UNIVERSITI TEKNIKAL MALAYSIA MELAKA
DESIGN A BENDING MACHINE FOR BOWL FEEDER
ATTACHMENT
This report is submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) fot the Bachelor Degree of Manufacturing Engineering (Robotic
& Automation) with Honours.
by
AMIRUL FARHAN B MOHD SALIH
FACULTY OF MANUFACTURING ENGINEERING
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
DECLARATION
I hereby, declared this report entitled “Design A Bending Machine For Bowl Feeder Attachment” is the result of my own research except cited in the references.
APPROVAL
This report is submitted to Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Robotic & Automation) with Honours. The member of supervisory committee is as follow:
ABSTRACT
ABSTRAK
DEDICATION
To my beloved father and mother who give me the strength and aspiration to move forward
ACKNOWLEDGEMENT
Assalamualaikum and full of grateful to Allah S.W.T. because the PSM project is successfully finish in duration of one year completing the PSM project. I would like to thanks to my supervisor Dr. Mohd Rizal b Salleh who guided me from the start until the end of this PSM project. Not forget to my fellow friends who also help me in a medium of giving suggestion, solution and so on. With the strong efforts, strong inspirations and hardworking, finally, this PSM project is successfully completed. Once again, thanks to my supervisor and friends.
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LIST OF TABLES
2.1 Types of stainless steel 35
2.2 Table of stainless steel and its properties 35
2.3 Unified Numbering System (UNS) for metals and alloy 37
4.1 Need-matics matrix 44
4.2 Concept combination table 54
4.3 Concept screening 60
4.4 Concept scoring 61
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5.10 An illustration of constraint at the key hole of a turbine shaft 72
5.11 An illustration of a force applied at the turbine shaft 73
5.12 A result of finite element analysis on the turbine shaft 73
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CHAPTER 1
INTRODUCTION
1.1 Overview
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The other problem of bending is uneven surface on the sheet metal due to hand bending using plyers. If the attachment of the bowl feeder is uneven, the parts of certain components are hard to feed to the machine. The parts have to overcome the gravity force that pulls the parts backward. Moreover, it takes longer time to feed the parts into the machines. When the time is longer, the productivity is decreasing. This will influence the output quantity of feeding because when the surface is not even, the parts is hardly feeded into the machine.
Matching the bowl feeder attachment to the bowl feeder is another process in feeding module. The bending of the sheet metal is a common process and it is done by human. Human can cause error when do the bending process. Therefore, the machinists are tending to do mistake and thus the bending of the sheet metal cannot be done only once. It needs several times to bend the sheet metal to get the shape of the bowl feeder so that the necessary attachment is match with the bowl feeder. Moreover, when doing the bending processes, the sheet metal have the spring back force and this type of force will need the machinists to bend the sheet metal several times.
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Figure 1.2: An illustration of bowl feeder, the region of the red line is the bowl feeder attachment, picture taken at Solid Heat (M) Sdn Bhd dated 15.10.2009
1.3 Objective of the study
The objectives are as below:
1. To investigate the difficulties in sheet metal bending for bowl feeder attachment. 2. To design a small scale sheet metal bending machine.
3. To analyze the performance of the proposed bending machine.
1.4 Scope of the study
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This study starts with investigation of the difficulties in sheet metal bending for bowl feeder attachment. The investigation is starting with stating with the problem statements. The idea of designing a bending machine can be seen clearly through the problem statements, which is a solution of designing a bending machine can be generated to encounter those problems. From this investigation, a literature review can be conducted. In the literature review, it will discuss about the reason to design a bending machine for bowl feeder attachment, the comparison of existing bending machine, classification of bending machine, working principle of bending machine, etc.
In methodology, the first process is identifying the need of designing a bending machine. A design will be based on the necessary criterion of a small scale bending machine can be continued. In conceptual design, a basic design is generated. When the best design is chosen, that design will undergo detail conceptual design. Every machine parts are considered in detailed conceptual design so that it is suitable with the process of bending a sheet metal. Next, design analysis will be conducted on the detail conceptual design. After that, evaluation is conducted to evaluate the design of bending machine. Lastly, report writing need to be written.
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CHAPTER 2
LITERATURE REVIEW
2.1 Overview
A bowl feeder is widely use in automation industry. The purpose of bowl feeder is feeding parts into a machine. To make a bowl feeder, a bending machine is used. The attachment of the bowl feeder plays the role in productivity of producing products. Unfortunately, there is no proper bending machine to bend a sheet metal for bowl feeder attachment. Moreover, the existing bending machine is big in size, consume a lot of space and it is use for big scale production. In this project, the literature review will discuss in detail in designing a bending machine, component features considered in designing a bending machine, etc.
2.2 Reasons to design a bending machine for bowl feeder attachment
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in curve shape. Compare to the press break bending machine, most product of the sheet metal is 90° bending. Same also to the folding machine, it produces sheet metal bending with desire degree of bending.
Other reason regarding to the bending machine design, the bending machine in the market come with big size and the bending machine is expansive. The existing bending machine in the market is created for huge capacity for bending a sheet metal. With the capacity of bending machine that exists in the market, the existing bending machine is not fulfilling the requirement of the usage. The requirement of operation of bending machine is simple. Thus it is not suitable to purchase existing bending machine to be used for simple bending machine operation. Moreover, the machine is heavy and use up a lot of space. In addition, the problem will arise when to move and put the bending machine due to heavy and space.
2.3 Existing bending machine
a) Press brake bending machine
Press brake bending machine use die and punch to bend a sheet metal. The die and punch of the bending machine have a variety of shape. Some of the common press brakes bending operations are bottoming, coining, air-bend, etc. Press brake bending machine is a machine that use motor to operate the bending machine. In addition, the press brake bending machine is come with big size and use a lot of space.
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Figure 2.1: An example of air bending and bottoming, Wick C. et. al., Tool and Manufacturing Handbook Volume 2 (Forming), 4th Edition
Figure 2.2: Illustration of press brake bending machine, Wick C. et. al., Tool and Manufacturing Handbook Volume 2 (Forming), 4th Edition
b) Roll bending machine
