This document describes the design and construction of a hydraulic pipe bending machine. The machine aims to address common problems with manually operated pipe bending systems, which require tremendous human effort, have high labor costs, and can result in defects. The hydraulic pipe bending machine uses a hydraulic jack to generate large bending forces with minimal human effort. It consists of a base frame, mounting points for pulleys of various diameters, a hydraulic jack between the pulleys, and retraction springs. Pipes are inserted between the pulleys and bent into the desired shape when the hydraulic jack handle is operated. The machine allows for safe and damage-free bending of pipes for applications in automotive, agriculture, and other industries.

1. Department of Mechanical Engineering
RKGIT , GHAZIABAD
Under the supervision of Mr. Ved prakash
By:
Sumit Sahgal
Sujeet Singh
Anmol Kumar
Vibhanshu kr. Tripathi
FABRICATION OF HYDRAULIC
BENDING MACHINE

2. INTRODUCTION
My project is to design and construct a bending machine.
This machine is used to bend steel into curve or other
curvature shape. The size of the machine is very convenient
for portable work. It is fully made by steel. Moreover it is
easy to be carried and used at any time and any place.
In various fabrication works as well as
in architectural work pipes are used in artistic ways. To bend
these pipes into these artistic forms is not easy thing to be
done manually. Using a particular machine specially
developed for bending of pipes helps.

3. CURRENT SCENARIO OF PIPE
BENDING MACHINE
Various type of pipe bending machines are used for
pipe bending. Majority of the machines are manually
operated and operating force is magnified using
mechanical advantage from an appropriate lever
system.

4. COMMON PROBLEMS WITH THESE
SYSTEMS
• Tremendous amount of human effort is
necessary.
• Labor cost is more.
• Time consuming in terms of setting of operation
setup.
• Defects in the form of angular deformation and
wrinkles are seen and quality is not good.

5. SOLUTION IS HYDRAULIC PIPE
BENDING MACHINE
• The bending force is generated is quite large
with a minimum human effort.
• Loading is done by operating handle of the
jack which carries the bending action
resulting into a safe and damage free
bending operation.

6. DESIGN
Design consists of application of scientific
principles, technical information, imagination for
development of new and improved machine or
mechanism to perform specific function with
maximum economy and accuracy. It consists of
two parts
1. System Design
2. Mechanical design

7. System Design
 System selection based on physical constraints.
 Arrangement of various component.
 Man machine interaction.
 Servicing facility.
 Height of machine.
 Weight of machine.
Mechanical Design
 Fabricated parts.
 Parts to be purchased.

8. WORKING PRINCIPLE
The Hydraulic Jack is a device used for lifting heavy loads by the
application of much smaller force. It is based on the Pascal’s law,
which states that intensity of pressure is transmitted equally in all
directions through a mass of fluid at rest.
The working principle of a hydraulic jack may be explained
with the help of Fig. shown below. Consider a ram and plunger,
operating in two cylinders of different diameters, which are
interconnected at the bottom, through a chamber, which is filled with
some liquid.

9. WORKING
The pipe is inserted between the pulleys and the Hydraulic jack
pulley as shown in figure. The Bending Force is applied with
hydraulic Jack when the handle is operated. Thus pipe is bent.
For desired diameter of bending curve the pulleys are changed or
altered.

10. CONSTRUCTION DETAILS OF PIPE BENDING
MACHINE
In the constructional part of the project work, a base
frame structure is fabricated using Mild Steel bars.
 Frame : A flat platform is formed on the top of this base
structure. On this platform two mounting points are fixed. These
mounting points are kept very robust in nature as they have to
withstand huge lateral forces during working of the device. Set of
combination of two numbers of affix able meshing pulleys of
various diameters are fabricated or machined.
 Supporting Pulley: The peripheral cross sectional area of
pulleys in pairs in any set is kept same either semicircular or half
square depending on the pipe to be bent like circular or square
cross section. Other pipes can also be bent but for that special
pulleys have to be made.

11.  Hydraulic Jack: Hydraulic jack with Semi Circular pulley as
shown in figure is fixed on the frame in between two pulleys
and below it by calculating working distance . Provision for
Adjustment of jack should be there to achieve any type of
shapes and curvature.
 Springs: Quick retraction springs are attached to hydraulic
jack upper end for easy and fast retraction of jack shaft.
Springs should be designated in such way that it will not add
more pressure or force for upper movement of the hydraulic
jack.
 Hydraulic Jack: Hydraulic jack with Semi Circular pulley as
shown in figure is fixed on the frame in between two pulleys
and below it by calculating working distance . Provision for
Adjustment of jack should be there to achieve any type of
shapes and curvature.
 Springs: Quick retraction springs are attached to hydraulic
jack upper end for easy and fast retraction of jack shaft.
Springs should be designated in such way that it will not add
more pressure or force for upper movement of the hydraulic
jack.

12. APPLICATIONS
 Used in automobile industry.
 Agricultural work components fabrication.
 Gym equipment's.
 Boat and swimming pool furnishings.
 Exhausts.
 Handles.
 Road signs and posters.
 Fuel pipes for diesel engines.

13. ADVANTAGES
• Hydraulic ram force reduces human effort in operation.
• Portable.
• Simple construction.
• Low cost.
• Less needs for maintenance.
• No extra skill is required for operating this system.

14. THANK
YOU