𝐼 =𝑏𝑑3

12 Therefore 𝐼 =

(0.3)(0.004)3

12= 1600 x 10-12m4

𝜎

𝑌=

𝑀

𝐼 Therefore

210𝑥106𝑁/𝑚2

2𝑥10−3𝑚=

𝑀

1600𝑥10−12𝑚4

(1600𝑥10−12𝑚4) x

210𝑥106𝑁/𝑚2

2𝑥10−3𝑚= 𝑀 so M = 168 Nm


𝐹

2𝑥 0.04 𝑚 = 0.02 F

𝑁𝑚


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TEST 4

b = 100 mm (0.1 m) d = 6 mm (0.006 m)

Y = 0.5 x d - so - Y = 3 mm (0.003 m)

𝐼 =𝑏𝑑3

12 Therefore 𝐼 =

(0.1)(0.006)3

12= 1800 x 10-12m4

𝜎

𝑌=

𝑀

𝐼 Therefore

210𝑥106𝑁/𝑚2

3𝑥10−3𝑚=

𝑀

1800𝑥10−12𝑚4

(1800𝑥10−12𝑚4) x

210𝑥106𝑁/𝑚2

3𝑥10−3𝑚= 𝑀 so M = 126 Nm


𝐹

2𝑥 0.04 𝑚 = 0.02 F

150𝑁𝑚


3.4 Conclusions of simple bending theory calculations

It is clear that the bending of materials of the same yield strength and the same thickness as

those in test 1 would give you the results that you would expect. For instance if the yield strength σ was the same and the sheet thickness d was the same but the width of the sheet b

was halved then you would require half of the original force F to bend the sheet, this is intuitive. However if the thickness d is doubled from 2mm to 4 mm for instance, the results will be radically different. If the thickness value is doubled it will multiply the original I

value by 8. In other words the original I value is multiplied by 23 .If the thickness is quadrupled from 2 mm to 8 mm, then this will multiply the original I value by 64, or 43 .This

shows that the original force F required for test 1 if the thickness was changed from 2 mm to 8 mm would exponentially increase from 4200 N to 67,200 N !

3.5 Calculating the velocity ratio for a screw jack

The velocity ratio of a screw jack is defined as follows:-

“Movement ratio (or velocity ratio) of a machine is defined as the ratio of the distance moved by the effort to the distance moved by the load.” (11). What this means simply is that the

radial length of the effort arm (turning handle) multiplied by 2π is then divided by the thread pitch of the screw or threaded rod. This gives us the velocity ratio VR. The velocity ratio for

any screw jack machine is ONLY a theoretical value and does not take into account the mechanical losses due to friction from gears or bearings or the friction of the threaded rod

moving through the threaded bores. The mechanical advantage cannot be calculated until the actual machine is tested, therefore no efficiency values can be calculated as of yet.

22

Velocity ratio calculations

From test 1

Load F = 5000N

Thread pitch = 2 mm (2 x 10-3 m)

Velocity ratio = (𝟐)𝒙(𝝅)𝒙(𝑬𝒇𝒇𝒐𝒓𝒕 𝒂𝒓𝒎)

𝑷𝒊𝒕𝒄𝒉

Velocity ratio = (𝟐) 𝒙 (𝝅) 𝒙 (𝟐𝟏𝟕.𝟓 𝒙 𝟏𝟎−𝟑 𝒎)

(𝟐 𝒙 𝟏𝟎 −𝟑 𝒎)

Velocity ratio = 683.3

Effort = 𝑳𝒐𝒂𝒅

𝑽𝑹

Effort = 𝟓𝟎𝟎𝟎 𝑵

𝟔𝟖𝟑.𝟑

Effort = 7.317 N

23

3.6 CREO 3D CAD Assembly drawings

3.6.1 Box section sub assembly

24

3.6.2 Idle end plate sub assembly

25

3.6.3 Gear end plate sub assembly

26

3.6.4 Hand crank sub assembly

27

3.6.5 Final complete assembly

28

3.6.6 Final machine assembly part drawing

29

Bill of materials and manufacturing plan

3.7 Bill of materials

MATERIAL TYPE OF SECTION LENGTH (MM) WIDTH (MM) DEPTH (MM) WALL THICKNESS (MM) DIAMETER (MM) BORE (MM) THREAD PITCH (MM) PITCH CIRCLE DIAMETER AMOUNT

