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Modification Of An Existing Metal Sheet-bending Machine
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CHAPTER FIVE
5.1 Analysis
Every sector of the economy is experiencing changes. The production sector is not left out of the changes, infact it is more affected. Sheet metal today is used for doors, windows, frames, gates, etc.
It’s worthy to mention, however that the road side welders have developed various ways of bending sheet metal manually, but most often, they generally have poor finishing. As a result, their output does not justify their effort or input.
It could be said, that the present design is an improvement on the road side fabricators design of a bending machine. Therefore, it is believed that this bending machine will meet the demand for a good and low cost sheet metal bending machine.
Cost reduction was major among the factors considered in the design. To this end, the initial cost of the machine is not beyond the reach of any small scale entrepreneur.
Construction
The construction process of the bending machine involved the purchasing of the required material, measuring of the materials to the required sizes, culling to the required dimension, welding or bolting the component to each other. It is also important to grind the welded parts to make the surface smooth and neat and also the application of metal filler to the unsmooth parts. Then, painting o the machine.
Finally, there is no intricate part. Majority of the components required are simple and regular enough to be produced.
5.3 Anticipated faults and Corrections.
Faults that will be anticipated during use will be minimal since are no any intricate parts. Such may include:
1. After a long use, the housing of the shaft or rod is likely to wear and much allowance will be created which will ailed the operator applying force. It could be corrected by constant lubrication and a replacement after a long use
2. There could be wear of the biding table, bending bar and bending blade. This is likely to occur after a long use. Wear also occurs when machine is use to bend metal above its capacity. Regrinding of the folding table, bending bar and bending blade will help regain their sharp edges.
3. Wear of the threaded shaft could occur. It should be lubricated regularly.
5.4 Maintenance
For every equipment to work adequately and continuously, maintenance is the key factor.
For this design, care should be taken not to use the machine to bend beyond the given thickness of metal sheet i.e. not beyond 2.5mm thickness.
The movable parts like the threaded shaft, pivot bracket an pin should be lubricated regularly to minimize wear.
The machine should be kept out of reach of water or rain to avoid rusting.
5.5 Conclusion
It has come to reality that there is a wide difference between design and construction. The ultimate goal in design is to see the construction work, after which you are fulfilled.
Our fulfillment came after the design have been tested and worked effectively. The use of the bending machine has more capacity, efficiency and durability compared to the skeletal sheet metal bending machine produced by the road side fabricators.
Consideration was given to simplicity in design selection of appropriate materials which contributed to the low cost of this design.
Its capacity is to bend 2.5mm gauges of mild steel of maximum width of 8ft (2400mm). A thickness of 3mm gauqes may be bent on the machine but it should be as a last option and not regularly. A plate of 2.8mm thickness has been tested and bent on the machine. It should be noted that this should he strictly adhere to.
5.6 Recommendations
To increase the efficiency of this design, the following should be considered:
The length of travel of over bending should he increased to allow for bend above 90°.
The pivot bracket should be drilled to allow for lubrication of the bending beam.
To enable the machine to bend above 2.5mm gauges sheet metals, more rigid materials (cast iron) should be used in subsequent construction.
The use of a work justifies its make. A particular product V completed only when a consumer uses it. To this regard, this machine should be put to use and not to be abandoned.
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ABSRACT - [ Total Page(s): 1 ]ABSTRACT IS COMING SOON ... Continue reading---
TABLE OF CONTENTS - [ Total Page(s): 1 ]TABLE OF CONTENTFront page Certification Dedication Acknowledgment Abstract Table of content Project topic Aim Procedures Selected materials Equipment CHAPTER ONE1.0 INTRODUCTION 1.1 Importance of Sheet Metal Work and Bending Machines 1.2 Historical Review and Classification of Bending Machines. 9-121.3 Operational Characteristic of the Bending Machine CHAPTER TWO2.0 BENDING TECHNOLOY 2.1 Principles of Bending 2.2 The mechanics of Bending 2.3 Pla ... Continue reading---
CHAPTER ONE - [ Total Page(s): 4 ]CHAPTER ONE1.0 INTRODUCTION1.1 Importance of Sheet Metal Work and Bending MachineWhat 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 sufficien ... Continue reading---
SELECTED MATERIALS - [ Total Page(s): 1 ]SELECTED MATERIALSGauge 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•  40mm Shaft ... Continue reading---
AIM - [ Total Page(s): 1 ]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. ... Continue reading---
PROEDURES - [ Total Page(s): 1 ]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 ... Continue reading---
EQUIPMENTS - [ Total Page(s): 1 ]EQUIPMENTSï¶ Moulding flaskï¶ Hack Sawï¶ Grinding Stonesï¶ Cutting Stoneï¶ Shearing Machineï¶ Arc Welding Machineï¶ Drilling Machineï¶ Grinding Machineï¶ Lathe Machineï¶ Metal Bending Machineï¶ Shapping machine ï¶ Muilding machine ï¶ Driving machineï¶ Feed taping tool ... Continue reading---
CHAPTER TWO - [ Total Page(s): 4 ]Fig 2.6: Over bending to compensate for spring back.The nose of the bending blade is at an angle of 45° to allow for over bending when bending at 900. After the force applied is released, the material spring back and the required bend is achieved. Fig 2.6(b) shows a bend having a spring back angle i.e. distance between the over bending and the assumed position.2.6 Method of Determining Angle of Spring BackThe only practicable method to determine spring back is by experiment, others are based ... Continue reading---
CHAPTER THREE - [ Total Page(s): 5 ]A little consideration will show that when a beam is subjected to the bending moment, the metal on the upper side of the beam will be shortened due to compression and those on the lower side will be elongated due to tension. It may be seen that somewhere between the top and bottom plane, there is a surface at which the metal s neither shortened nor lengthened. Such a surface is called “Neutral surface†The intersection of the neutral surface with any normal cross-section of the beam ... Continue reading---
CHAPTER FOUR - [ Total Page(s): 1 ]CHAPTER FOURCOMPONENT DESIGN AND CONSTRUCTION Sand casting is one of the quickest and most cost effective methods adopted in the production of metal prototypes and is an excellent solution for low to medium run of pasts that do not require a specific or precise shape repeatability. The summary of making a cast material using sand casting process are as follows.1. A mold was created by placing the mixture of sand, clay and water on a pattern, and when the pattern was removed ... Continue reading---
REFRENCES - [ Total Page(s): 1 ]REFERENCESCourtney, J.V. (1980): Workshop Processes and Materials. Van Nosh Reinhold Company Ltd Workinghan, England, Pg. 21.John, R. Walker (1976), Exploring Metal Work-Basic Fundamentals. Good Head-will Cox, South Holland, Pg. 78-80.Khurmi, R.S. and Gupta J.K. (1979). A textbook of Machine Design. Eurasia publishing house (pvt) ltd New Delhi, Pg. 15.Smith, F.J.M. (1982): Basic Fabrication, and Welding Engineering: Longman, England, Pg. 23-24Surenda, Singh (1979): Strength of material, Vikas Pu ... Continue reading---
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ABSRACT - [ Total Page(s): 1 ]ABSTRACT IS COMING SOON ... Continue reading---
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