Department of

Mechanical and Industrial Engineering

MANUFACTURING TECHNOLOGIES LAB

(ME 364)

Experiment title ROLL BENDING MACHINE

Experiment No. 2

Experiment date 19/2/2021

By

Student name ID Section

1 Mazen Saeed Alamoudi 439012341 1

2 Mohammed Ibrahim ALharbi 437013618 1

3 Naif Abdullah Alanazi 436016935 1

4 Rakan Abdalrazak Alanazi 438014596 1

Instructor: Dr. BARUN HALDAR

 Department of
Mechanical and Industrial Engineering

Evaluation sheet (Official use)

Marks
Checklist Details Marks Remarks
Deducted

Cover Page 5
Plagiarism in results & discussion part must be <

Table of Content 5
Introduction
10
(Experiment objectives, theory, etc.)
± 5 marks, depending
Contents

Experiment Procedure & setup 20 on the nature of

50%

department/lab
Data, Results & calculations 25

Discussion and/or Conclusion 10

References, Standard, appendix, etc. 5

Subtotal 80 Min. 48

Text 12 Regular, with Spacing 1.5 4

Heading 14 Bold 2
Formatting

Standard Front Type 2

Paragraph: Justified 2

Figures/Tables/Equations: Numbered,
10
Caption & Cited in text
Subtotal 20 Min. 12

Total 100
 Table of Contents

...................................................Introduction .1 .1

....................................................Objectives .1.1 .2

.......................................Background / Theory .1.2 .3

........................Experiment Procedure and Setup .2 .4

............................Apparatus/device description .2.1 .5

....................................................Procedure .2.2 .6

........................................................Results .3 .7

.................................................Observations .3.1 .8

......................................Discussion / Analysis .4 .9

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1. Introduction
The purpose of a roll bending machine is to roll a different kind of sheet into a round
shape and for this experiment we will preform it by using this machine to turn a flat
sheet material into a roll material where could be used in different type of
applications.

1.1. Objectives
To study and demonstrate the roll bending of various plates using single pinch type roll machine

1.2. Background / Theory

CONVENTIONAL ROLLING OPERATIONS: -

Conventional Rolling is the process of reducing the thickness or changing the X-
sectional of a long work piece by compressive forces applied through a set of rolls.
The initial form of material is ingot. In this process, heated metal is passed b/w the
rolls that rotate in opposite direction, the gap b/w the rolls is being less than the
thickness of the entering metal. It was first developed in the late 1500,s and It
accounts for 90% of all metals produced by metal working processes.

Figure (2.1)
ROLL BENDING OPERATIONS: -
It is a process in which large metal sheets and plates are formed into curved
sections using rollers. It is continuous form of three point bending.

Figure (2.2)

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ROLLER MATERIAL: -
● Requirements → Strength & resistance to wear.
 Cast Iron.
 Cast Steel.
 Forged Steel.
DEFECTS IN ROLLING:
Surface Defects.
Structural Defects.
● Surface defects may results from inclusions & impurities in the material, rust, dirt,
roll marks & causes related to prior treatment & working of material.
● Structural defects are defects that affect the integrity of rolled product. It includes
wavy edges, cracks and alligatoring (results from inhomogeneous deformation of the
material during rolling).

IMPORTANT TERMINOLOGIES
Ingot:- An ingot is a piece of relatively pure material, usually metal, that is cast into a
shape suitable for further processing. In steelmaking, it is the first step among semi-
finished casting products.
Bloom:- A bloom has a square or rectangular X-section with a thickness greater than
6” & a width no greater than twice the thickness.

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 Billet:- A billet is usually smaller than a bloom & has a square or circular X-section. It
is produced by some of deformation processes such as rolling or extrusion. Bloom &
billets can be further rolled into finished products such as structural shapes or rail
road rails or they can be processed into semi-finished shapes such as bar, rod, tube
or pipe.
Slab:- A slab is a rectangular solid where the width is greater than twice the
thickness. It can be further rolled to produce plates, sheets & strips.
Plates:- t > ¼” (6 mm), are used for structural applications such as ship hulls, boilers,
bridges, machine structures etc.
Sheets:- t < ¼” (6 mm), are used for automobiles bodies, appliances containers for
foods & beverages, office equipment. Sheets are provided as flat pieces or as strips
in coils to manufacturing facilities for further processing into products.

