Special Issue - 2017 International Journal of Engineering Research & Technology (IJERT)

ISSN: 2278-0181
ETDM - 2017 Conference Proceedings

Design and Fabrication of Hydraulic Zigzag

Bending Machine
Manoj Kumar.S1, Ravi Kumar. A2, Sakthivel. R2, Sundra Balaji. R2,
1
Assistant Professor, Suresh Kumar. S2,
Department of Mechanical Engineering, 2
UG Scholar,
Hindusthan Institute of Technology, Coimbatore, India. Department of Mechanical Engineering,
Hindusthan Institute of Technology, Coimbatore, India.

Abstract--The main aim of our Project is to develop a model of Bending implies the deformation of a work piece
hydraulic Zigzag bending machine which is a developed one produced by loads perpendicular to its axis as well as force
that of the conventional one. It is more advantageous for couple acting in a plane passing through the axis of the bar.
making Zigzag bending in work piece, such that it can form Bending is only occurred when the load is acting
Zigzag profile using normal hydraulic press. It can be placed in
perpendicular to the neutral axes of pipe.
all machine shop and all sheet metal bending workshops to
replace the conventional thing with less cost and low Work piece bending as a process starts with
maintenance. loading a wok piece into a work piece bender and clamping
A work piece can be bent in multiple directions and it into place between two dies, clamping block and forming
angles. Common simple bends consists of forming elbows die. The work piece is also loosely held by two other dies,
which are bends that are range from 2 to 90 0, and zigzag the wiper die and the pressure die.
bends which are 1800 bends.
2.2: Bending terminology
1. INTRODUTION
This machine is used to bend steel into curve or
curvature shape. The size of machine is very convenient for
portable work. It is fully made by steel. Moreover it is easy
to 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. We 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, we had design this machine
with the maximum quality and low cost
A Hydraulic cylinder is a mechanical actuator that is used
to give a unidirectional force through a unidirectional
stroke. It has many applications, notably in engineering
vehicles, industrial application, and civil applications. Fig. 2.1: Bending terminology
Hydraulic cylinders get their power from
pressurized hydraulic fluid, which is typically oil or air. The 2.3: Types of bending
hydraulic cylinder consists of a cylinder barrel, in which a Bending is a manufacturing process that produces
piston connected to a piston rod moves back and forth. The V-shape, U-shape, channel shape, zigzag shape along a
barrel is closed on one end by the cylinder bottom (also straight axis in ductile materials, most commonly sheet
called the cap) and the other end by the cylinder head (also metal. Equipment includes box and pan brakes, brake
called the gland) where the piston rod comes out of the presses and other specialized machine presses. Typical
cylinder. The piston has sliding rings and seals. The piston products that are made like this are boxes such as electrical
divides the inside of the cylinder into two chambers, the enclosures and rectangular ductwork.
bottom chamber and the piston rod side chamber.
 Air Bending
2. BENDING  Rotary Bending
Bending is usually defined as "the plastic  Roll Bending
deformation of a sheet metal along a straight line".  Wiping
Bending is defined as the straining of metal around  Coining
a straight axis. During this process, the metal on the inside  Folding
of the neutral axis is compressed, while the metal on the
outside of the neutral axis is stretched.

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Special Issue - 2017 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
ETDM - 2017 Conference Proceedings

2.4: Zigzag Bending out by means of actuating rod which is provided with the
A zigzag is a pattern made up of small corners at bottle jack. After the bending operation is done, the
variable angles, though constant within the zigzag, tracing a hydraulic jack is made to come to the original position by
path between two parallel lines. opening a relief valve which is placed in the hydraulic jack.
From the point of view of symmetry, a regular The returning stroke of the cylinder is done with the help of
zigzag can be generated from a simple motif like a line the spring attached between the sliding arrangement and the
segment by a repeated application of a glide reflection. top beam.
This study presents methods for suppression of
defects observed in zigzag bending of sheet-metal or plate. 3.3: Components
This type of bending is widely used in industry for 1. Hydraulic system.
manufacturing structural parts in automobiles. Although it is 2. Pumping rod/ Sucker rod.
easily conducted by press forming using upper and lower 3. Spring.
dies which have zigzag shape, it often has defects, such as 4. Sliding block.
spring-back and dents. A series of finite element analyses 5. Bending tool.
and experiments were conducted for suppression of the 6. Work piece.
defects in two-place bending, which has three segments. As 7. Frame .
a result, it is revealed that that the distance between two
bending positions is dominant for occurrence of the dents 3.3.1: Hydraulic System
and that the dent area was able to be reduced by selecting i. Principles of hydraulic drive
the optimum moving direction of the upper die. It is also Pascal’s law is the basis of hydraulic drive system.
revealed that the cause of spring-back is elastic recovery of As the pressure in the system is the same, the force that the
the straight segments instead of the bent parts against fluid gives to the surroundings is therefore equal to pressure
engineers' and technicians'' intuition, and that there is an x area. In such a way, a small piston feels a small force and
optimum moving direction of the upper die for the least a large piston feels a large force.
spring-back. Furthermore, another realistic method for
suppression of spring-back was suggested for four-place ii. Hydraulic jack
bending. Use of jacks not designed for a specific vehicle
requires more than the usual care in selecting ground
conditions, the jacking point on a vehicle, and to ensure
stability when the jack is extended.

