Machine Design Project
Sheet Rolling Machines
Overview:-
.. اَال اغهثىا اكٍذ اخذ فكزج ػامح ػه انمشزَع اَ اذؼمق فً ذفاصٍم شٌُح-
: تصُرج ػامح
Sheet rolling machines are used mainly to obviously roll metallic sheets by
bending them, several desired shapes can be done specially cylindrical ones ,
such as tanks and pipes ,pressure vessels are also made by this operation and
cones also .
We are considered in rolling thin sheets (0.5 mm – 7mm) which most of
available sheet rolling machines are capable of rolling them .
Principles and mechanisms:-
As we know we must bend sheets by using rollers of various dimensions , main
operation is to stick the sheet inside a lower roller .. an upper roller then is pushed
down compressing the sheet to do the bending job, then lower and upper rollers are
rolled in opposite directions to move the sheet forward and backward, rollers must
roll with same velocity and opposing directions so we must use gears to transmit
motion from one roller-which connected to power source – to the other roller .
Rollers are simple cylinders which are made from materials that have a higher
tensile strength than the rolled sheets …
Sheets also must have certain properties , it is important to have a suitable ranges
of ductility , hence we can roll stainless steel / carbon steels / and aluminum ..etc
Rolling is a cold forming operation which changes material properties … as the
thickness is reduced , the strength of the material is increased , it is also obvious
that rolling thicker sheets must be harder.
We must concern studying bending moment during analysis but not as a feared
failure , plastic deformation is desired.
In operation of fabricating pipes for example , after rolling sheets … leading edges
must be welded together perfectly to avoid any leakage that may occur during the
motion of the fluid , those pipes are welded by using several techniques such as /
SAW – MIG – TIG – SMAW.
Also pre-bend operation is important to achieve more précised works.
Types of rolling machines:-
There are different types of sheet rolling machines designed for specific
applications and varying levels of complexity. Here are some common types:
Two-Roll Machines:
Initial-Type Rolling Machines: These machines have two rolls, one of which
is fixed, and the other can be adjusted vertically. The sheet is initially inserted
between the rolls and then bent as it passes through.
Double-Pinch Rolling Machines: In this type, both rolls are adjustable,
allowing for a more precise and efficient bending process. The sheet is gripped
between the rolls at both ends, reducing the amount of material wasted.
Three-Roll Machines:
Initial-Type Three-Roll Machines: Similar to two-roll machines, these have
two adjustable rolls and one fixed roll. The sheet is fed through the gap formed by
the rolls, and the bending occurs as it is pulled through.
Variable-Geometry Three-Roll Machines: These machines have all three rolls
adjustable. This allows for more flexibility in the bending process, making it
possible to achieve complex shapes.
Four-Roll Machines:
Double-Pinch Four-Roll Machines: These machines have two rolls on the top
and two on the bottom. The top rolls are adjustable, providing greater control and
precision in the bending process.
4-Roll CNC Machines: These are advanced machines with all four rolls
independently controlled by a computer numerical control (CNC) system. CNC
machines offer high precision and are suitable for complex bending tasks.
The choice of the sheet rolling machine depends on factors such as the type and
thickness of the material to be rolled, the required precision, and the complexity of
the desired shapes.
In our project we can consider designing the Pyramid type machines , These
machines have three rolls arranged in a pyramid configuration. The top roll is
fixed, and the two bottom rolls are adjustable. This design allows for the bending
of thicker sheets and is commonly used for the production of large-diameter pipes.
: تىصح تانفٍذٌٌُاخ دي نرُسؼح انفٍم, تؼذ وظزج سزٌؼح ػهى انمُضُع
https://youtu.be/1y-QD0J09Ko?si=Il_Hinl-Uq6hbqy_
ممكه ٌكُن ذقٍم شٌُح تس ٌٍفٍذوا وؼزف االجشاء انذاخهٍح َ ال
Assembly
https://youtu.be/50DfkV9Y4Dk?si=iu5kHaGKQg4TIpJk
https://youtu.be/emueGfvcOB8?si=_SD2MLVidA3xWMkm
https://youtu.be/_EAx49X7AWg?si=5Vv2SMZQ06I0P6HY
https://youtu.be/B3xbWVA3gYw?si=hHjobIei0U1fL3Np
..وثذأ تؼذ كذا تانثالن َانخط انشمىً َذقسٍم انشغم
تاكقزاَوذ َ وثذج ػه اَنح+ _ ٌىؼمم اورزَدكشه محرُاي ذؼزٌف نهمشزَع َ انىظزج انؼامح1
مزفق.. )َذطُرٌا مغ انشمه (انذكرُر كان وثً ػهٍٍا
Pdf : development of a motorized sheet rolling machine
)_ وجً نمثادئ انذٌشاٌه ( انهٍهح كهٍا2
.Marerial selection for machine components
Depending on sheet metal materials , also common base metal used for
machines is cast iron and so on..
.Determination of sheet thicknesses and width range
.
.Calculation of rolling force and torque requirements
Considering a motorized machine ..
.Selection of the proper drive system(motor)
.Calculations of bending moment and other effecting forces to
determine the suitable material and dimensions
.Consider designing rolls – bearings – frame , choosing prober ball
bearings and oiling systems in general.
.. رسم االجشاء تانسُنٍذ تانماذزٌال انهً مرحذدج سهفا.. _ اما اللعبة االٌم3
كم تارخ ف رسمح مغ االتؼاد.. سي انهً كىا تىؼمهً ف اَنى
Consider fits and tolerance – BOM table …etc
_ تؼذ كذا محراجٍه وؼمم انرحانٍم انالسمح4
“Finite element analysis- analysis of machine stability and rigidity “
ًٍتصُرج ػامح ذأكٍذ ػهى حساب االتؼاد انالسمح نكم جشء َانرأكذ مه ان كم جشء تٍرحمم انهُد انهً ػه
_ اخٍزا انرؼهٍق ػهى كم انخطُاخ فً انمجمم5
Case studies ( presentation of real-world examples of sheet rolling machine designs
– analysis of design challenges and solution implemented – performance
evaluation and comparison of different machine configurations )
- Future trends and challenges
- Eventually conclusions ( summary of key findings and contributions –
recommendations for future improvements and research directions)
- Research references .
ذقسٍم انشغم
ٌىمشً تخطُج مىرظمح تحٍث وثقى مزذاحٍه فً انُقد
ٌؼمهُي مغ تؼض4 َ ا3 ػشان كذا ٌكهف.. ًسي ما الحظرُا اذقم ذاسك ٌُ انراو
)انراسك االَل ان شاء هللا سٍم (فزد َاحذ
) 3 َانراسك انراند َانزاتغ ٌرؼمهُا مغ تؼض ( فزدٌه ا
)انراسك انخامس (فزدٌه
َممكه اكُن اخرزخ وفس، )ًٌُسع انشغم كانرانً ( نُ حاتة ممكه ذغٍز مغ سمٍهك انراسك انهً ٌٍؼمه
..ًاالشخاص فً اكرز مه ذاسك حسة صؼُتر
Task 1 :
Heba Salama
Task 2:
Omar – Mohammed Osama – Esraa – Gamal
Task 3/4:-
Mohammed elhassan – Nihal – Gamal
Task 5 :-
Heba – Nihal
Time schedule and deadlines :-
Task Deadline
1 Friday Sep 1st – 11 pm
2 Sunday Sep 3rd – 9 pm
3 Wednsday Sep 6th – 9 pm
4 Friday Sep 8th – 11 pm
5 Sunday Sep 10th – 11:59 pm
..َهللا انمُفق َانمسرؼان
