DESIGN AND FABRICATION OF

SHEET ROLLING MACHINE

A PROJECT REPORT

Submitted by

K.FEROZE ALI 950612114030

S.ABDUL RHAMAN 950612114301

V.BALA SANKAR 950612114305

A.GURUVARAN 950612114306
In partial fulfilment of the award of the degree

Of

BACHELOR OF ENGINEERING

in

MECHANICAL ENGINEERING EINSTEIN

COLLEGE OF ENGINEERING

TIRUNELVELI

ANNA UNIVERSITY: CHENNAI 600 025

APRIL-2015

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 ANNA UNIVERSITY: CHENNAI 600 025
BONAFIDE CERTIFICATE
Certified that this project report “DESIGN AND FABRICATION OF
SHEET METAL ROLLING MACHINE” is the bonafide work of
“K.FEROZE ALI (950612114030), S.ABDUL RHAMAN (950612114301),
V.BALA SANKAR (950612114305),A.GURUVARAN (950612114306)” who
carried out the project work under my supervision.

SIGNATURE SIGNATURE

HEAD OF THE DEPARTMENT SUPERVISOR

Mr. K. Arul Raj, M.E., (Ph.D.), Mr. R. Karthikeyan, M.E.,

Professor, Assistant Professor,

Dept. of Mechanical Engineering, Dept. of Mechanical Engineering

Einstein College of Engineering, Einstein College of Engineering,

Tirunelveli – 627 012 Tirunelveli – 627 012

Submitted Viva Voce Examination held at

EINSTEIN COLLEGE OF ENGINEERING, Tirunelveli,

On………………………

INTERNAL EXAMINER EXTERNAL EXAMINER

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 DEDICATED TO OUR FOUNDER

It is honour to be the ninth batch of student of Einstein College of

Engineering K. Feroze Ali, S. Abdul Rhaman, V. BalaSankar, A. Guruvaran,of
Third year of Mechanical Engineering takes this opportunity as a privilege to
dedicate our project to ThiruAladiAruna M.A., B.L.

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 ACKNOWLEDGEMENT

It is our great privilege to express hearty thanks to our Managing

Trustee Prof. A. Ezhilvanan MBA or kind encouragement throughout this
project.

My sincere thanks to our Principal Prof.Dr. K. Ramar Ph.D., F.I.E.,

for kind encouragement in carrying out this project.

We sincerely and whole heartedly thank our Head of the Department,

Mechanical Mr. K. Arul Raj M.E., (Ph.D.), for his effective support for our
project.

We gratefully thank our co-ordinator Mr.M.BALA RAMA

MOORTHY, M.E., who guided us to make a special contribution to the
project.

We gratefully thank our guide Mr.R. Karthikeyan,M.E., who gave us

the opportunity to make a useful contribution to our project and to set a worthy
present for the student’s community.

We sincerely thank all the faculty members of our department and our
lab in-charges for their immense help during the course of the project.

We also thank God and our Parents for their immense help an support
to make this project.

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 INSTITUTIOIN PROFILE

An adobe of excellence, a pinnacle of glory, a name that deserves

mention whenever there initiates a discussion about the world of Engineering;
Einstein College of Engineering. The institution was found by Late
Mr.AladiAruna, former Tamil Nadu Law Minister in 2004, with the sole
purpose of providing cutting edge technical education that is both accessible
and affordable. From the year 2004, The College embarked on programs of the
college offers 5 B.E. degree courses. The College also offers 6 M.E. courses in
Engineering and Master of Business Management. About 15 km away from
Tirunelveli towards the well-known Courtralam, the college is situated in Sir.
C.V. Raman Nagar. The Institution is spread over an area of about 30 acres. The
College maintains a royal existence with its marvelou infrastructure and widely
acclaimed for its meticulous planning, resource scheduling and institutional
management.

Our founder son of the soil Thiru. AladiAruna M.A., B.L., a prolific
reader and great orator, was one of the senior most politician of Tamil Nadu
with a great vision for providing high quality technical education to the rural
and the weaker section. He was a Member of Parliament and MLA for more
than a decade and was also the Minister of Law, Govt. of Tamil Nadu 1996-
2001.

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 ABSTRACT

This project work titled “SHEET ROLLING MACHINE” has been

conceived having studied the difficulties in making bending in sheet metal. This
project facilitates in making bending accurate in sheet metal with easy. The
project employee by using the roller for bending purpose by manual.

This machine can be used in various fields. Our project the sheet metal
rolling is very simple in operation by using roller which is coupled with handle.
In Sheet Metal working industry a wide range of power and hand operated
machines are used. This machine is simple in construction and working.

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 PROJECT OBJECTIVE

To implement the skills acquired in previous semester to practical

problems as prescribed in ME-68 DESING AND FABRICATION
PROJECT,MECHANICAL ENGINEERING ANNA UNIVERSITY
curriculum to fulfil the above, we are focused in the area of
“MANUFACTURING TECHNOLOGY” subject which we have studied in
previous semester by getting basic ideas from it. We have designed and
fabricated “SHEET METAL ROLLING MACHINE” and calculated the
experimental results theoretically

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 LIST OF FIGURE
PAGE NO
1.1 Stress in bending 12
3.1: Process of rolling 14
4.1 Stress induced in sheet metal 15
5.1 Steps in rolling 16
6.1 Sheet rolling machine 17
8.1Shape rolling mechanism 19
8.2 Stress and Strain Curve for Steel20
8.3 Plastic Theory of Bending 21
8.4 Geometrical analysis 22

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 LIST OF CONTENT
Page No

1. ACKNOWLEDGEMENT I

2. DECLARATION II

3.CERTIFICATE III

4. Introduction 1

5. Bending 2

5.1 Roll bending 2

6. Process of rolling 3

7. Stress induced in sheet metal 4

8. Steps in rolling 5

9. Description of the machine 6

10. Working principle 7

Design 8

8.1 General design principles 9

8.2 Stress and strain in steel 10

8.3 Plastic theory of bending 11

8.4 Design calculation 12

12. Synopsis 18

13. Application 19

11. Advantages 20
12. Disadvantage 21

13. Estimation of cost analysis 22

 1. INTRODUCTION

Sheet Metal industry is a large and growing industry. There are many special
purposes machines used in this industry to-day. The proper selection of the
machines depends upon the type of the work under-taken by the particular
industry. There are many examples of Sheet Metal work, which can be seen in
our everyday lives. The metals generally used for Sheet Metal work include
black iron sheet, copper sheet, tin plate, aluminium plate, stainless sheet and
brass sheet.

Our project the “SHET METAL ROLLING MACHINE” finds huge

application in Sheet Metal industry. Rolling is the process of bending sheets to a
curved form. The article in the shape of cylinders is made by rolling roller.
Rolling operation can be done on hand or power operated rolling machines. In
forming cylindrical shapes a gradual curve is to be put in the metal rather than
sharp bends. The gap between the rollers can be regulated by hand operated
screws

Sheet metal is available in flat pieces or as a coiled strip. Various forming

process in sheet metal include
 Punching
 Roll forming
 Rolling
 Spinning
 Stamping
 Bending
 Deep drawing
 Expanding
 Curling
 Press brake forming

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  Decambering
 Ironing
 Laser cutting
 Incremental sheet forming etc.

2. BENDING
Bending is one of the most common forming operations. We merely have to
look at the components in an automobile or at a paperclip to see how many parts
shaped by bending. Bending is usually defined as the deforming of the sheet
metal along the straight line around a straight axis called neutral axis, result in
the plane surface at an angle to the original plane. During bending the top layers
are subject to tension and the bottom layer are subjected to compression. The
width of the part in the outer region is smaller and in the inner region it is larger
than the original width because of the poisson ratio as shown in fig 1.1

1.1 Stress in bending

Tyes of bending operation are classified into

 U-Die bending
 V-Die bending
 Roll bending
 Bending in the four slide machine
 Curling
 Dimpling
 Flanging
 U-Die bending with spring pad
2.1 Roll bending
A continuous form from of three-point bending is roll bending, where plates,
sheet and rolled on each end, one of the support can often be swung clear to
permit the removal of closed shapes from the rollsshapes can be bent to a
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desired curvature on forming rolls. These machines usually have three roll in the
of a pyramid, with the two lower rolls being driven and the position of the upper
roll being adjustable by a frame

