HYDRAULIC ROD BENDING MACHINE

SYNOPSIS

When considering industrial machinery, the hydraulic ROD bending machine is the perfect
machine shop tool for the ROD bender. Our bending machine consists of a hydraulic cylinder,
hydraulic pump, die holder, ram and die. This is a hand operated one. The hydraulic pump is
supplying pressurized oil to the hydraulic cylinder. The hydraulic cylinder consists of piston, and
piston rod. The ram is fixed at the end of the hydraulic cylinder. The pressurized oil pusses the
hydraulic cylinder piston forward due to oil pressure. Already the ROD is fixed at the die holder.
The ram is striking the ROD forcely, due to the movement of the hydraulic piston.
INTRODUCTION

The hydraulic bending press is one of the most flexible machines on the market, allowing the
fabricator or iron worker to shear, punch, bend, scroll, and press thousands of different parts.
When considering industrial machinery, the hydraulic bending press is the perfect machine shop
tool for the metal fabricator. The hydraulic ROD bending press fits any small to medium-sized
industry when machinery for large-scale production must necessarily make way for machinery
with distinctly lower production costs.

The operating procedure of hydraulic ROD bending machine is simple when compared to other
ROD bending machine. Biggest improvements were placing the hydraulic cylinder near the die
holder. The hydraulic ROD bending press is most bend accuracy due to less deflection in the
table. The die holder is used to hold the die in the proper position. We have to change the die to
produce different shape of ROD such as V type, L type etc.
LITERATURE REVIEW:

Design and Fabrication of Hydraulic Rod Bending Machine, I.Muhammed Hanoof,

S.Ravi Vishwanth,

Nowadays the world is focusing into automation. Each and every work of human is reduced by
a machine, but few areas like construction the usage of machines for bending rods for
stirrups which are used to withstand loads in beams and columns are not done by machine
because the cost of machine is high and need skilled labours to operate it. So this project is
aimed to do bending operation for stirrups using hydraulics and named as hydraulic rod
bending machine. The main objective of our project is to implement the hydraulic rod
bending machine in the construction sites with less cost compared to the existing bending
machines, and increasing the productivity of the stirrups. Hydraulic rod bending machine
consist of Double acting cylinder, P-40 Direction control valve, Hoses, Motor, Pump,
Rack and Pinion, Free wheel, Fixture. The rod is bent by the hydraulic cylinder piston with
holding the rod in the fixture. The main advantage of our project is the square shape of the
Stirrups is bent continuously without repositioning the rod in the machine.

DESIGN AND FABRICATION OF PIPE BENDING MACHINE,

As the name suggests this project is about fabrication of a machine that is used for bending of
pipes. My project is to design and construct a bending machine. This machine is used to bend
steel into curve or other curvature shape. The size of the machine is very convenient for portable
work. It is fully made by steel. Moreover it is easy to be carried and used at any time and any
place.

DESIGN AND FABRICATION OF BENDING MACHINE,

My project is to design and construct a bending machine. This machine is used to bend steel into
curve or other curvature shape. The size of the machine is very convenient for portable work. It
is fully made by steel. Moreover it is easy to be carried and used at any time and any place. To
build this machine many equipment or machine is used. By using all this equipment, process for
making the project is faster and easier. I had also learned a proper method for operating all this
machine and equipment. Choosing component material is very important, because it will affect
the overall cost of the machine and the product quality. With this consideration, I had design this
machine with the maximum quality and low in cost.
 COMPONENT DESCRIPTION

HYDRAULIC DRIVE SYSTEM

A hydraulic drive system is a drive or transmission system that uses pressurized hydraulic fluid
to power hydraulic machinery. The term hydrostatic refers to the transfer of energy from flow
and pressure, not from the kinetic energy of the flow.

A hydraulic drive system consists of three parts: The generator (e.g. a hydraulic pump), driven by
an electric motor, a combustion engine or a windmill; valves, filters, piping etc. (to guide and
control the system); and the actuator (e.g. a hydraulic motor or hydraulic cylinder) to drive the
machinery.

PRINCIPLE OF HYDRAULIC DRIVE SYSTEM

Pascal's law is the basis of hydraulic drive systems. As the pressure in the system is the same, the
force that the fluid gives to the surroundings is therefore equal to pressure area. In such a way,
a small piston feels a small force and a large piston feels a large force.
The same principle applies for a hydraulic pump with a small swept volume that asks for a small
torque, combined with a hydraulic motor with a large swept volume that gives a large torque. In
such a way a transmission with a certain ratio can be built.

Most hydraulic drive systems make use of hydraulic cylinders. Here the same principle is used
a small torque can be transmitted into a large force.

By throttling the fluid between the generator part and the motor part, or by using hydraulic
pumps and/or motors with adjustable swept volume, the ratio of the transmission can be changed
easily. In case throttling is used, the efficiency of the transmission is limited. In case adjustable
pumps and motors are used, the efficiency, however, is very large. In fact, up to around 1980, a
hydraulic drive system had hardly any competition from other adjustable drive systems.

Nowadays, electric drive systems using electric servo-motors can be controlled in an excellent
way and can easily compete with rotating hydraulic drive systems. Hydraulic cylinders are, in
fact, without competition for linear forces. For these cylinders, hydraulic systems will remain of
interest and if such a system is available, it is easy and logical to use this system for the rotating
drives of the cooling systems, also.

An important advantage of a hydraulic drive is its high power density: the mass of a hydraulic
drive is several times smaller than the mass of an electric drive of the same power

Calculation

F = Ab * pb - Ah * ph

F = Pushing Force in N
Ab = (/4) * (Bottom-diameter)^2 [in m2]
Ah = (/4) * ((Bottom-diameter)^2-(Piston-rod-diameter)^2)) [in m2]
pb = pressure at bottom side in [N/m2]
ph = pressure at cylinder head side in [N/m2]

ADVANTAGES
 The major components of any fluid power system include: a pumping device a
hydraulic pump or air compressor to provide fluid power to the system. fluid conductors
tubing, hoses, fittings, manifolds and other components that distribute pressurized
fluid throughout the system.

APPLICATIONS

Hydraulic systems are used widely in both industrial and mobile equipment. ... In motor
vehicles, hydraulics are most commonly found in the application of brakes. The
relatively small force exerted by the driver's foot on the pedal is transmitted through the
fluid in a small piston.

HYDRAULIC JACK

A jack is a device that uses force to lift heavy loads. The primary mechanism with which force is
applied varies, depending on the specific type of jack, but is typically a screw thread or a
hydraulic cylinder. Jacks can be categorized based on the type of force they employ: mechanical
or hydraulic. Mechanical jacks, such as car jacks and house jacks, lift heavy equipment and are
rated based on lifting capacity (for example, the number of tons they can lift). Hydraulic jacks
tend to be stronger and can lift heavier loads higher, and include bottle jacks and floor jacks.
How Hydraulic Jacks Work

Hydraulic jacks depend on force generated by pressure. Essentially, if two cylinders (a large and
a small one) are connected and force is applied to one cylinder, equal pressure is generated in
both cylinders. However, because one cylinder has a larger area, the force the larger cylinder
produces will be higher, although the pressure in the two cylinders will remain the same.
Hydraulic jacks depend on this basic principle to lift heavy loads: they use pump plungers to
move oil through two cylinders. The plunger is first drawn back, which opens the suction valve
ball within and draws oil into the pump chamber. As the plunger is pushed forward, the oil
moves through an external discharge check valve into the cylinder chamber, and the suction
valve closes, which results in pressure building within the cylinder.
TYPES OF HYDRAULIC VALVES

Two common types of hydraulic jacks include bottle jacks and floor jacks.

BOTTLE JACKS

Bottle jacks became popular in the early 1900s when the automobile industry began to take off.
Also called hand jacks, bottle jacks provided an easy way for an individual to lift up a vehicle for
roadside inspection or service. Their resemblance to milk bottles earned bottle jacks their name
today, they range in size and weight to offer a lifting capability ranging from one hundred to
several tons. Bottle jacks feature a vertical shaft, which supports a platform (called a bearing
pad) that directly bears the weight of the object as it is lifted.

Although they are most commonly used in the automobile industry (1.5 to 5 ton jacks are
frequently used to lift cars), bottle jacks have other uses as well. In the medical industry they can
be used in hydraulic stretchers and patient lifts. In industrial applications, they can be found as
pipe benders used in plumbing, as cable slicers for electrical projects, and as material lifts within
warehouses. Their ability to lift heavy loads plays a big role in enabling the repair of large
agricultural machinery and in many construction operations. Bottle jacks can be secured within a
frame, mounted on a beam, or simply used as they are for easier jack transportation.

FLOOR JACKS

Unlike bottle jack shafts, the shaft in a floor jacks is horizontalthe shaft pushes on a crank that
connects to a lifting pad, which is then lifted horizontally. Floor jacks typically provide a greater
range of vertical lift than bottle jacks, and are available in two sizes. The original jack is about
four feet long, a foot wide, and weights around 200 poundsthey can lift 4-10 tons. A more
compact model was later made, which is about three feet in length, and can lift 11/2 tons.
Although mini jacks are also produced, they are not a recognized standard type of floor jack.
Typically, one of the first two sizes should be used.

