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Available online at ScienceDirect Materials Today: Proceedings 4 (2017) 1121011217 AMMMT 2016 Design and Development of Multi-Profile Sheet Forming Machine for Small Scale Industries Chetan Nejea, Balappa B.Ua,* aDepartment of Mechancial and Manufacturing Engineering, M. S. Ramaiah University of Applied Sciences, Bangalore-560 058, India Abstract Sheet forming machine is a general device in machine shop, which has utilized to bend the sheet metal in various profile. It is generally used in different industrial operations like bending a sheet metal in different profile like corrugated shape, square shape, half hexagonal shape etc. There are many kind of sheet forming machine that can found in small and large scale industries which are not feasible for forming a sheet with multi profile Hence fulfil the gap project has taken, and by conducting literature review, it was identified that there is lack of machine to form a small pieces and also identified the cost of the machine as too high. To understand the type of user and machine environment, data collection process is carried out with small scale industries. By considering customer requirement QFD and PDS was generated for Machine. To solve the current problems and issues with the user workplace, five concepts of Multi Profile Sheet Forming Machine were generated. The best among the five concepts was selected as final concept by weighted ranking method and the geometric model of final concept was generated. To validate the machine Kinematic simulation, static and modal analysis has been done. A working mock-up 1:1 scale multi profile sheet forming machine was made to validate the design with the user group and feedback is positive and satisfactory. 2017 Published by Elsevier Ltd. Selection and Peer-review under responsibility of Advanced Materials, Manufacturing, Management and Thermal Science (AMMMT 2016). Keywords: Sheet metal forming, roller design, small scale industry, Multi profile sheets, portable rolling machine. 1. Introduction The study is about the work of designing a sheet forming machine to appearance a different profiles on the sheets. Metal forming is very important manufacturing operation. The products we are using daily life are Chetan Neje/ Materials Today: Proceedings 4 (2017) 1121011217 11211 * Corresponding author. Tel.: (+91) 9945093937 ; E-mail address: 2214-7853 2017 Published by Elsevier Ltd. Selection and Peer-review under responsibility of Advanced Materials, Manufacturing, Management and Thermal Science (AMMMT 2016). manmade, engineering parts 3. These products are produced from some raw materials through some manufacturing process, developing a structure and final product from raw material is the very significant stage in production. Manufacturing refers to change raw materials in to end product using suitable techniques. Different types of manufacturing techniques are metal casting, metal forming, metal machining, and metal joining etc 3. To reduce the production cost and energy consumption is totally depended on right type of material and right type of equipment for manufacturing. There is a various manufacturing techniques are available such as joining, dividing, coating, modification, forming, shaping. The geometry of the sheet is same as die in sheet metal forming process, because sheet forming machine using rollers, so sheet metal is achieve roller profile and machine and tool are used for production can be very costly some time, Because of complicated geometry of the part1. Forming process is carried out in several steps to achieve a desired shape. In the sheet metal forming process various parameters such as tools, machines, material properties and tribology influence the product cost and quality. In these parameters some of them are directly proportional to the each other 2. The production of sheet metal parts depends on material properties, applied forming techniques, process parameters. In these all process different deformation modes are stretching, drawing, bending, stretch and bend, and compression and bend 1. The hitherto available designs are characterized by two major shortcomings, namely, current models are not compact and additionally, current models are equipped to cater only for single profile and not multipleprofiles. Hence, this research aims at bridging the aforesaid gaps and developing a new multi-profile sheet forming machine. 