AUTOMATIC SPRING ROLLING MACHINE

ABSTRACT

In spring working industry a wide range of power and hand operated

machines are used. As the industry is a large and growing industry different type
of machines are used for different operations. Our project the spring rolling
machine is very simple in operation by using spur gear arrangement which is
coupled with motor. This machine produces round spring of different diameters
and length. This machine can be used in various fields. This machine consist of
flywheel which is coupled with a motor by belt and the cylindrical tool shaft is
directly connect to the flywheel shaft. This machine is simple in construction and
working principle.
 CHAPTER 1

INTRODUCTION

A spring is a device that changes its shape in response to an external force,

returning to its original shape when the force is removed. The energy expended
in deforming the spring is stored in it and can be recovered when the spring
returns to its original shape. The amount of deformation is directly proportional
to force exerted. Spring rolling industry is a large and growing industry. There
are many special purpose machines used in this industry to-day. The proper
selection of the machines depends upon the type of the work under –taken by the
particular industry. There are many examples of spring rolling work include iron,
copper, tin, aluminum, stainless and brass. This project the “SPRING ROLLING
MACHINE” finds huge application in all spring rolling industry. Rolling is the
process of bending metal wire to a curved form. The article in the shape of round
is made by spring roller shaft. Rolling operation can be done on hand or power
operated rolling machine. In forming round spring shapes a gradual curve is to be
put in the metal rather than sharp bends. The gap between the springs can be
regulated by proper arrangement. Spring is elastic bodies (generally metal) that
can be twisted, pulled or stretched by some force.

They can Return to their original shape when the force is released. In other
words it is also termed as a resilient member. A spring is defined as an elastic
machine element, which deflects under the action of the load & returns to its
original shape when the loadsimple mechanism arrangement for the production
of closed and open coil helical springs. The specific characteristics being variable
spring diameters, variable spring coil diameters of various materials by manual
rolling process. The scope of this project is the application of this “MANUAL
SPRING ROLLING MACHINE” in small scale industries for the production of
open and closed helical springs of varying spring coil diameters and varying
spring diameter, without much expense in a small scale level. The importance of
this study was that to know about the different springs that are used in many
automobile parts and other mechanisms, and the crucial role that they play in
different mechanisms. The spring machine is made by a very simple
arrangement. This machine is operated by manual method. This machine
produces closed coil helical spring of different diameter and different length. In
our project is the spring rolling machine. Rolling is the process of bending metal
wire to a curved form.

Our project the “SPRING ROLLING MACHINE” finds huge application

in all spring rolling industry. Rolling is the process of bending metal wire to a
curved form. The article in the shape of round is made by spring roller shaft.
Rolling operation can be done on hand or power operated rolling machines. In
forming round spring shapes a gradual curve is to be put in the metal rather than
sharp bends. The gap between the springs can be regulated by proper
arrangement.
 CHAPTER 2

LITERATURE SURVEY

Ahmed Ktari:-In his paper he has done Modeling and computation of the
three-roller bending process of steel sheets. This experiment consists of two-
dimensional finite element model of this process was built under the Abaqus
/Explicit environment based on the solution of several key techniques, such as
contact boundary condition treatment, material property definition, meshing
technique, and so on.

Jong GyeShin:-In their paper he has done the experiment on Mechanics-

Based Determination of the Center Roller Displacement in Three-Roll Bending
for Smoothly Curved Rectangular Plates. The objective of this paper is to
develop a logical procedure to determine the center roller displacement, in the
three-roll bending process, which is required in the fabrication of curved
rectangular plates with a desired curvature.

M K Chudasama:-In their paper he has done the experiment on Analytical

Model for Prediction of Force during 3-RollerMulti-pass Conica Bending. In this
paper, the total deflection of the top roller required is divided in steps to get the
multi pass bending.

M. B. Bassett, and W. