1. Joseph Stynes
X00105837
Project supervisor
Tom Healy

2. 1/ The rollers are positioned in a pyramid configuration
2/ The top roller is vertically adjustable
3/ Two bottom feed rollers rotate in the same direction
Feed rollers
Top feed roller
Material being rolled

3.  Original concept sketch for pyramid type slip rolls

5. Four phases of manufacture
1/ Cutting of all materials to specified dimensions
2/ Machining all components to specified dimensions
3/ Fabrication and Welding
4/ Assembly

9. Testing criteria
1/ Testing of a range of different materials
2/ Testing of a range of different thicknesses of materials
3/ Theoretical testing of machine using the formulae for simple
bending theory
4/ Practical testing of machine using a range different materials in
various thicknesses
5/ Establishing whether the theoretical testing is validated by the
practical testing
6/ Record and tabulate practical testing results

10. Mild steel
b = 0.5m / d = 0.003m / y = 0.0015m / Yield (σ) = 210mPa
I =
𝒃𝒙𝒅 𝟑
𝟏𝟐
𝒔𝒐 𝑰 =
(𝟎.𝟓𝒎)𝒙(𝟎.𝟎𝟎𝟑) 𝟑
𝟏𝟐
𝒔𝒐 𝑰 = 𝟏𝟏𝟐𝟓 𝒙 𝟏𝟎−𝟏𝟐
𝒎 𝟒
𝝈
𝒀
=
𝑴
𝑰
so M =
𝝈
𝒀
𝒙 𝑰 𝒔𝒐 𝑴 =
𝟐𝟏𝟎 𝒙 𝟏𝟎 𝟔 𝑵𝒎
𝟎.𝟎𝟎𝟏𝟓 𝒎
𝒙 𝟏𝟏𝟐𝟓 𝒙 𝟏𝟎−𝟏𝟐
𝒎 𝟒
Therefore M = 157.5 Nm
M =
𝑭
𝟐
𝒙 𝟎. 𝟎𝟒𝒎 so M = 0.02F so F =
𝑴
𝟎.𝟎𝟐
so F =
𝟏𝟓𝟕.𝟓 𝑵𝒎
𝟎.𝟎𝟐 𝒎
Therefore F = 7875 N

11. TABLE OF RESULTS FOR THE TESTING OF THE FUNCTIONAL LIMITS OF PYRAMID TYPE SLIP ROLLS
TESTS MATERIAL b (m) d (m) Y (m)
FEED ROLLER CENTRES
(m)
POINT OF MAXIMUM BENDING
(m) S.M.O.A I (m^4) YIELD STRENGTH σ (Pa)
MAXIMUM BENDING MOMENT
(Nm) FORCE (N) STATUS
TEST 1 STEEL 0.5 0.001 0.0005 0.08 0.04 4.16667E-11 2.10E+08 17.5 875 PASS
TEST 2 STEEL 0.5 0.002 0.001 0.08 0.04 3.33333E-10 2.10E+08 70 3500 PASS
TEST 3 STEEL 0.5 0.003 0.0015 0.08 0.04 1.125E-09 2.10E+08 157.5 7875 PASS
TEST 4 STEEL 0.2 0.004 0.002 0.08 0.04 1.06667E-09 2.10E+08 112 5600 PASS
TEST 5 ALUMINIUM 0.15 0.002 0.001 0.08 0.04 1E-10 1.25E+08 12.5 625 PASS
TEST 6 ALUMINIUM 0.1 0.002 0.001 0.08 0.04 6.66667E-11 1.25E+08 8.33E+00 416.667 PASS
TEST 7 COPPER 0.1 0.006 0.003 0.08 0.04 1.8E-09 2.68E+08 160.8 8040
PASS (AT
LIMITS)

13. MANUFACTURING PLAN FOR PYRAMID TYPE THREE ROLL SLIP ROLLS
COMPONENT MANUFACTURING PROCESSES TIME TAKEN (Hours) WEEK STATUS
RHS BASE FRAME CUTTING, DRILLING, WELDING 2 14 Completed
THREADED INSERTS FOR RHS FRAME CUTTING, DRILLING, TAPPING, WELDING 2 14 Completed
IDLE END PLATE CUTTING, DRILLING, TAPPING, MILLING 12 15 Completed
GEAR END PLATE CUTTING, DRILLING, TAPPING, MILLING 12 16 Completed
TOP ROLLER CUTTING, TURNING, 4 16 Completed
BOTTOM FRONT FEED ROLLER CUTTING, TURNING, MILLING 6 17 Completed
BOTTOM BACK FEED ROLLER CUTTING, TURNING, MILLING 6 17 Completed
GEAR KEYS FOR BOTTOM FEED ROLLERS CUTTING, MILLING, FILING 4 17 Completed
INTERMEDIATE GEAR SHAFT CUTTING, TURNING, MILLING 2 18 Completed
INTERMEDIATE GEAR SHAFT KEY CUTTING, MILLING, FILING 1 18 Completed
BRASS TOP ROLLER GUIDES CUTTING, DRILLING, FILING, MILLING 6 18 Completed
BOTTOM LOCKING BLOCKS CUTTING, DRILLING, COUNTERSINKING 4 18 Completed
TOP LOCKING BLOCKS CUTTING, DRILLING, COUNTERBORING 4 18 Completed
THREADED ROUND SCREWJACK GUIDE CUTTING, DRILLING, TAPPING, WELDING 2 19 Completed
SCREWJACK TURNING HANDLES CUTTING, WELDING 2 19 Completed
SCREWJACK TURNING HANDLE BODIES CUTTING, DRILLING, TAPPING, WELDING 2 19 Completed
RETAINING RING FOR BRASS GUIDES CUTTING, DRILLING, WELDING 2 19 Completed
THREADED ROD CUTTING 1 19 Completed
CRANKING HANDLE CUTTING, DRILLING, WELDING 2 19 Completed
CRANKING HANDLE BOSS CUTTING, DRILLING, FILING,WELDING 2 19 Completed
PRESSING BEARINGS HYDRAULIC PRESSING 1 19 Completed
ASSEMBLY ASSEMBLING OF COMPONENTS AND TORQUEING OF BOLTS 4 20 Completed
TESTING OF FINISHED MACHINE TESTING THE THEORETICAL ABILITIES OF THE MACHINE 6 21 Completed
TESTING OF FINISHED MACHINE TESTING THE THEORETICAL ABILITIES OF THE MACHINE 6 22 Completed

15. Any questions ???