Introduction

Preface

Our capstone project is Metal Bender and team members involved in this work are Amal Thomas, Britto Thomas, and Sachu Kuriakose. We would like to thank all of those who supported and helped us in the design and execution of this project, without their valuable input we could have made mistakes but their comments made us better. Deven Taylor our technical adviser was there to clear machining doubts. Prof. Martin volkening for his guidance and steps to be followed to complete this project.Prof. Henry Hegger has helped throughout this semester by effective feedback and group meetings.Prof.Ed Hawkeswood for his effort to developing communication skills and building coordination among us.

Purpose of Report

This report intends to describe the whole of this capstone project. It contains a detailed description of the project design and parts used. Project Methodology included for review in detail the entire process that the team followed to do this project specifying project phases and milestones. The report has also included the project management section to discuss the project schedule and cost with respect to original plans submitted with scope statements and other documents.furthermore a section added to describe the lessons and knowledge we have learned throughout this project.

Abstract

Metal Bender is an affordable and useful device with less cost providing maximum efficiency in working and can be easily carried to different locations without effort.

The device can be used to bend a metal rod or sheet up to 360 degrees. Manual operation by hand makes it user friendly. The body of the device was planned to make with Aluminium as base metal so that it can be machined easily and precisely. Roller mechanism has used for effective bending and getting accurate results. Solidworks software had used in the design phase.

The report provides details about each phase of the project, technical sides, and project management that we used. But due to COVID-19 our planning and budget were affected. Booked machine labs were closed and deliverables in the scope statement were unable to complete. At starting project was on schedule but unfortunate conditions made it fell behind. Machining and presentation of the project were canceled and a design evaluation conducted to calculate how many minutes needed to make the part and how much material going to use for it. Thus cost was calculated using the shop rate for the machines.

Project Description

The machine consists of simple design and works manually makes it easy to use. Bearings rotating in horizontal spacing and roller in the vertical axis performs the bending. Furthermore, the machine body is made up of aluminum provides great strength and quality to the work. Metal pieces of different dimensions and shapes are joined by Allen key bolts provides a secure design. Roller attached to the screw arrangement transfers bending force against the bar or rod needs to be bent and which is operated by manually. Workpieces have held the top of the two roller bearings arranged in parallel and as the roller touches the workpiece worker starts to rotate the handle attached to the roller. The forward motion of bearings and bending force from vertical roller causes the metal bar to undergo plastic and elastic deformation. Thus we can make a bent part up to 360 degrees.

Technical problems: Spring back can be occurred, because as bent pressure is removed from the workpiece elastic energy remains in the bent part and causing it to come back partially into original shape. It can result in a decrease in bend angle and an increase in bend radius