SPECIFICATION

BEARING

A bearing is a machine element that constrains relative motion to only the desired
motion, and reduces friction between moving parts. The design of the bearing may, for example,
provide for free linear movement of the moving part or for free rotation around a fixed axis; or, it
may prevent a motion by controlling the vectors of normal forces that bear on the moving parts.
Most bearings facilitate the desired motion by minimizing friction. Bearings are classified
broadly according to the type of operation, the motions allowed, or to the directions of the loads
(forces) applied to the parts.

Rotary bearings hold rotating components such as shafts or axles within mechanical
systems, and transfer axial and radial loads from the source of the load to the structure
supporting it. The simplest form of bearing, the plain bearing, consists of a shaft rotating in a
hole. Lubrication is often used to reduce friction. In the ball bearing and roller bearing, to
prevent sliding friction, rolling elements such as rollers or balls with a circular cross-section are
 located between the races or journals of the bearing assembly. A wide variety of bearing designs
exists to allow the demands of the application to be correctly met for maximum efficiency,
reliability, durability and performance.

The term "bearing" is derived from the verb "to bear";[1] a bearing being a machine
element that allows one part to bear (i.e., to support) another. The simplest bearings are bearing
surfaces, cut or formed into a part, with varying degrees of control over the form,
size, roughness and location of the surface. Other bearings are separate devices installed into a
machine or machine part. The most sophisticated bearings for the most demanding applications
are very precise devices; their manufacture requires some of the highest standards of current
technology.

TYPES

There are at least 6 common types of bearing, each of which operates on different principles:

Plain bearing, consisting of a shaft rotating in a hole. There are several specific styles: bushing,
journal bearing, sleeve bearing, rifle bearing, and composite bearing. A plain bearing (in
railroading sometimes called a solid bearing) is the simplest type of bearing, comprising
just a bearing surface and no rolling elements. Therefore, the journal (i.e., the part of
the shaft in contact with the bearing) slides over the bearing surface. The simplest example
of a plain bearing is a shaft rotating in a hole. A simple linear bearing can be a pair of flat
surfaces designed to allow motion; e.g., a drawer and the slides it rests on or the ways on
the bed of a lathe.Plain bearings, in general, are the least expensive type of bearing. They
are also compact and lightweight, and they have a high load-carrying capacity.
WORKING PRINCIPLE:

Hydraulic pump consists of piston, piston rod and oil. The hydraulic pump reciprocating handle
is move upward and downward continuously, so that the compressed oil goes to the hydraulic
cylinder. The hydraulic cylinder consists of piston and piston rod. The end of the piston rod the
ram is fixed. The compressed oil pushes the hydraulic cylinder piston forward. Already the ROD
to be bended is fixed in between die and ram. The die is supported by the die holders.

By changing the die in the hydraulic ROD bending machine, we have to produce different shape
of bended ROD such as V type, L type etc. The ram is strike the ROD forcely, so that the
ROD is bended according to the shape of the die in the die holder. This is a simple pressing
mechanism.
ADVANTAGES

1. Hydraulic ROD bending machine develops greater forces than mechanical pressure and hence
it is for forming, bending, and drawing and extrusion operations.
2. The hydraulic ROD bending machine can exert its full forces at any position of the ram stroke
whereas the force is maximum at the end of stroke in mechanical press.
3. The sliding action of the punch slide is uniform.
4. The length of stroke can be varied even within small ranges.
5. No noise, no vibrations and hence smooth operation.
6. Stroke length and position of stroke can be varied easily.
7. Wide speed ranges.
8. Inertia losses are less.

DISADVANTAGES

1.Initial cost is high.

2. High maintenance cost.
APPLICATION:

1. The hydraulic ROD bending machine brakes can be fitted with hundreds of tooling
options for acting as a press brake (using the table as the level for accuracy),

2. Ram bender (for ROD or solids),

3. Rotary draw tubing bender

4. Shear, punch, ornamental iron twisting machine, straightener, etc.

5. This machine tool is great for any welding shop, fabricator, or general job shop.

REFERENCES:

[1]. Anthony Esposito (2012) Fluid Power Pearson, ISBN 978-81-775-8580-

3

[2]. Dr.R.K.Bansal (2010) Fluid Mechanics and Hydraulic Machines Laxmi

Publications, ISBN 978-81-318-0815-3

[3]. Er.R.K.Rajput (2006) Strength of Materials S.Chand, ISBN 81-219-2594-

0

[4]. PSG College of Technology PSG Design Data Book(2012)

[5]. T.J.Prabhu (2011) Design of Transmi ssion Element

[6]. V.B.Bhandari (2012) Design of Machine Element s Mc Graw Hill, ISBN

978-0-07-0681798

[7]. Vanalkar.A.V., Mechanism Synthesis for Stirrup Making Machine,

Proceeding, 4th International Conference on Mechanical Engineering,
ICME-2001, BUET, Dhaka, BANGLADESH, pp. 271, December-2001

[8]. www.sciencedirect.com