3.PROCESS OF ROLLING

In the first stage the plate is kept between top roller and bottom rollers as shown
in Figure2.1 and the top roller is given vertical displacement to get the required
bend. In next stage the bottom rollers are driven using motors in forward
direction to get the roll bending of the plate. Similarly the rollers are driven
inverse direction to get better dimensional accuracy of the final product. The
bent plate is than unloaded by raising the top roller. For continuous single-pass
four roll thin plate bending a model was proposed considering the equilibrium
of the internal and external bending moment at and about the plate-top roller
contact.

They had considered varying radius of curvature for the plate between the
rollers and proposed mathematical model to simulate the mechanics in a steady
continuous bending mode for four-roll thin plate bending process and also
investigated In sequence of material strain hardening on the mechanics of
steady continuous roll and edge-bending mode in the four-roll plate bending
process For continuous multi-pass bending of cylinder on 3-roller bending
machines (cylindrical) rollers, They incorporated the effect of change of young
modulus during the deformation in the formulation to study the effect on spring
back prediction. For plane strain of sheet metal subjected to strain rate effects
during cyclic bending under tension.

Figure 3.1: Process of rolling

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The roll bending process is used to be observed from the literature reviewed that
conical bending process is untouched area as far as force prediction is
concerned. Even in the industries the normal practice of plate roller bending still
heavily depends upon the experience and the skill of the operator. Working to
templates, or by trial and error.

4. STRESSES INDUCED IN SHEET METAL

The working by bending of work-pieces creates inner of this in deformed zone
stresses in tangential and radial directions. The metal strata placed to curving
centre are pressed in tangential directions, becoming shorter and in especially
cases are stretchingin transversal direction. The metal strata placed to external

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piece are stretching in tangential direction and in especially cases are pressed in
transversal direction, making the piece narrowing. Between the stretching and
pressing strata is founded the neutral status. The neutral status with the radius is
founding displaced to the curving centre before the weight centre,

4.1 Stress induced in sheet metal

5.STEPS IN ROLLING

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 5.1 Steps in rolling

6. DESCRIPTION OF THE MACHINE

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 The Sheet Metal Rolling Machine works according to the principle of
three point bending. The rotation of the driven rolls being utilized to feed the
metal through the rolls by means of the frictional forces present between the
surface of the rolls and sheet. No lubricant is used at its presence interference
with the ability to grip. Sheet Metal Rolling Machine essentially consists of
three rollers, used to manufacture circular components like cylinders. Sheet
Metal Rolling Machine is classified into two types based on the arrangement of
the rollers. They are as follows.

1. Pinch type machine

2. Pyramidal type machine

This machine is of pinch type here only the top roll serves as a driven, bottom
roller are idler and rotates on friction with the work metal blank.

6.1 Sheet rolling machine

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7. WORKING PRINCIPLE

The Sheet Metal, which is to be formed in cylindrical shape, is present at

the edge by hammering. To start the operation easily and to avoid flats at the
beginning and at the ends of the rolled form. In rolling cylindrical shapes a
gradual curve is to be put in the metal rather than sharp bends. Now the sheet
metal is introduced between the top and the bottom rolls, the gap between the
top and bottom rolls are adjusted as per the required diameter by regulating the
screw rods.
The rollers were arranged in triangular form; two sets of rollers below and
one above. The upper roller providethe bendingforcewhilethebackbaseroller
provides the required driving force and the front end
Roller bends the metal according to set radius of bend. Aperture adjuster
on each block assembly ensure loading of workpiece and adjustment to required
radius of bent. Thefreeendofthetopbearingblockis springloadedtoincrease or
toreducetop-baseroller clearance. Twootherboresoneach bearing blocks provide
an adjustment for the roller gap variability. Top roller

Provides the bearing load (bending force)and also compliments the driving
roller when working on thick materials. Thelowerbackroller provides the
necessary driving forces while the idler roller does the bending and material
delivery. There are two crank levers, one on the toprollerand anotheronthefront-
end roller. The lever (handle) couplinghead hasasquare configuration
whichfitsinto thesquareendoftherollershaft.

The frame structure made of(50×50×5)mm angle iron for the purposes of
strength. The tool table is provided below the rollers for safe keeping of tools
and cranks. Therollerhead assembly is detachablefrom
theframeandcanbemountedonatable tobeused asatabletop machine fortinkering
works.

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 8.DESIGN
8.1General design principles
Following basic shearing operation on a sheetmetal, components
canberolled to give it a definite shape.

Bendingofpartsdependsuponmaterial propertiesatthe location ofthebend.

Toachievebending,thework materialmust be subjected to twomajorforces;
frictional forcewhich causesano-slip actionwhenmetalandroller cameincontact
anda bendingforceactingagainst the forward speed and the torque applied to
move the material. Fig8.1

8.1Shape rollingmechanism

Where,a=distancefromexitzonetotheno-slippoint(assumea=L/2);
F=forceappliedtorollers;T=torqueappliedtorollers;L=rollgap;
r=radiusofrollers;μ=frictionalforce;ho,hf=thicknessof thesheet before and
after timet.

Atleast two rollers were involved in flatrolling dependingonthe thicknessand

properties ofmaterial whilethreeormultiplerollersystem isrequiredinshape
rolling. A work material under bending load is subjectedtosomeform
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ofresidualstressanddeformation asit bends. Materials at the outerbend
radiusundergo tensile plastic deformation whilethematerial at theinner
bendradiusundergoescompressiveplasticdeformation.
8.2 Stress and Strain in steel:
Bending is a process by which a metal can be deformed by plastically
deforming the material and changing its shape. The material is stressed beyond
the yield strength but below the ultimate tensile strength. Roll forming, [also
known as roll bending], is a process for forming plates, sheets, bars, beams,
angles or pipes into various shapes by passing the work piece between the
properly spaced rolls. Sheet and plate are the mill products often formed by the
roll bending process. Because of the elastic plastic behaviour of the sheet
material, deformation imposed on the sheet when it is forced to conform to the
rolls, has both elastic. The plastic part of the deformation is permanent and it is
not recovered when the sheet is unloaded by removing it from the roll system.
The elastic part of the deformation is recovered up on removal of the load. This
phenomena is known as “spring back” or elastic recovery

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8.2Stress and Strain Curve for Steel

8.3 Plastic Theory of Bending:

(a) Fully elastic state(b) partially plastic state (c) fully plastic state

Fully Plastic Rectangular Section:

For the rectangular section of width b and depth d the plastic moment of the
resistance of plastic hinge can easily be found. The total loads above and
below the neutral axis NA are both equal to in magnitude but opposite in
direction. Further each of these loads acts at a distance d/4 from the neutral
axis. Thus at plastic hinge, the plastic moment of the rectangular section

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8.4 Design Calculation:

8.4 Geometrical analysis

FORCE ANALYSIS:
The material selected for analysis is mild steel. The mild steel plate
Properties are
m 2
Young’s Modulus, E=207GN/
σ 2
Elastic limit (yield stress) y =515MN/ m

Poisson’s ratio=0.34
Given data from the specification of the machine
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 The plate thickness t=1mm
Upper roller diameter, du=50mm
Lower roller diameter dl=50mm
Lower rolls centre distance 2f=120mm
Theplate rolling speed v =5.5m/s
Using a geometrical analysis based on the assumption that the deflected form of
the plate is an arc of a circle and this analysis is used to predict the upper roll
vertical force, the torque required for bending and other requirements

K
=√(Ri+rl)2 −f 2
=
0.0250.02520.062

K=0.048m

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 2

 f 2  t  rl 
2
K  ru
R 
i
2r rtK
u l

(
0.048−0.025)2 +0.062−0.0262
= =0.0863m
2 (0.025+0.025−0.048)

To find the shift of contact angle(θ) of bend plate with rolls:

f
sin θ= (Ri+rl+t )

−1 0.06
θ=sin (0.863+0.025+0.001)

= 48.7o
To find the length:

48.7
0.025 sin ¿
¿ 2∗0.06−2 ¿

l=0.0824m

The deflection of the plate below its support point is calculated by taking the
ratio of length square to eight times internal radius

(0.0824 )2
= 8× 0.048
δ
=0.017m

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The plate will undergo elastic spring back after the maximum bending
moment has been applied. The relaxed radius, after spring back, of the plate
may be determined from the following equation.

