Modification of an Existing Metal Sheet-Bending Machine

TABLE OF CONTENT

                                                                                                    PAGES

Front page…………………………………………………………………………                i

Certification………………………………………………………………………..      ii-iii

Dedication………………………………………………………………………                   iv

Acknowledgement…………………………………………………………….                 V

Abstract…………………………………………………………………………….                vi

Table of content……………………………………….……………………               vii-ix

Project topic…………………………………………………………………….                  1

Aim………………………………………………………………………………..                  1

Procedures……………………………………………………………………….                 1

Selected materials……………………………………………………………                  2

Equipment…………………………………………………………………………                3

 

CHAPTER ONE

1.0      INTRODUCTION................................................................      4

1.1      Importance of Sheet Metal Work and Bending Machines .  4-9

1.2      Historical Review and Classification of Bending Machines. 9-12

1.3      Operational Characteristic of the Bending Machine……….    12-14

CHAPTER TWO

2.0      BENDING TECHNOLOY………………………………………………………………….  15

2.1      Principles of Bending……………………………………………….      15-17

2.2      The mechanics of Bending………………………………………..     17-19

2.3      Plastic Deformation Due to Bending……………………………     20-21

2.4      Spring Back………………………………………………………………    21-22

2.5      Method for Compensating Spring Back……………………         22-16

2.6      Method of Determining Angle of Spring Back………………     26-27  

CHAPTER THREE

3.0      DESIGN CONSIDERATION………………………………………… 28

3.1      Bending Stress……………………………………………………………  28-31

3.2      Material Selections…………………………………………………………          32

3.2.1   Physical Properties of Metal………………………………………….  32-33

3.2.2   Mechanical Properties of Metal……………………………………..  34-38

3.3      Material Selection Table………………………………………………..  39

 

CHAPTER FOUR

4.0      COMPONENT DESIGH, CONSTUCTION,

CHAPTER FIVE

5.0      ANALYSIS……………………………………………………………………          54

5.1      Construction………………………………………………….…………….. 55

5.2      Anticipated Faults and Corrections…………….………………..… 55-56

5.3      Maintenance…………………………………………………………………56-57

5.4      Conclusion……………………………………………………………………. 57

5.5      Recommendations………………………………………………………… 58

          References……………………………………………………………………

PROJECT TOPIC:

DESIGN AND CONDTRUCTION OF A METAL SHEET-BENING MACHINE Component

AIM:

          To design and construct a mental sheet-bending machine component which is manually operated. A machine with working capacity to complete a 90o fold of a full-length plate (8ft = 2400mm) and up to 2.5mm thickness.

PROEDURES:

          These are the procedures for designing and constructing a metal sheet-bending machine.

-        Initial Machine Design

-         Materials Selection

-        Costing

-        Purchasing of the selected Materials

-        Equipment Used for the Construction

 

 

SELECTED MATERIALS

Gauge                                                                        Dimension

·        4mm plate                                              -         1200 x 1200mm

·        H Channel (8inch x 5inch)               -         2.550mm

·        12mm Plate (8ft x 1ft)                              -         2.850mm

·        12mm Plate                                            -         304 x 2550mm

·        50mm Plate                                            -         2,352 x 588mm

·        Æ 40mm Shaft                              -         2550mm

·        2” x 2” Angle Bar                                     -         2 lengths (18ft)

·        Æ 30mm Shaft                              -         40mm

·        Metal Weight                                -         40kg

·        Electrodes (Gauge 10)                              -         2 Packets

·        Bolts/ Nuts                                             -         Different Sizes

·        Hydro lift out crucible furnace

 

 

EQUIPMENTS

v  Moulding flask

v  Hack Saw

v  Grinding Stones

v  Cutting Stone

v  Shearing Machine

v  Arc Welding Machine

v  Drilling Machine

v  Grinding Machine

v  Lathe Machine

v  Metal Bending Machine

v  Shapping machine

v  Muilding machine

v  Driving machine

v  Feed taping tool

CHAPTER ONE

1.0        INTRODUCTION

1.1        Importance of Sheet Metal Work and Bending Machine

What is a metal? It is a strong shinny, which conducts electricity and melts when you make it hot enough. But surely metal must be something more than this because there are other substances such as carbon,, glass and rubbers, which are, obviously not metals but can also variously claim to have strength, elasticity or electrical conductivity. Furthermore, most of the metals will melt when heated sufficient. What then is a metal? A study of simple metallurgy will show that there is one important factor, which distinguishes metals from non-metals and that is the neat, orderly arrangement of the atoms into regular geometric molecules. Metal is a good conductor of heat and electricity and forming basic oxides. An alloy is a fused mixture or compound of two or more pure metals. The reasons for making these mixtures are many and various. Pure metals have certain desirable properties but are often lacking in other ways. Therefore it is necessary to mix other metals with them in order to preserve and improve their basic properties. To quote a well known example: Aluminum is a light weight metal which makes it useful for aircraft construction, but it is also soft and weak so a small quantity of copper is added to it to give the necessary strength and rigidity (Courtesy, 1980). The subsequent development of iron and steel to suit its use in various forms enables it to serve effectively wherever used. Iron and steel remains the most vastly used material for structural works, enclosures and packages.  The most popular forms of iron and steel remains the sheet form, mostly used in enclosure and vessel fabrication. The term metal sheet refers to lighter gauges of steel in rolled form ranging in thickness from approximately 0.4mm to 3.2mm. (Surenda singh, 1979). Many engineering components are produced from flat sheets of metal which are cut to shape and then folded to form the finished article. The edges are then secured by a variety of methods such as welding, soldering and riveting. The accuracy of the size of drawing the shape on the flat sheet know as the development. Allowance is made at this stage for folding or bending, the amount varying with the radius of the bend and the metal thickness.