Calculations - First Edition
Calculations - First Edition
Calculations - First Edition
CALCULATIONS:
(A) Design the upper roller.
(B) Design of the lower roller.
(C) Dynamic analysis.
(D) Power calculations.
(E) Summary of the calculations.
_Roll bending process is an important metal forming process used to produce cylindrical sections for
various applications. 3-roller bending is one such process. For this process it is important to evaluate
the maximum force acting on the rollers during the rolling process for designing the rolling machine.
The force applied by the press roll represents the load applied on the Metal sheet, which can be
calculated using the expression: {1}
Where:
(E) is the modulus of elasticity of the material of the sheet. It is a material property that characterizes
the stiffness of the material. It describes how much the material will deform under a given load.
(I) represent the moment of inertia of the sheet. It is a measure of the distribution of material around
the neutral axis of the sheet. A larger moment of inertia indicates more resistance to bending.
Material: The most metal to deal with would be 205 stainless steel (UNS S20500) which is a versatile
metal commonly used to produce food-grade equipment and components. It has become
increasingly popular for its impressive corrosion resistance, excellent heat conductivity, sanitary
qualities and easily maintained surfaces. 205 stainless steels might be found in commercial baking
ovens, braising pans, steamers, conveyor toasters, dry kettles and many other kitchen appliances
used in cooking establishments. This metal also finds applications outside of the food industry, such
as large-scale construction projects where its tensile strength is beneficial.
Table (1): --- {2}
Dimensions: Thickness = 5 mm
--Consider the Upper roller simply supported: (Let the total length of the roller=1250mm)
_Roller specifications:
Hardness Brinell -
180
The maximum bending the roller is subjected to = 20521 x 1250 (roller length)
= 25.65125x10^6 N.mm
σx = (My/I)
σx = (32M/ π d^3)
σ1 = σx , σ3=0
Applying Tresca:
Therefore, since 108.129 mm is enough to get the work done it is safer to choose a bigger diameter
Lower roller is subjected to torque due to: (1) Their function of moving the sheet. (2) Friction.
(1) Load Torque = (w /2) x d1, where (d1: the lower roller diameter)
𝜏=(Tr/J)
𝜏xy= (64 T/ π d^3) 𝜏xy= (64 x 18469 d1/ π d1^3) = (64 x 18469 / π d1^2)
Lower roller is also subjected to bending stress: it is the same as the bending stress the upper roller
is subjected to, but it is distributed over the 2 lower rollers
σ1 =
σ3 =
Applying Tresca:
Therefore, since 75 mm is enough to get the work done it is safer to choose a bigger diameter
σa = σm = (136x10^6)/12^3 Mpa
Se= (0.5 x 630) Kf= 4.51(630)-0.265 Ks= 1.189(10)-0.112 Kr= 0.82 Kt= 1
using Soderberg’s and Kf equals 0.7 we get a safety factor equals = 1.85 which means that both will
be safer under oscillating load
From the previous analysis it is now clear that the total torque required for this machine is
Lower Rollers
Tensile Strength ST 52 - Carbon Steel Length= 1250mm
Hardness, Resilience Material Group
Carbon Steel Diameter=100mm
Alloy - ST 52
Refrences:
{1} Development of a Motorized Sheet Metal Rolling Machine Olunlade Bankole Adeoye1, Ogundola Jide1, O.
Odiba1* and Obaje Onuche1