International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 12 December 2017

Design and Dynamic Analysis of Hydraulic Press Machine for Sheet and Pipe bending Operations

Chinthakindi Vinod, Assistant Professor, VJIT, Hyderabad. P. Chandra Kumar, Assistant Professor, VJIT, Hyderabad. CH. Sharath Reddy, Assistant Professor, JBREC, Hyderabad.

 Abstract: In present world industries are running into hydraulic, medical, and many other applications. automation in order to reduce human effort. In recent Tubes are measured by their outer diameter. Pipes years pipe bending and sheet bending machines are used are vessels that are used in transport systems for in industries as well as domestic purpose for bending the fluids. They are measured by their inside diameter. pipes and sheets of required angles. Types of Pipe Bending process In our project the Hydraulic Press Machine is implemented for pipe bending and sheet bending 1. Rotary draw bending operations. Hydraulic bending machine consists of 2. Compression bending Double acting cylinder, P-40 Direction control valve, 3. Ram bending Hoses, Motor, Pump, Rack and Pinion, Free wheel, 4. Roll bending bending tools and fixture. The pipe or sheet is bent by the hydraulic cylinder piston with holding the pipe or sheet in the fixture. The main advantage of our project is dual operations can be done on the machine. Designing of the machine is done in computer aided software CATIA. Structural loads are applied, so analysis of work piece and tools are done to find stress, strain, deformation, von misses stresses with the help of ANSYS software. Keywords: Hydraulic Press machine, tools, pipe and sheet bending, Hydraulic operation

I. INTRODUCTION Pipes and Sheets are used in artistic ways in various fabrication works as well as in architectural works. To bend these pipes and sheets into required angles is not easy thing to be done manually. Using a Fig. Types of pipe bending methods particular machine specially developed for bending of pipes and sheets will be helpful. To design and manufacture such machines many equipment’s are 1.2 Sheet bending machine used. Bending of is a common and vital 1.1 Pipe bending machine process in manufacturing industry. Sheet metal bending is the plastic deformation of the work over Tube and pipe bending machines are used to bend an axis, creating a change in the part's geometry. tubes and pipes in order to produce finished parts. After bending of sheet the thickness of sheet may Tubes are structural, hollow conduits which are changes a little. But in majority cases bending will used as flow lines for fluids in pneumatic, produce essentially no change in the thickness of the sheet metal. Bending is also used to impart strength and stiffness to sheet metal. Metal bending 1106 Chinthakindi Vinod, P. Chandra Kumar, CH. Sharath Reddy International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 12 December 2017 enacts both tension and compression within the wall. A fluid, such as oil, is displaced when either material. piston is pushed inward. Since the fluid is Types of sheet metal bending process incompressible, the volume that the small piston displaces is equal to the volumedisplaced by the 1. Sheet metal bending with a v large piston. This causes a difference in the length 2. Edge bending with wiping die of displacement, which is proportional to the ratio of areas of the heads of the pistons, given that volume = area × length.Therefore, the small piston must be moved a large distance to get the large piston to move significantly. 2.2 Application Hydraulic presses are commonly used for , clinching, moulding, blanking, , deepdrawing, and metal operations. Fig. Sheet metal bending with a V die 2.3 Material Data The materials which are used are mentioned below with their properties. 2.3.1 Properties of Gray Cast Iron Table Density 7.2e-006 kg mm^-3

Coefficient of Thermal Expansion 1.1e-005 C^-1

4.47e+005 MJ kg^-1 Specific Heat C^-1

5.2e-002 W mm^-1 C^- Fig. Edge bending with wiping die Thermal Conductivity 1 Resistivity 9.6e-005 ohm mm

II. PIPE AND SHEET BENDING MACHINE Compressive Ultimate 2.1 Hydraulic Press Strength 820 MPa A hydraulic press is a device (see ) Compressive Yield using a hydraulic cylinder to generate acompressive Strength 0 MPa force. It uses the hydraulic equivalent of a mechanical lever, Principle The hydraulicpress Tensile Yield Strength 0 MPa depends on Pascal's principle: the pressure throughout a closed system is constant. One partof Tensile Ultimate the system is a piston acting as a pump, with a Strength 240 MPa modest mechanical force acting on a small Reference Temperature 22oc crosssectional area; the other part is a piston with a larger area which generates a correspondingly large Young's Modulus 1.1e+005 MPa mechanical force. Only small diameter tubing Poisson's Ratio 0.28 (which more easily resists pressure) is needed if Bulk Modulus 83333 MPa thepump is separated from the press cylinder. Pascal's law: Pressure on a confined fluid is Modulus 42969 MPa transmitted undiminished and acts with equal force Relative Permeability 10000 on equal areas and at 90 degrees to thecontainer 1107 Chinthakindi Vinod, P. Chandra Kumar, CH. Sharath Reddy International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 12 December 2017

2.3.2 Properties of 2.4. Construction details of hydraulic pipe and Table sheet bending machine Density 7.85e-006 kg mm^-3 The Hydraulic pipe and sheet bending machine consists of the following parts: Coefficient of Thermal 1. Base Plate Expansion 1.2e-005 C^-1 Base Plate is the base member of the machine. The Specific Heat 4.34e+005 MJ kg^-1 C^-1 entire assembly of the machine is done onto the Thermal Conductivity 6.05e-002 W mm^-1 C^-1 base plate. Base plate is structural steel (EN9). The Resistivity 1.7e-004 ohm mm pillars are mounted on to the base plate using Socket head bolts M8. Compressive Ultimate 2. Pillar Strength 0 MPa Pillar is an structural steel (EN9 vertical Compressive Yield member of the structure of the press whichis Strength 250 MPa held on to the base plate using Socket head bolts Tensile Yield Strength 250 MPa M8. The pillar is provided with holes equi-spaced Tensile Ultimate Strength 460 MPa (3 No’s ) to receive the Dowell pins which act as pivot for the die roller Reference Temperature 22oc 3. Top Fix Plate Young's Modulus 2.e+005 MPa Top plate is structural steel (EN9 horizontal Poisson's Ratio 0.3 member of the structure of the press which is held Bulk Modulus 1.6667e+005 MPa on to the top of the LH & RH_ Pillars and held in Shear Modulus 76923 MPa place by using horizontal support, M20 Hex nut, and Lock nut. Relative Permeability 10000 4. Hydraulic cylinder Hydraulic cylinder is fixed vertically at horizontal 2.3.3 Properties of support rods at top place and provide thehydraulic Table cylinder piston and attached sheet and pipe press Density 7.75e-006 kg mm^-3 parts are attached to the ram of the jack which provide the automatic return after bending operation Coefficient of Thermal Expansion 1.7e-005 C^-1 is over. Specific Heat 4.8e+005 MJ kg^-1 C^-1 5. Machine properties Hydraulic press machine is 3000 kg capacity with Thermal Conductivity 1.51e-002 W mm^-1 C^-1 the following parts: Resistivity 7.7e-004 ohm mm a. Release valve Compressive Ultimate b. Base Strength 0 MPa c. Adjusting screws Compressive Yield Strength 207 MPa d. Ram Tensile Yield Strength 207 MPa e. Cylinder Tensile Ultimate Strength 586 MPa f. Oil Tight tank Reference Temperature 22oc g. Sheet and pipes bend parts Young's Modulus 1.93e+005MPa h. Pump Body Poisson's Ratio 0.31 i. Pump Plunger Bulk Modulus 1.693e+005 MPa j. Safe valve Shear Modulus 73664 MPa k. Handle. Relative Permeability 10000

1108 Chinthakindi Vinod, P. Chandra Kumar, CH. Sharath Reddy International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 12 December 2017

2.5. Advantages of hydraulic pipe and sheet III. DESIGN OF PIPE CUM SHEET BENDING bending machine MACHINE 1. 5000 kg push force, makes possible bending of heavy sections possible CATIA enables the creation of 3D parts, 3D 2. Ease of operation sketches, sheet metal, tooling parts up to the 3. Gradual application of force prevents the pipe definition of mechanical assemblies. The software and sheet damage. provides advanced technologies for mechanical 4. Quick release of the ram using relief valve surfacing & BIW. CATIA offers a solution to shape makes operation fast. design, styling, surfacing workflow and 5. Ease of maintenance. visualization to create, modify, and validate 6. Less cost complex innovative shapes from industrial design. 2.6. Applications CATIA supports multiple stages of product design. 1. Automobile industry 2. Process equipment press. 3.1 Schematic diagrams 3. Industrial piping and sheet errection. 4. Small industries works. 3.1.1 Sketch of Sheet bending tool 2.7. Technical specifications of project Below are the 2-D Sketch diagrams of Sheet Table Bending tool with dimensions. All dimensions are in mm. 20mm x 1.5mm Max. Tube Capacity (Ferrous tubes UTS (D x T) 45 Kg/mm2) Min. Tube Capacity (Diameter) 6mm Min sheet capacity (mm) 0.5 mm Max. Bend Radius(CLR) 80mm Max sheet press 25mm Min. Bend Radius(CLR) 20mm Min. Bend Radius (in terms of D) 1.5D Standard Length over mandrel 550 Metres Cc 5 to 180 degrees pressing Direction Clockwise Front View Side View Pressing Speed 60 degrees / second Indicative Production 200 (90 degrees Fig. Sketch of Sheet Bending Tool Rate bends / hour ) Press Angle Accuracy ± 0.25 degrees 3.2.2 Sketch of Pipe bending tool Motor 4.0 HP Below are the 2-D Sketch diagrams of Pipe Bending Oil Tank capacity 20 Litres (built in) tool with dimensions. All dimensions are in mm.

