DESIGN AND FABRICATION OF A

STEEL ROD
BENDING MACHINE

LUCILA AGNES A. BRANZUELA

CHARLENE JHANNE C. CABIGON
JABEL VOLTAIRE GODWELL G. JARAMILLO
MICHAEL T. TIMKANG
ANDRE EARL B. WABAN

NOVEMBER 20, 2015

Introduction
Corrugated bars or rods are used to form the
basic frame of a building.
Reinforcements are used to resist shear and
diagonal tension stresses in a concrete
constructional member
Reinforcements in the form of rectangular
shaped bars are the integral part of columns and
beams in the construction.

Statement of the Problem

In the present times, these reinforcement bars are
made with bare hands manually in small
construction sites in the Philippines; this manual
making process causes lack of uniformity, low
productivity and fatigue for the one making them.

Significance of the Study

The study will be conducted to attain solution on the
problems encountered upon producing the manually
reinforced bars.

Objectives of the Study

Design a steel bar bending machine powered by an
electric motor with the use of gear drives and shafts;
Design and fabricate a machine that will produce a
rectangular stirrup having a dimension of 25 cm x 30
cm out of a 1 in. rod;
Design and fabricate circular reinforcing bars with a
diameter of 30 cm out of a 1 in. rod; and
Assess the performance of the designed steel rod bar
bending machine in terms of productivity in comparison
with the manual-making process.

Scope and Limitations

The study would include making a rectangular stirrup
having a dimension of 25 cm x 30 cm and a circular
stirrup having a diameter of 30 cm. The maximum
diameter of the rod is 1 in. for all dimensions.

Conceptual Framework
Gear Drives
Spur Gears
Belts and Chains
Research Design

Design of the Steel Rod Bending Machine

8
7

5
9

4
2

(a) Machine main parts with

label

Design of the Steel Rod Bending

Machine

(b) Trimetric view

of the bending
machine

(c) Top
view

Design of the Steel Rod Bending

Machine

(d)
Attachments

(e) Side
view

Design Calculation
Calculation of the Maximum Bending Force

So,

Finally,

 Bender and Post

Where,
and
So,
Thus,

Calculation of Power

Typical Power Transmission

Efficiencies

Machine

V-belt Drives
Timing Belt Drives
Poly-V or Ribbed Belt Drives
Flat Belt drives, Leather or Rubber
Nylon Core
Variable Speed, spring loaded, wide range
V-belt Drives
Compound drive
Cam-reaction drive
Helical Gear Reducer
Single-stage
Two-stage
Worm Gear Reducer
10:1 ratio
60:1 ratio
Roller Chain
Leadscrew, 60 deg helix angle
Flexible Coupling, shear-type
Spur gear

Typical Efficiency
95%
98%
97%
98%
98% to 99%

80% to 90%
75% to 90%
95%

98%
96%

86%
82%
98%
65% to 85%
99%+
94% to 98%

 Power of pulley no. 2 with reducer ratio of 1:30 and

spur gear ratio of 1:2
Where,
and
So,


= 3.73 hp
Thus,
= 4.642 hp

 Power at pulley no. 1 is equal to the power transmitted

by the motor.
To get the power transmitted in pulley no. 1,
where,
Efficiency of V-belt = 95%

Shafts design
The
Design Factor is taken to be N=2
Designed Stresses, page 160 (Mott, 1999)

So,

and

Computing
for the torque in the shaft,

The torque of the shaft is equal to the torque of the rod to be bent;

Thus,

Solving for Moment, M

Where the rectangular section modulus S

And from equation 12-21, page 488 (Mott, 1999),

Then the polar section modulus,


and section modulus is,

Then,

Thus,

from equation 12-24, page 489 (Mott, R.L, 1999),

where, =1.5 (well rounded fillet)

From Chapter 14 of the book of Gupta and Khurmi (2005),

page 531, the standard size of transmission shaft starts
from 25 mm.
Then the shaft diameter is considered to be,

 Design
of Pulley and Belt

The design of the pulley and belt is adopted from Machine Elements in
Mechanical Design, 3rd Edition by Robert L. Mott, 1999.
P = 5hp
From Table 7-1 V-belt Service factors, page 235
Service factor = for less than 6 = 1.1
(Desired rpm for 2:3 pitch ratio, Nominal output speed)

Solution:
1. Design Power = input power based on the available standard motor output
service factor
= 5hp 1.1 = 5.5 hp
2. For 5.5 hp and 1720 rpm
From Figure 7-9, page235; a 3VX belt is recommended

3.
Speed Ratio (SR)
= = 1.5
4. Guide for selecting standard sheave, use belt speed of 4000
Vb = belt speed = ; = = = 8.88 in
5. Trial and error for selecting input sheave and output sheave
= = 8.88 in (1.5) = 13.32 in.
For selecting standard sheave sizes;
From Figure 7-10, Power Rating for 3V Belts, page 236
= 7.95 in
= 13.95 in
= ; =(=(
= 980.21 rpm < 1146.67 rpm (NOT DESIRABLE)

= 5.55 in
= 5.55in.(1.5) = 8.325 7.95 in for standard size
= ( = ( = 1200.75 rpm > 1146.67 rpm (APPLICABLE)

6. Rated Power
From figure 7-10, page 236. For a 5.55 in sheave at 1720 rpm
= = 1 belt
1 belt is required, 1 groove
7. Trial center distance
< C < 3()
< C < 40.5
For conserving space, try 12 in.