MILD STEEL RHS 2200 50 50 3 - - - - -

MILD STEEL ROUND SOLID 2100 - - - 50 - - - -




MILD STEEL ROUND TUBE 50 - 10 2 20 16 - - -

MILD STEEL FLAT SQUARE SOLID 500 180 25 - - - - - -




BRASS FLAT SQUARE SOLID 200 40 25 - - - - - -

KEY STEEL FLAT SQUARE SOLID 250 10 10 - - - - - -

HIGH TENSILE STEEL THREADED ROD 300 - - - 16 - 2 - -

HIGH TENSILE STEEL HEX HEAD BOLTS 40 - - - 16 - 2 - 4

HIGH TENSILE STEEL CSK HEX HEAD BOLTS 50 - - - 12 - 1.75 - 4

HIGH TENSILE STEEL HEX HEAD CAP SCREWS 50 - - - 12 - 1.75 - 4

CARBON MANGANESE SPUR GEAR - 40 - - 55 20 - 50 3

STAINLESS STEEL SEALED ROLLER BEARING - 14 - - 47 20 - - 5

BILL OF MATERIALS FOR THE MANUFACTURE OF A PYRAMID SRTYLE SLIP ROLLS

FASTENERS

GEARS AND BEARINGS

30

3.8 Manufacturing plan

COMPONENT MANUFACTURING PROCESSES TIME TAKEN (Hours) WEEK STATUS

RHS BASE FRAME CUTTING, DRILLING, WELDING 2 14 Completed

THREADED INSERTS FOR RHS FRAME CUTTING, DRILLING, TAPPING, WELDING 2 14 Completed

IDLE END PLATE CUTTING, DRILLING, TAPPING, MILLING 12 15 Completed

GEAR END PLATE CUTTING, DRILLING, TAPPING, MILLING 12 16 Completed

TOP ROLLER CUTTING, TURNING, 4 16 Completed

BOTTOM FRONT FEED ROLLER CUTTING, TURNING, MILLING 6 17 Completed

BOTTOM BACK FEED ROLLER CUTTING, TURNING, MILLING 6 17 Completed

GEAR KEYS FOR BOTTOM FEED ROLLERS CUTTING, MILLING, FILING 4 17 Completed

INTERMEDIATE GEAR SHAFT CUTTING, TURNING, MILLING 2 18 Completed

INTERMEDIATE GEAR SHAFT KEY CUTTING, MILLING, FILING 1 18 Completed

BRASS TOP ROLLER GUIDES CUTTING, DRILLING, FILING, MILLING 6 18 Completed

BOTTOM LOCKING BLOCKS CUTTING, DRILLING, COUNTERSINKING 4 18 Completed

TOP LOCKING BLOCKS CUTTING, DRILLING, COUNTERBORING 4 18 Completed

THREADED ROUND SCREWJACK GUIDE CUTTING, DRILLING, TAPPING, WELDING 2 19 Completed

SCREWJACK TURNING HANDLES CUTTING, WELDING 2 19 Completed

SCREWJACK TURNING HANDLE BODIES CUTTING, DRILLING, TAPPING, WELDING 2 19 Completed

RETAINING RING FOR BRASS GUIDES CUTTING, DRILLING, WELDING 2 19 Completed

THREADED ROD CUTTING 1 19 Completed

CRANKING HANDLE CUTTING, DRILLING, WELDING 2 19 Completed

CRANKING HANDLE BOSS CUTTING, DRILLING, FILING,WELDING 2 19 Completed

PRESSING BEARINGS HYDRAULIC PRESSING 1 19 Completed

ASSEMBLY ASSEMBLING OF COMPONENTS AND TORQUEING OF BOLTS 4 20 Completed

TESTING OF FINISHED MACHINE TESTING THE THEORETICAL ABILITIES OF THE MACHINE 6 21 Completed

TESTING OF FINISHED MACHINE TESTING THE THEORETICAL ABILITIES OF THE MACHINE 6 22 Completed

MANUFACTURING PLAN FOR PYRAMID TYPE THREE ROLL SLIP ROLLS

31

4 Testing and evaluation of manufactured artefact

4.1 Testing the functionality of the manufactured artefact

A range of materials were formed in the rollers to test the functional limits of the design and the ease with which these finished profiles were achieved. The materials tested were mild steel, 6061 Aluminium, and Copper. Various lengths and thicknesses were tested. As one

would imagine thinner sections were rolled with ease and thicker sections were more difficult. Testing calculations for simple bending theory and a table of results are listed

below.

4.2 Testing calculations

*** For all tests the point of maximum bending is 0.04m (0.5 x feed roller centres) ***

4.2.1 Test 1

Mild steel

b = 0.5m / d = 0.001m / y = 0.0005m / Yield (σ) = 210mPa (12)

