AUTOMATIC STIRRUP BENDING

MACHINE

GUIDED BY
Mr. A R ABELIN ROY
Assistant Professor
Department Of Mechanical Engineering
Team Members

1. Prince V

2. Rishi Mohan

3. Nikhil Chandran

4. Karan Ranjit

5. Sujith S Nair
 ABSTRACT

In various fabrication works as well as in construction works steel bars are

used in various shapes depending on type of use.

To bend these bars into various forms is not easy thing to be done manually.
This project is about fabrication of a machine that can be used for bending
of bars which are used for construction purposes.

The project is to design and construct an automatic bending machine. This

machine can be used to bend bars of various diameters.

By using all this equipment, process of bending can be made faster and
easier. This would reduce the cost in labour to a great extent.
INTRODUCTION
As increases population day by day, demand of construction
for built the building for living, industries, overhead bridges is
continuously increases.

Several problems come in to the picture when we consider

human power with respect to automatic mechanism.

Stirrup is nothing but a square, rectangular or trapezoidal

shaped rod which is tied with the structural rod together at
specific distance for strength improvement purpose.
Relevance of the project

The stirrup bending machine can reduce the

labour cost in construction sites on stirrups.

It can increase the speed of construction.

It can not only be used for bending stirrups but

can also be used to bars of various shapes.

Can be used for creating stirrups on large scale

production which are created on standard sizes.
Phase one

Concept Development
Study and Reference
Journal Presentation
Design Calculations
CAD GENERATED MODEL

Considerations made in the design

The calculation and selection for the model is done based on 6 mm and 8
mm stirrups.

The TMT bars agrees with the theory of simple bending.

The yield stress and ultimate stress of 6mm TMT bars averaged to be 690
N/ and 732N/ respectively

The yield stress and ultimate stress of 8mm TMT bars averaged to be 678
N/ and 722N/ respectively.

The material used in the making of gear is mild steel by considering the
endurance stress equal to half the ultimate stress.

To get maximum torque, the rpm is reduced to a value of 20rpm

Calculation of force required to bend 6mm bar

= 690 N/
= 732N/
=, where
,,

P = 332.5N
Calculation of force for 8mm bar

= 678 N/
= 722N/
=, where
,,

P = 774.5N

Torque Calculation

The total force required may be approximated to a value of 800N for both 6mm
and 8mm bars

Therefore the torque is given by force* perpendicular distance

The perpendicular distance is = 6cm= 6*m

Therefore the torque is 800* 6*= 48Nm

Power calculation of the motor required

Torque( Nm) =

We got the torque required as = 48Nm

The rotational speed of the motor is 20rpm

48=
Power in watts = 100watts = .1348 HP
Need of speed reduction

As mentioned in the design considerations, the

torque has to be increased at the expense of rpm.

The motors available in market offers a speed of

1440 rpm.

So speed reduction can be achieved using reduction

gears.

Here we use three sets of gears for speed reduction-

two pairs of spur and a pair of bevel gear
 First pair of spur gear

Pinion Gear
Module is taken as 2 Module is taken as 2

Number of teeth is taken as 25

Number of teeth may be taken as 75
Therefore the pitch circle diameter is 50mm
Therefore the pitch circle diameter required is
150mm Addendum circle diameter is 52mm

Addendum circle diameter is 152mm Dedendum circle diameter is 47mm

Dedendum circle diameter is 147mm

, n1=1440rpm
Therefore n2=480 rpm
 Second pair of spur gear

Pinion Gear
Module is taken as 2 Module is taken as 2

Number of teeth is taken as 25

Number of teeth may be taken as 75
Therefore the pitch circle diameter is 50mm
Therefore the pitch circle diameter required is
150mm Addendum circle diameter is 52mm

Addendum circle diameter is 152mm Dedendum circle diameter is 47mm

Dedendum circle diameter is 147mm

, n1=480rpm
Therefore n2=160rpm
 Pair of bevel gear

Pinion Gear
Module is taken as 2 Module is taken as 2

Number of teeth is taken as 25

Number of teeth may be taken as 18

Tan1= 1.8 Tan2= 1/1.8

Therefore the pitch circle diameter required is Therefore the pitch circle diameter is 58mm
32mm

, n1=160rpm
Therefore n2=88rpm
 The final rpm achieved is around 88rpm.

The rpm available after all the losses may be

approximately around 50rpm.

By controlling the voltage input to the motor we can

achieve an rpm equal to 20rpm.

So for the ease of controlling voltage and the availability

of power supply we are going for a single phase ac motor.
Work progress

The 3d model of the machine is created.

The components are available after fabrication.

The frame to hold the components is completed.

The feed mechanism and its programing need to be completed.

The project is estimated to be completed by 15/03/2017

Thank You