σb t2
M= 4

N
σ =594.67× 106 m 2

594.67 × 106 × 0.45 ×0.0012

M= 4 =66.89 Nm
bt3 0.4 ×0.0013 −11

×10
I= 12 = 12 =3.333

1 66.89
ρe = 207 ×10 ×3.333 ×10−11
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=9.704m

R+ t
ρ p = i 2 =0.863+0.0005=0.8635m

1 1 1
=¿
ρr = 0.08635 − 0.103 1.872m
ρ =¿
r 0.534m

Upper roll vertical force applied on the plate (Pv)

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 66.89= P ( 4 + 2 tan 48.7)
1 0.017
v

P =¿
V 257.59N

The lower rolls force to drive the plate is

P l= 257.59
2× cos 48.7 =195.14N

The side thrust force on the plate is

P 48.7=¿
s =195.14 146.60N
× sin ¿

Power required for driving the machine:

P= (Mρ V ) = (66.890.534×0.0215 ) =2.69kw

p
r

The torque required to roll the plate is calculated:

T= (Mρ r ) = (660.89.534×25 )
p l
r =¿ 3131.55N-mm

Shaft diameter:
For greater strength 45c8 (steel) is common for shafts

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 N
Syt = 580 mm 2

N
Sut = 770 mm2

Using maximum shear stress theory of failure:

τ
16
3 kb M b 2  Kt M t 

max =d
(60106 )P

Mt
= 2n

0.092 ×60
=¿
= 2 × π ×0.025 35rpm

For roller speed of 35rpm & with 2.69kw M t

= (
(60 ×106 )×2.69 5
) =7.33 ×10 N-mm
2× π ×35

K K
b =1.5, t =1

τ
max = 0.3syt = 0.3(580) = 174N/mm2

τmax = 0.18sut = 0.18(720) = 138.6N/mm2

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Taking the min value of 138.6 N/mm2

d3 = (π ×16138.6 )√(1.5 ×1942300) +(1 ×733931.65)

2 2

d=47.97mm let d be 50mm (standard)

9.SYNOPSIS
In Sheet Metal working industry a wide range of power and hand operated
machines are used. As the sheet metal industry is a large and growing industry
different type of machines are used for different operations. Our project the
sheet metal rolling is very simple in operation by using roller which is coupled
with handle. This machine produces cylindrical objectives of different
diameters. This machine can be used in various fields. This machine consist of
three roller which is coupled with a handle and connecting the handle shaft
with worm shaft. This machine is simple in construction and working.

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 10.APPLICATIONS

Sheet Metal rolling machine is used to make,

Outer cylindrical casing for motors employed in

submersible pumps.
Hydraulic and pneumatic cylinders
Bodies of shells and condensers
Dairy equipment
Compressors storage tanks etc…
It is also used to make cylinders of different diameters

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 11.ADVANTAGES
Operation of this machine is very
simple Unit is compact so less space is
required No hand tools are required
Cylindrical shaped objects of dia 50mm to 225mm can be
produced
The dia can be easily operate this machine
The machine is hand operated. So the cost of the finished
product will be less.
The total cost of the machine is less.
Maintenance of this machine is very easy.
Easy to handle
Less effort & productive
Easy to install at any were
Skilled workers are not
required Convenient for mass
production Less in weight

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 12.DISADVANTAGES
 This machine has a hand operated one
 Production time is high.


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13.ESTIMATION AND COST ANALYSIS:

SL.N NAME OF MATERIALS QUANTITY AMOUNT

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1. Steel Hollow Shaft 3 1500
2. Steel Square Pipe 2 500
3. Base 1 500
4. Nut and Bolt 6 100
5. Bearing 6 400
6. Welding Work 500
7. Cutting Work 500

TOTAL 4000/-

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