1109 Chinthakindi Vinod, P. Chandra Kumar, CH. Sharath Reddy International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 12 December 2017

3.3 Catia parts

Front View Side View

Support Fig. Sketch of Pipe Bending Tool Below are the 2-D Sketch diagrams of Pipe Bending tool assembled part. Fig. Pipe bending tool design

Fig. Pipe bending tool design

Fig. Pipe bending tool Assembled part

1110 Chinthakindi Vinod, P. Chandra Kumar, CH. Sharath Reddy International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 12 December 2017

Fig. Pipe bending machine design

Fig. Sheet bending machine design:

Fig. Drafting views of pipe bending machine

Fig. Drafting views of sheet bending machine

IV. ANALYSIS Generally Ansys in the field of Mechanical Engineering provides solutions for many typesof analyses including structural, thermal ,modal, linear buckling and shape optimization forstudies. The output of the simulation can be observed in many ways like deformation and strength values. The values of the various parameters over the different time steps are noted and they are plotted to produce graphs. By observing these graphs and contours the results of the simulation can be Fig. Sheet bending tool design analysed.

1111 Chinthakindi Vinod, P. Chandra Kumar, CH. Sharath Reddy International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 12 December 2017

Fig. Total deformation of pipe bending tool in ansys

Fig. Total deformation of sheet bending tool in ansys

Result TOTAL EQUIVALANT DEFORMATION ELASTIC Fig. Equivalent (Von-Mises)stress in ansys STRAIN Minimum 0. Mm 0. Mm/mm Maximum 65. Mm 1.4656e-008 mm/mm

V. CONCLUSION As compare to the manually operated sheet and pipe bending machine the hydraulic power operated press machine is better. The productivity of Fig. Equivalent elastic strain hydraulic power operated press machine is higher. The part of machine is able to handle the heavy load Result on machine. The time required to complete press and bending operation is less and the requirement of TOTAL EQUIVALANT extra worker’s reduced. Hydraulic Power operated DEFORMATION ELASTIC press is less time consuming process with high STRAIN productivity. MINIMUM 0. mm 1.4208e-014 mm/mm Scope for Future Work MAXIMUM 90. mm 4.9562e-012 The scope for the future work is as follows: mm/mm i. Analysis of present designed machine and bending tools can be done with various materials. ii. Extending the design for other operations. iii. Present design can be modified to make suitable for electric operated or pneumatic operated machines by using necessary equipment’s. iv. Changes in present design can be done to increase its strength and to reduce structural loads. Fig. Equivalent elastic strain in ansys v. 1112 Chinthakindi Vinod, P. Chandra Kumar, CH. Sharath Reddy International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 12 December 2017

VI. REERENCES machine,” J. strain Analysis, vol. 1, no. 5, pp. 398, 1. Himanshu V. Gajjar, Anish H. Gandhi, Tanvir A 1996. Jafri, and Harit K. Raval, World Academy of 5. Bendability Analysis for Bending of C-Mn Steel Science, Engineering and Technology International Plates on Heavy Duty 3-Roller Bending Machine, Journal of Mechanical, Aerospace, Industrial, International Journal of Aerospace and Mechanical Mechatronic and Manufacturing Engineering Vol:1, Engineering 1:2 2007, presented by Himanshu V. No:8, 2007 Gajjar, Anish H. Gandhi, Tanvir A Jafri, and Harit 2. M. Hua, D. H. Sansome, and K. Baines, K. Raval. “Mathematical modeling of the internal bending 6. Mechanics-Based Determination of the Center moment at the top roller contact in multipass four Roller Displacement in Three-Roll Bending for roll thin plate bending,” J. mater. Process.Technol., Smoothly Curved Rectangular Plates, KSME vol. 52, pp. 425-459, 1995. International Journal Volume 15. No.12, pp. 1655- 3. M K Chudasama1 and H K Raval Analytical Model 1663, 2001. Presented by Jong Gye Shin, Jang Hyun For Prediction Of Force During 3-Roller Multi-pass Lee, HyunjuneYim and Iu Kim. Conical Bending And Its Experimental Verification, 7. Wang C., Kinzel G., Altan T., Mathematical international journal of mechanical engineering and modeling of plane-strain bending of sheet and plate, robotics research, ISSN 2278-0149S, VOL.1, NO.3, Journal of Materials Processing Technology, 1993, October 2012. Vol-39, pp. 279–304. 4. M. B. Bassett, and W. Johnson, “The bending of plate using a three roll pyramid type plate bending

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