I = 𝒃𝒙𝒅𝟑

𝟏𝟐 𝒔𝒐 𝑰 =

(𝟎.𝟓𝒎)𝒙(𝟎.𝟎𝟎𝟏)𝟑

𝟏𝟐 𝒔𝒐 𝑰 = 𝟒𝟏. 𝟔𝟔𝟕 𝒙 𝟏𝟎−𝟏𝟐𝒎𝟒

𝝈

𝒀=

𝑴

𝑰 so M =

𝝈

𝒀 𝒙 𝑰 𝒔𝒐 𝑴 =

𝟐𝟏𝟎 𝒙 𝟏𝟎𝟔 𝑵𝒎

𝟎.𝟎𝟎𝟎𝟓 𝒎𝒙 𝟒𝟏. 𝟔𝟔𝟕 𝒙 𝟏𝟎−𝟏𝟐𝒎𝟒

Therefore M = 17.5 Nm

M = 𝑭

𝟐 𝒙 𝟎. 𝟎𝟒𝒎 so M = 0.02F so F =

𝑴

𝟎.𝟎𝟐 so F =

𝟏𝟕.𝟓 𝑵𝒎

𝟎.𝟎𝟐 𝒎

Therefore F = 875 N

4.2.2 Test 2

Mild steel

b = 0.5m / d = 0.002m / y = 0.001m / Yield (σ) = 210mPa


𝟏𝟐 𝒔𝒐 𝑰 =

(𝟎.𝟓𝒎)𝒙(𝟎.𝟎𝟎𝟐)𝟑

𝟏𝟐 𝒔𝒐 𝑰 = 𝟑𝟑𝟑. 𝟑𝟑𝟑𝟑 𝒙 𝟏𝟎−𝟏𝟐𝒎𝟒

𝝈

𝒀=

𝑴

𝑰 so M =

𝝈


𝟐𝟏𝟎 𝒙 𝟏𝟎𝟔 𝑵𝒎

𝟎.𝟎𝟎𝟏 𝒎𝒙 𝟑𝟑𝟑. 𝟑𝟑𝟑𝟑 𝒙 𝟏𝟎−𝟏𝟐𝒎𝟒

Therefore M = 70 Nm

M = 𝑭

𝟐 𝒙 𝟎. 𝟎𝟒𝒎 so M = 0.02F so F =

𝑴

𝟎.𝟎𝟐 so F =

𝟕𝟎 𝑵𝒎

𝟎.𝟎𝟐 𝒎

Therefore F = 3500 N

32

4.2.3 Test 3

Mild steel



𝟏𝟐 𝒔𝒐 𝑰 =

(𝟎.𝟓𝒎)𝒙(𝟎.𝟎𝟎𝟑)𝟑

𝟏𝟐 𝒔𝒐 𝑰 = 𝟏𝟏𝟐𝟓 𝒙 𝟏𝟎−𝟏𝟐𝒎𝟒

𝝈

𝒀=

𝑴

𝑰 so M =

𝝈


𝟐𝟏𝟎 𝒙 𝟏𝟎𝟔 𝑵𝒎

𝟎.𝟎𝟎𝟏𝟓 𝒎𝒙 𝟏𝟏𝟐𝟓 𝒙 𝟏𝟎−𝟏𝟐𝒎𝟒


M = 𝑭

𝟐 𝒙 𝟎. 𝟎𝟒𝒎 so M = 0.02F so F =

𝑴

𝟎.𝟎𝟐 so F =

𝟏𝟓𝟕.𝟓 𝑵𝒎

𝟎.𝟎𝟐 𝒎


4.2.4 Test 4

Mild steel



𝟏𝟐 𝒔𝒐 𝑰 =

(𝟎.𝟐𝒎)𝒙(𝟎.𝟎𝟎𝟒)𝟑

𝟏𝟐 𝒔𝒐 𝑰 = 𝟏𝟎𝟔𝟔. 𝟔𝟔𝟕 𝒙 𝟏𝟎−𝟏𝟐𝒎𝟒

𝝈

𝒀=

𝑴

𝑰 so M =

𝝈


𝟐𝟏𝟎 𝒙 𝟏𝟎𝟔 𝑵𝒎

𝟎.𝟎𝟎𝟐 𝒎𝒙 𝟏𝟎𝟔𝟔. 𝟔𝟔𝟕 𝒙 𝟏𝟎−𝟏𝟐𝒎𝟒

Therefore M = 112 Nm

M = 𝑭

𝟐 𝒙 𝟎. 𝟎𝟒𝒎 so M = 0.02F so F =

𝑴

𝟎.𝟎𝟐 so F =

𝟏𝟏𝟐 𝑵𝒎

𝟎.𝟎𝟐 𝒎


4.2.5 Test 5

Aluminium



𝟏𝟐 𝒔𝒐 𝑰 =

(𝟎.𝟏𝟓𝒎)𝒙(𝟎.𝟎𝟎𝟐)𝟑

𝟏𝟐 𝒔𝒐 𝑰 = 𝟏𝟎𝟎 𝒙 𝟏𝟎−𝟏𝟐𝒎𝟒

𝝈

𝒀=

𝑴

𝑰 so M =

𝝈


𝟏𝟐𝟓 𝒙 𝟏𝟎𝟔 𝑵𝒎

𝟎.𝟎𝟎𝟏 𝒎𝒙 𝟏𝟎𝟎 𝒙 𝟏𝟎−𝟏𝟐𝒎𝟒


M = 𝑭

𝟐 𝒙 𝟎. 𝟎𝟒𝒎 so M = 0.02F so F =

𝑴

𝟎.𝟎𝟐 so F =

𝟏𝟐.𝟓 𝑵𝒎

𝟎.𝟎𝟐 𝒎

Therefore F = 625 N

33

4.2.6 Test 6

Aluminium



𝟏𝟐 𝒔𝒐 𝑰 =

(𝟎.𝟏𝒎)𝒙(𝟎.𝟎𝟎𝟐)𝟑