8.
Required Belt Length
L = 2C + 1.57 () +
= 2(12) + 1.57 (7.95 + 5.55) +
L = 45.315 in.
9. Standard Belt Length and Center Distance
From Table 7-2, page 238
Standard Belt Length = 45.315 47.5 in
B = 4L 6.28 ()
B = 4(47.5) 6.28 (7.95 + 5.55)
B = 105.22
C= =
C = 13.09 13.1 in.


10. Angle wrap of the belt

11. Correction Factors for angle of wrap and Belt length

For from Figure 7-14 and L = 47.5 in. from Figure 7-15, page 238
And L = 47.5 in. from Figure 7-15
12. Corrected Rated Power per Belt

13. Corrected number of belts

Table
Oscillating

The dimension of the rotating table is based on the length of the

rocker and the diameter of the post. Thus:
Oscillating Table Diameter,
Oscillating Rotating Table Thickness,
Frame
The dimensions of the frame is taken to be,
Frame Thickness,
Frame Length, 60 cm
Frame Width, = 50 cm
Frame Height, = 82

Summary of the Computed Values

MATERIALS

SPECIFICATIONS

SYMBOL

UNIT

CALCULATED
VALUES

STANDARD
VALUES

Motor

Power Rating

Hp

4.866

Pulley 1

Diameter

In

5.55

5.55

Pulley 2

Diameter

In

8.325

7.95

Belt

Belt Length

in

45.315

47.5

Reducer

Speed Ratio

SR

1:30

Bender

Bender Diameter

mm

1.70

25.4

Post

Post Diameter

mm

1.70

25.4

Oscillating
Table

Rotating Table
Diameter

cm

20.32

20.32

Rotating Table
Thickness

cm

2.54

2.54

Thickness

cm

0.635

0.635

Length

cm

60

60

Width

cm

50

50

Height

cm

82

82

Frame

METHODOLOGY

The steps to be employed in the conduct of the study are presented in Figure 4.1

Data Gathering
Material Selection
Fabrication and Installation

Process Description
Performance testing
Figure 4.1

REFERENCES
AMONKAR, S., NAIK, V., CHOUGALE, S., ANAVKAR, S., PRABHAVALKAR, M., (2015).
Design and Development Stirrup Making Machine, IJRTS, Volume 2, Issue 5. India.
AWANCHAT, P.N., DASTGEER, G., GOHITE, A., (2015). Design and Analysis of ReBar Machine, IJIRSET, Volume 2, Issue 4. India.
DOUGHTIE V.L., JAMES W.H. (1954). Elements of Mechanism, John Wiley and Sons Inc.
New Jersey.
HANOOF M., VISHWANTH R., SURESHKUMAR P., SARAVANAN N. (2014). Design and
Fabrication of Hydraulic Rod Bending Machine, IJIRSET, Volume 3, Special Issue 2.

India.

PADOLE P. M., VANALKAR A.V. (2001). Optimal Design of Mechanism for Stirrup Making
Machine- A Computer Approach. India.
PYTEL, A. AND SINGER, F. (1987). Strength of Materials, HarperCollins Publishers Inc., 4 th
Edition. New York.
ROBERT L. MOTT. (1999). Machine Elements in Mechanical Design, 3 rd Edition, PrenticeHall Inc., Inc. New Jersey.
SHETH S., TAMBOLI K., VEKARIYA J., VIRANI M. (2013). Design and Development of
Automatic Stirrup Bending Mechanism, INACOMM. India.
VANALKAR A.V. , et. al. (1999). Design Development and Fabrication of Stirrup Making
Machine, Proceeding, 9th National Conference on Machines and Mechanisms, NACOMM
1999, I. I. T. , Powai, Mumbai, India.

Budgetary Requirement

Quantity

Material

Estimated
Price

Electric Motor 5 Hp

12,000 Php

Flange Bearing

800 Php

Ball Bearing

900 Php

Pulley (7.95 in. and 5.55 in)

500 Php

Pedal Switch

200 Php

Electrical Wire

250 Php

Circuit Breaker

500 Php

30

Bolts

750 Php

Overload

1000 Php

Contactor

2000 Php

2
1
1
1

10

Limit Switch
Shaft
1 x 2 ft. Steel Plate
1:30 Reducer
Machining
Angle Bar
Gear oil
V-belt (groove)
Tools
1 in Steel Rod
Cutting Disc
Belt, Paint, Brush
Fabrication Cost and Labor
Gear Fabrication
Hacksaw Blade
Others (Transportation, Food, Canvassing,
Printing, etc)

1500 Php
1000 Php
1800 Php
5000 Php
1000 Php
5000 Php
210 Php
1000 Php
290 Php
2500 Php
40 Php
300 Php
15000 Php
6900 Php
750 Php
10, 000 Php