3.3.2: Pumping Rod

A pumping rod/sucker rod is a steel rod, typically
Fig.3.1: zigzag bending between 12 and15 centimeter (7 to 9 inches) in length,
and threaded at both ends, used in the oil industry to join
3: WORKING AND COMPONENTS
together the surface and down hole components of a
3.1; Working Principle
reciprocating piston pump installed in an oil well.
When bending force is applied to work piece under
free bending conditions, the initial bending is elastic in
3.3.3: Sliding block
character. This is because the stresses that are developed in
Sliding block may refer to:
the opposites faces of the material are not sufficiently high
1. sliding-block action
to exceed the yield strength of the material. The stresses
2. sliding-block puzzle
developed on the inside of the bend tend to shorten the metal
3.3.4: Bending Tools
and are, therefore, compressive stresses. The movement or
Its purpose is to assemble a bend on a work piece.
strain which takes place in the work piece as a result of the
A bends is manufactured by using a bending tool during a
initial bending force is elastic only and, upon removal of the
linear or rotating move.
force, the work piece springs back to its original shape.
3.3.5: Spring
A spring is an elastic object used to store
3.2: Working
mechanical energy. Springs are usually made out of spring
Here our project consists of a hydraulic bottle jack
steel. There are a large number of spring designs; in
which is placed vertically. The bottom portion of the jack is
everyday usage the term often refers to coil springs.
welded to a beam which slides on two pillars which are
When a spring is compressed or stretched from its
placed parallel to each other. The bending tool is welded to
resting position, it exerts an opposing force approximately
the beam which is attached to the lower end of the hydraulic
proportional to its change in length (this approximation
cylinder. The bending tool is also welded to the bottom
breaks down for larger deflections). The rate or spring
beam of the frame in a relative position, which results in
constant of a spring is the change in the force it exerts,
forming Zigzag profile. There will be a gap provided
divided by the change in deflection of the spring. That is, it
between the bending tools to form the bending accordingly.
is the gradient of the force versus deflection curve.
The piston from the cylinder is connected to the top beam of
An extension or compression spring's rate is expressed in
the frame. The sheet metal to be bended is placed in
units of force divided by distance, for example lbf/in or
between the bending tools, and then the operation is carried

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Special Issue - 2017 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
ETDM - 2017 Conference Proceedings

N/m. A torsion spring is a spring that works by twisting; 1. Oil Filler Plig
when it is twisted about its axis by an angle, it produces
2. Handle Assembly
a torque proportional to the angle. A torsion spring's rate is
in units of torque divided by angle, such as N-m/rad or ft- 3. Release Valve Assembly
lbf/degree. The inverse of spring rate is compliance, that is:
if a spring has a rate of 10 N/mm, it has a compliance of 4.2: Design
0.1 mm/N. The stiffness (or rate) of springs in parallel
is additive, as is the compliance of springs in series.

4: DESIGNING
4.1: Hydraulic Bottle Jack
 Product description
Hydraulic Bottle Jacks are designed to lift, but not
sustain, loads ranging from 1.385tons thru 2 tons depending
on the rated capacity of the bending needed. They are
designed to be used vertically. Each model is suitable for
use in an appropriately rated and designed vertical or bench
press structure. These jacks are not appropriate to use for
lifting or positioning construction trailers, houses and/or
other building structures.
 Product Specification
 Capacity: 2ton
 Min. height: 7”
 Max. height : 135/8”
 Extension screw: 2” 4.3: Fabricated Work

Fig.4.2: Fabricated piece

5: CONCLUSION
Thus the hydraulic zigzag bending press is one of
the most flexible machines on the market, allowing the
fabricator or iron worker to shear, punch, and bend. When
considering industrial machinery, the hydraulic bending
press is perfect machine shop tool for metal fabricator. The
hydraulic zigzag bending press fits any small to medium-
sized industry when machinery for large-scale production
must necessarily make way for machinery with distinctly
Fig. 4.1: Bottle jack construction lower production costs.

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Special Issue - 2017 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
ETDM - 2017 Conference Proceedings

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