𝟏𝟐 𝒔𝒐 𝑰 = 𝟔𝟔. 𝟔𝟔𝟕 𝒙 𝟏𝟎−𝟏𝟐𝒎𝟒

𝝈

𝒀=

𝑴

𝑰 so M =

𝝈


𝟏𝟐𝟓 𝒙 𝟏𝟎𝟔 𝑵𝒎

𝟎.𝟎𝟎𝟏 𝒎𝒙 𝟔𝟔. 𝟔𝟔𝟕 𝒙 𝟏𝟎−𝟏𝟐𝒎𝟒


M = 𝑭

𝟐 𝒙 𝟎. 𝟎𝟒𝒎 so M = 0.02F so F =

𝑴

𝟎.𝟎𝟐 so F =

𝟖.𝟑𝟑𝟑 𝑵𝒎

𝟎.𝟎𝟐 𝒎

Therefore F = 416.65 N

4.2.7 Test 7

Copper



𝟏𝟐 𝒔𝒐 𝑰 =

(𝟎.𝟏𝒎)𝒙(𝟎.𝟎𝟎𝟔)𝟑

𝟏𝟐 𝒔𝒐 𝑰 = 𝟏𝟖𝟎𝟎 𝒙 𝟏𝟎−𝟏𝟐𝒎𝟒

𝝈

𝒀=

𝑴

𝑰 so M =

𝝈


𝟐𝟔𝟖 𝒙 𝟏𝟎𝟔 𝑵𝒎

𝟎.𝟎𝟎𝟑 𝒎𝒙 𝟏𝟖𝟎𝟎 𝒙 𝟏𝟎−𝟏𝟐𝒎𝟒


M = 𝑭

𝟐 𝒙 𝟎. 𝟎𝟒𝒎 so M = 0.02F so F =

𝑴

𝟎.𝟎𝟐 so F =

𝟏𝟔𝟎.𝟖 𝑵𝒎

𝟎.𝟎𝟐 𝒎


*** This test brought the machine to its functional limits ***

34

4.2.8 Table of results for practical testing of slip rolls

TESTS MATERIAL b (m) d (m) Y (m) FEED ROLLER CENTRES (m) POINT OF MAXIMUM BENDING (m) S.M.O.A I (m^4) YIELD STRENGTH σ (Pa) MAXIMUM BENDING MOMENT (Nm) FORCE (N) STATUS

TEST 1 STEEL 0.5 0.001 0.0005 0.08 0.04 4.16667E-11 2.10E+08 17.5 875 PASS

TEST 2 STEEL 0.5 0.002 0.001 0.08 0.04 3.33333E-10 2.10E+08 70 3500 PASS

TEST 3 STEEL 0.5 0.003 0.0015 0.08 0.04 1.125E-09 2.10E+08 157.5 7875 PASS

TEST 4 STEEL 0.2 0.004 0.002 0.08 0.04 1.06667E-09 2.10E+08 112 5600 PASS

TEST 5 ALUMINIUM 0.15 0.002 0.001 0.08 0.04 1E-10 1.25E+08 12.5 625 PASS

TEST 6 ALUMINIUM 0.1 0.002 0.001 0.08 0.04 6.66667E-11 1.25E+08 8.33E+00 416.667 PASS

TEST 7 COPPER 0.1 0.006 0.003 0.08 0.04 1.8E-09 2.68E+08 160.8 8040 PASS (AT LIMITS)

TABLE OF RESULTS FOR THE TESTING OF THE FUNCTIONAL LIMITS OF PYRAMID TYPE SLIP ROLLS

35

4.2.9 Photo image of the final fabrication

36

4.2.10 Discussion of functional testing results

It was an inherent design feature for the slip rolls to be able to roll a piece of 2mm mild steel sheet 0.5 metres long into a full tubular section. As the test results clearly show that was

achieved with ease while staying well within the functional limits of the machine. The exceeding of the design specification was clearly demonstrated by the rolling of a piece of 3mm mild steel sheet 0.5 metres long into a full tubular section. A piece of 4mm mild steel

sheet 0.2 metres long was also rolled with ease. Various pieces of 6061 Aluminium were rolled with ease and as the testing results show, the machine was nowhere near its functional

limits. However when a piece of Copper was tested, the machine could barely roll the material. While the 0.5 metre long piece of 3mm sheet was rolled into a full tubular section, it was carried out with considerable effort. The force required to roll this length and thickness

of mild steel was 7875 N. Taking a referenced yield strength value for this particular Copper alloy to be 268 mPa, this would require a force of 8040 N to successfully roll into a full

tubular section. Based on these facts a reasonable estimate of the safe functional limits of this particular machine and the force it can exert would be approximately 8000 N.