2. Concept generation, mind mapping and concept selection method Idea making is one of the important steps in improvement of every successful invention. In this project machine concept design has been done by considering various factors which are recognized by literature survey, product study, and user study. Mind mapping has been used for concept generation by branching out the keywords such as materials, sheet material, quality, price, operating type, and environment. These are again broken down in to several sub factors to consider each and every minute detail in design concepts, Like environment consist small scale industry, medium scale industry, large scale industry. Sheet material consist aluminium, galvanized, steel. Quality consist durability. Sheet metal thickness consists 0.5mm, 0.8mm, 1mm, 1.2mm metal sheets. Price consist low cost, medium cost, high cost. Operating type consist manual and automatic. Material consist mild steel, cast iron etc. Concepts have been generated using Google sketch up tool as shown in figure.1. Considering QFD and PDS short listing of the concept design has been done. Further short listing of the selected concepts is done as per ranking method for different parameters such as safety, functionality, weight, ease manufacturing, mechanism and cost. As shown in the Table 1, concept selection process was carried with Pughs method. The factors considered for evaluating the five concepts were Safety, Functionality, Weight, Manufacturing ease, Mechanism and cost. Out of the five concepts, and concept 5 has got highest points of 24. So considering all accepts and requirement Concept 5 is selected as final and started iteration on it. Concept five is provided with adding different features like adjustable rollers, guide way for inserting sheet metal, easy assembly mechanism, and all parts are exchangeable. In this concept part reduction is taken care such as gears are eliminated from the concepts can reduce the machine maintenance time and improves the productivity. 11212 Chetan Neje/ Materials Today: Proceedings 4 (2017) 1121011217 Fig. 1 Different concept design 3. Design calculation of multi-profile sheet forming machine Bearing Design Chetan Neje/ Materials Today: Proceedings 4 (2017) 1121011217 11213 P= 1570.74N Therefore selecting 61808 series of deep groove ball bearing 2 Shaft design calculation 2 = 0.75 *0.3*(Syt) = 81 N/mm2 = 0.75 *0.18*(Sut) = 94.5 N/mm2 Torque transmitter by the shaft given by = 338772.66 N- mm Self-weight of the roller N-mm By considering gradual load application on shaft, the standard diameter of the shaft to be 35 mm Keyways design 2 Shaft diameter d = 35mm Transmitted power (p) = 1.5 kW N = 42 RPM Material for keyway is steel 50C4 =153.3 According to maximum shear stress theory of failure 4 = 76.66 Chetan Neje/ Materials Today: Proceedings 4 (2017) 1121011217 = 25.2 million revolution = 29.92N R= , , Q = 4623.82 N, S = -308 N R H 2 v 2 2 + 2 = 460 = = = N, 14115.52 N N Radial force acting on the gear, = 0.5 * 460 = 230 = 0.5 = = 11214 The torque transmitted by the shaft is given by = 286478.89 N-mm = 8.75mm, depth = 5mm. 4. Geometrical model Considering manufacturability aspects and dimensional detail Product detailing has been done for the final selected concept. All the assistant parts and sub-assemblies in final idea are analysed to recognize its developed process, its purpose and assembly cycle. Design iterations have been done considering DFMA and FMEA. Assemble model of the sheet forming machine is shown in the figure. 2, which has modelled using CATIA V5 software. Initially each parts of the machine are also modelled using CATIA V5 software and assembled. 5. Finite element analysis (FEA): Discretization: The geometry of multi-profile sheet forming machine is discretised with suitable element using HyperMeshTM. Material property: Material used for manufacture the parts of multi-profile sheet forming machine is mild steel and mechanical properties of the mild steel are density (7800 N/mm2), youngs modulus (210 GPa), poisons ratio (0.29), yield strength (300-400 MPa) Material property assigned in HyperMesh. In the FE- model shown in figure.3, the element used is solid 45, number of elements in the model are 219514 and number of nodes in the model are 258020. To mesh the model, hexahedral mesh type is used. Fig. 2 Geometrical model of multi profile sheet forming machine = b = h = = Chetan Neje/ Materials Today: Proceedings 4 (2017) 1121011217 11215 Fig. 3 Finite element model Boundary conditions: To multi-profile sheet forming machine all DOF has been given at anchoring location. Analyses: Model and static (self-weight) is carried out in ANSYS Post processing: post processing was carried out to plot mode shape, critical stress locations and deformation due to self weight is carried out in Hyper View Modal analysis: Modal solution is obtained to find out natural frequency and mode shapes. Modal solution was obtained by ANSYS. Natural frequency taken from sixteen modes and compare the first natural frequency (0.8) is with system frequency (0.7). This is not matching, so there is no resonance in the system. 