Figure (2.3)

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2. Experiment Procedure and Setup

2.1. Apparatus/device description

EQUIPMENT: -

A Plate Rolling Machine is a machine that will roll different kind of metal sheet into a
round or conical shape. It can be also called “Roll bending machine” or “Plate
bending machine”

Figure (2.4)

Figure (2.5)

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 Figure (2.6)

2.2. Procedure

Experiment Procedure
Switch on the machine by pressing the pump switch located on electrical cabinet. (1
Set the position of roller from pinch roll position indicator.(2
Make sure that the work piece is clean and flawless. (3
Move up pinch roll to proper height (4
Insert the work piece in between the upper and bottom rolls and lying on pinch (5.
Adjust bottom roll by manual hand wheel so that the work piece is firmly held(6
Move pinch roll position to the same height of bottom roll(7.
Depress foot switch pedal so that the work piece travels to the other side(8.
9) Repeat the procedure until the desired radius will be achieved.

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3. Results
3.

3.1. Observations

Step No. Forword Backword

1 -107 X

2 X -109

3 -112 X
4 X -114

5 -116 X

6 X -119

7 -122 X

8 X -124

9 -127 X

10 X -129

11 -132 X

12 X -134
13 -136 X

14 X -138

15 -140 X

16 X -142

17 -144 X

18 X -148

19 -149 X

20 X -151

21 -153 X

22 X -157

23 -158 X

24 X -160

25 -161 X

Table (2.7)

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4. Discussion / Analysis

For this experiment we preformed the roll bending experiment by using the roll
bending machine which is a machine that will roll different kind of sheet metal into a
round shape. After preforming the experiment we obtained a round shape material by
putting a flat material into the machine in a forward position and then letting the
material go back in a backward position after preforming this process with a number
of times and with changing the degree we achieved our goal from this experiment.

Q01: Is our experiment referring to conventional rolling or roll bending

?operations? Briefly elaborate
Roll bending, it is a process in which large metal sheets and plates are formed into
.curved sections using rollers
?Q02: Identify the purpose of control components of the rolling machine
Up and down roll: as an important part of the rolling machine, the material is made of
.high quality carbon steel for forging
Q03: Illustrate the difference between single pinch type and double pinch type
?rolling machine
Single pinch : generally are for light-capacity applications and it could be for
electromechanical or hydraulic, Double pinch: are available in light to very heavy
capacities and can have three or four terminology that confusing as these units to
.double-pinch pyramid plate rolls or double-initial-pinch plate rolls
?Q04: Illustrate the advantages and drawbacks of sheet rolling process
Most roll forming is done with long strips of metal in coils, so the process is high-
speed, with low labor demands, allowing higher volume production for most products
.with higher efficiency than with press braking or stamping
?Q05: Describe the effect of plate material on sheet rolling process
Plate rolling is one of the most complex metal fabrication processes. Changing just
one variable directly affects numerous others. When a plate roll is set up, spring back
is a major factor, as is the material's chemical composition and its work-hardening
.characteristics
Q06: Differentiate bloom, billet and slab with the help of figure using any
?drawing software
A bloom is a rolled steel work piece with a square cross section of about 150 mm by
150 mm. A slab is rolled from an ingot or a bloom and has a rectangular cross
section of about 250 mm by 40 mm. A billet is rolled from a bloom and has a square
.cross section of about 40 mm by 40 mm

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?Q07: What is Alligatoring
Alligatoring is the large formation or pattern of shallow and deep cracks, which look
like the skin of an alligator or crocodile on the surfaces of: Paint with limited flexibility,
excessive thickness, top coat that did not bond well or shrunk faster than the
.underneath layer
?Q08: Discuss and classify various defects in rolling processes
Wavy edges and zipper cracks can occur as defects in the material, if the rolls are
.bended, but not, folds or laminations or alligatoring
?Q09: Enlist various differences between sheets and plates
Generally speaking, a sheet is a thinner item of metal that has been cut from a
continuously rolled coil. As such, it can be less than 1mm, or up to 25mm, in
thickness. A plate is a thicker item of metal that has been produced (rolled) as a
.single item
Q10: Discuss the importance of lubrication in rolling and enlist various
?lubricants used in rolling process
Lubrication is absolutely essential to the proper operation of ball and roller bearings.
A proper lubricant will reduce friction between the internal sliding surfaces of the
bearings components and reduce or prevent metal-to-metal contact of the rolling
elements with their raceways. Calcium: Inherent EP ability, corrosion resistance, safe
.for food processing, low temp. Lithium: Higher temperature, high speeds
?Q11: What is the final roll form of slab
.It can be further rolled to produce plates, sheets & strips
Q12: What is an ingot? Which manufacturing process does it require to
?manufacture
Ingots are block of steel, gold, silver, or other metal, typically oblong in shape. Ingots
are generally made of metal, either pure or alloy, heated past its melting point and
cast into a bar or block using a mold chill method. A special case are polycrystalline
.or single crystal ingots made by pulling from a molten melt