37

5 Progress of project

In this section it will be outlined the general progress of the project from the initial concept

design to final completion of the manufactured artefact. Any problems encountered with the project such as sourcing of materials to manufacturing complexities of specific components

will be discussed.

5.1 Progress and working to set deadlines

The project was completed within the set time frame and there were no significant problems encountered at any stage of the project. There were a few minor issues with manufacturing of

specific components due to the fact that some components had to be hand made because in some instances there was no machinery at my disposal capable of manufacturing said components. However these minor inconveniences were quickly overcome due to a prior

extensive background in precision engineering fabrication.

5.1.1 Design using CREO Parametric

Having not used the CREO design software in the twelve months previous to the initial stages of the design phase of the project it was a challenge to learn how to use the software properly

and to learn by doing, making mistakes and overcoming the initial lack of knowledge and understanding to becoming quite familiar and adept with the software. All CREO drawings

were completed before Christmas 2014 which meant that the final design stage remained on schedule.

5.1.2 Sourcing of materials

There were no problems in sourcing the materials required for the fabrication of the machine apart from sourcing the spur gears. To source the spur gears meeting the required

specification it was necessary to purchase the components from a specialist supplier in England due to the fact that there were no gear suppliers in Ireland that could supply the

gears in the specified dimensions required.

5.1.3 Manufacturing of components and final assembly

There were no problems in manufacturing the machines base frame, the support structure upon which the slip rolls is fixed. This was the phase of manufacturing that came with the least amount of difficulty. The machines three rollers were then machined to the required

dimensions on the lathe with relative ease. However when components were to be milled on the milling machine it was a challenge due to a lack of recent experience on the milling

machine so it was necessary to become familiar with the process of changing the cutting tools and the various types of cutters required. The manufacture of the boss for the hand crank presented a bit of a problem because there was an internal keyway to be cut into the inside of

the boss and this could not be manufactured on any machinery in the manufacturing lab. So this feature had to be drilled and filed square manually to the required dimension, this was

tiresome but successful. The end plates which house the bearings and carry the rollers were machined to a close tolerance on the CNC milling machine with only one minor issue when there was a glitch in the G code and the CNC machine milled a part of the component that

was not specified on the drawing. The problem was rectified by TIG welding a layer of new material into the miss machined area and then milled flush. This did not affect the completion

of manufacturing deadline. Final assembly presented no problems whatsoever.

38

5.1.4 Final testing of the functional capabilities and limits of the machine

The testing phase of the project was a success and was a validation of the chosen design for

the slip rolls. The desired features and functional ability of the design were exceeded as can clearly be seen in the table of test results in the previous chapter. Various materials form mild

Steel to Aluminium and Copper were chosen for the testing phase of the project for the simple reason that these materials were cheap and readily available. All materials chosen for the test passed the test, however the copper test piece was too difficult to roll into a cylinder

even though it was rolled into an arc. However in defence of the selected design, the machine was never designed to roll 6mm material whether it was copper or steel or anything else.

39

6 Conclusions

The progress and end result of the project was a success. However upon reflection there are

inherent short comings in the “three roll pyramid style” design for sheet metal rollers. This is an inherent short coming in any machine manufactured to this design, not just this project.

After successful rolling of a sheet there are two flat spots on the finished rolled sheet. These flat spots are on either side of the finished sheet and each measure half the distance of the feed roller centres. This can be overcome by adding this amount of material onto the length

of material required and then cut off so as to give a true cylindrical profile. Another way of overcoming this is to roll the sheet into a tubular section until the two peaks meet and the

tacking the sheet in place the rolls. By grinding the tacks flat and then continually rolling the sheet and the profile will become cylindrical as required. Upon reflection it is concluded that the “Initial pinch” style design is a superior design and it is the only design to be considered

for industrial applications where anything over 3mm in thickness is to be rolled. “Four roll initial pinch type” plate rollers such as the “Haeuslur VRM hy 4200 3730”are used in heavy

industry to easily roll material 3 metres wide and 0.1m (100mm) thick and 30 metres long!. This could never be achieved with a pyramid type design. So in saying all of this, if this project was to be embarked upon again with unlimited time and resources then the fabrication

of an industrial scale four roll initial pinch type machine driven by a motor so as to roll much heavier materials with ease would be a better design.

40

7 Appendix (Piece Part Drawings)

7.1 Box section long

41

7.2 Box section short

42

7.3 Tapped threaded flat bar

43

7.4 Bottom locking block

44

7.5 Top locking block

45

7.6 Idle end plate

46

7.7 Gear end plate

47

7.8 Brass roller guide

48

7.9 Brass guide retaining ring

49

7.10 Top block threaded round

50

7.11 Body of threaded rod

51

7.12 T bar turning handle

52

7.13 Top roller

53

7.14 Front feed roller

54

7.15 Back feed roller

55

7.16 Intermediate gear shaft

56

7.17 Intermediate gear shaft disc

57

7.18 Front feed roller key

58

7.19 Back feed roller key

59

7.20 Intermediate shaft key

60

7.21 Sealed roller bearing

61

7.22 Spur gear

62

7.23 Hand crank boss

63

7.24 Hand crank handle

64

7.25 M16 x 2mm Threaded bar section

65

7.26 M12 x 1.75mm CSK Hex head bolt

66

7.27 M12 x 1.75mm Cap head bolt

67

7.28 M16 x 2mm Hex head bolt

68

7.29 M8 x 1.25 Hex head bolt

69

8 Works Cited

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October 2014. [Cited: Thursday October 2014.]

2. http://www.perrybiomassengineering.co.uk. http://www.perrybiomassengineering.co.uk/folding. [Online] Perry biomass engineering,

Thursday October 2014. [Cited: Thursday October 2014.]

3. clip-204211-stock-footage-forging-machine. http://www.shutterstock.com/video/clip-

204211-stock-footage-forging-machine.html. [Online] Thursday Ocotber 2014. [Cited: Thursday October 2014.]

4. www.atimetals.com. https://www.atimetals.com/markets/aerospace/net-shapes-

components/net-shape-parts/Pages/Extrusions.aspx. [Online] Aerospace component manufacturer, Thursday October 2014. [Cited: Thursday October 2014.]

5. http://www.mastersteels.com/content/index/id/27.html. http://www.mastersteels.com. [Online] Specialist steel stockists, Thursday October 2014. [Cited: Thursday October 2014.]

6. http://www.tubelinks.com/blog/bri-steel-establishes-new-benchmark-in-large-seamless-

pipe-manufacturing-in-north-america.html. http://www.tubelinks.com/. [Online] Online industry journal, 2 July 2013. [Cited: Thursday October 2014.]

7. http://www.motorauthority.com/news/1058070_magnesium-car-bodies-the-new-steel-carbon-aluminum. http://www.motorauthority.com/. [Online] Online industry journal, 8 April 2011. [Cited: Thursday October 2014.]

8. http://www.metalworkingworldmagazine.com/a-short-sheet-metal-history/. www.metalworkingworldmagazine.com. [Online] Online industry journal, 9 June 2014.

[Cited: 9 October 2014.]

9. Metals handbook (ninth edition). [book auth.] ASM International.

10. http://www.practicalmachinist.com/vb/general/diy-plans-minature-sheet-metal-roller-

261599/. http://www.practicalmachinist.com/. [Online] Online Craftsperson publication, 3rd April 2013. [Cited: 10th October 2014.]

11. Toolbox, Engineering. http://www.engineeringtoolbox.com/movement-ratio-d_1295.html. http://www.engineeringtoolbox.com. [Online] [Cited: 20th November 2014.]

12. http://www.meadinfo.org/2010/03/s45c-jis-mechanical-properties.html.

http://www.meadinfo.org. [Online] 2008-20012. [Cited: 31st March 2015.]

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final third year project report (joseph stynes x00105837)

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