6. Results and discussion: Static analysis: Static analysis is done using ANSYS software, to determine the deformation and von misses stress generated in the structure as shown in figure.4. As a considered self weight of the structure through gravity deformation in the structure is 0.002 mm and von misses stress developed in the structure is 1.090 N/mm2. Fig. 4 Details of static analysis Modal analysis: Modal solution is obtained to find out natural frequency and mode shapes as reported in Table.2. Modal solution was obtained by ANSYS. As per analysis natural frequency obtained at mode 1 to 16 is 0.8049Hz to 594.8Hz as per machine speed frequency of the machine is 0.67 Hz and through modal analysis first mode natural frequency is 0.85 Hz so both are not machining so there is no resonance in the machine and machine operate smoothly. Chetan Neje/ Materials Today: Proceedings 4 (2017) 1121011217 Table 2 Natural frequency of the sheet forming machine at different modes Mode Number Natural frequency Mode Number Natural frequency 11216 1 0.854 9 37.37 2 1.290 10 49.25 3 2.441 11 97.41 4 5.995 12 269.4 5 5.995 13 328.5 6 6.882 14 339.4 7 9.410 15 416.1 8 34.74 16 594.8 7. Fabricated model: As per analytical calculation, the dimensions of parts are determined and machine parts are manufactured as shown in figure 5. To manufacturing of machine parts by using different machining process like turning, milling, drilling, taping, granding etc. by using different machining technics obtained the exact shape and dimension for machine parts. Fig. 5 Fabricated model Once machining of all parts has been done as per dimension next step is assemble the model, Before assemble have to made a machine frame so parts can insert easly. Frame design has been done considering features like all parts exchangeble and machine is ment for servisability and portable. So using different joint technics like fasteners and welding machine frame has made. Quality fuction deployment chart helps to reach the aim with considering features. In developed machine can stamp the multi-profiles on the sheet metal by passing sheet from one side of the machine where guideway are provided, and achieve a profiles on different thinkness sheets so adjustable rollers are provided. Machine is with manual loading of sheets and automated rotation of rollers using chain drive mechanism. Guide way helps in inserting the sheet in to the machine. 8. Conclusions In developed model of Multi- Profile Sheet Forming Machine meant for small scale industries because machine is compact in size, portable, less cost compare to other sheet forming machine. As per name says multi- profile, machine is stamping different profiles on the sheets though rollers. Machine is meant for serviceability like replacing rollers, sprockets, bearings etc. which will help in easy of assembly and productivity has improved. Stamping can achieve on the sheet of thickness at 0.5 to 1.5mm thickness. Features provided like adjustable rollers and guide way helps to inserting sheets and adjust the clearance between upper and lower shaft. Hence Chetan Neje/ Materials Today: Proceedings 4 (2017) 1121011217 11217 these features are influence to achieve an variety of profiles on the different sheet thickness so this machines is feasible for use in a small scale industries and skilled labors are not required for machine operation. Acknowledgements The authors acknowledge the support of M. S. Ramaiah University of Applied Sciences, Bangalore-58 for carrying out this research work. References 1 Smitech. Introduction to sheet metal forming process, SimTech Simulation et Technologies, (1999) 10-27. 2 Bhandari, V. B. Design of Machine Elements, New Delhi: Tata McGraw-Hill, (2010), 323-385. 3 R. Chandramouli. Fundamental concepts of metal forming technology 4 Padmanabhan S., Design optimisation of bevel gear pair. International Journal of Design Engineering 4.4 (2011): 364-393.