DOI: 10.14704/nq.2022.20.6.NQ22167
Design of a hydraulic roll forming machine for metal profiles forming
Abstract
The research shows the implementation of a profile bending machine in the manufacture of flanges. The machine performs the rolling process through a hydraulic mechanism and three rollers that are connected through a gear transmission, allowing it to fix the desired curvature to the profiles to be worked with. For the development of the bending machine, the production parameters, static and dynamic load analysis, material selection, machining of mechanical elements, assembly of mechanical parts, and control and force systems were analyzed, achieving an efficient design. The hydraulic system used was 11 tons with an internal gear pump with a capacity of 2 GPM, displacement of 4.5 cm3/rps, and a maximum pressure of 250 bar, with a 3 HP electric motor and a tank of 42000 cm3. A 2.2 kW geared motor with an angular velocity of 1720 rpm was used for the transmission mechanism. According to the Von Mises stress analysis, a standardized AISI 4340 steel shaft and AISI 8620 steel for the gears were selected. The table was constructed of A36 steel and an electric control circuit. The bending machine can bend profiles up to 1/4 inch and a minimum bending radius of 11 inches. The manufacturing cost was estimated to be approximately $5500, corresponding to 50% of the machine in the trade
Keywords
bending machine, homogeneous deformation, hydraulic motors, effective stress, rolls.
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