MECHANICAL DESIGN AND ANALYSIS OF AUTOMATIC PIPE BENDING MACHINE

Abstract

Pipe bending is the metal forming processes used to permanently form
pipes or tubing. One has to differentiate between form-bound (secure with a cover of bending)
and freeform bending procedures, as well as between supported and cold forming procedures.
Form bound bending procedures like “press bending” or “rotary draw bending” is used to form
the work piece into the shape of a die. Straight tube stock can be formed using a bending
machine to create a variety of single or multiple bends and to shape the piece into the desired
form. This process can be used to form complex shapes out of different types of ductile metal
tubing. Freeform-bending processes, like three-roll-push bending, shape the work piece
kinematically, thus the bending contour is not dependent on the tool geometry. The main aim of
this project is composition of deformation in tube or pipe bending theory and the effects of Pipe
bending machine parts including; clamp die, bend die and support die to obtain optimum
bending requirements. Deformation of tubes can be achieved in numerous ways. This bend
shaping requires sensitive operation on each component to ensure regularity of production
processes with high quality end-product. However it brings some troubleshooting like wrinkling;
spring back, breakage and validation. This failure depends on geometry of the material such as
bending radius, tube thickness and also friction factor between dies and the tube. Effects of all
parameters should be examined before generating the theory for a best solution. Therefore,
prediction of the required moment for the proper bending process with low cost and shortened
production time is needed. The solid model is generated in Catia V5. Then the model is imported
to Ansys through Iges format. The quality mesh is prepared in Ansys for converged solution
(analysis package with high optimizing results).