Design and Fabrication of Sheet Metal Rolling Machine

Tan, Shi Wen (2020) Design and Fabrication of Sheet Metal Rolling Machine. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

Text TanShiWen_Full Text.pdf Restricted to Registered users only Download (8MB)

Abstract

This dissertation presents the industry project for Solidify Technology Sdn Bhd of developing a sheet metal, pipe and tube rolling machine. The aim of the research is to design and fabricate a metal rolling machine that can roll sheet metal of up to 5 mm in thickness. The metal rolling is a process of converting a workpiece into a desired radius of curvature. The machine consists of three long rollers, pipe and tube rollers, bearings, hydraulic jack, handwheel and structural frame. The three long rollers are one upper roller and two lower rollers. These long rollers are 35 mm in diameter and 1 m long. For the upper roller, the hollow bar is 65 mm of outer diameter, connecting with the upper roller shaft. The frame of the machine is made up of rectangular hollow section with size of 60 × 40 mm. The upper roller can be adjusted in vertical displacement up to 55 mm by lifting of hydraulic jack. 5 tonnes of hydraulic jack and UCP 207 35 mm pillow block bearings type are selected for the machine design specification. Stress and displacement simulation in static analysis is done by using SolidWorks. The machine is tested with sheet metal of mild steel and aluminium from thickness of 2 mm to 5 mm, mild steel solid bar with diameter from 10 mm to 18 mm and mild steel square hollow tube with size of 1 × 1 inch with thickness of 1 mm to 3 mm. For thicker material, the vertical displacement of the upper roller must be higher to get smaller radius of curvature. The rolling machine is commissioned as in Appendix B and in used in Solidify Technology Sdn Bhd. Additional features which can be added to the machine’s functionality are also discussed.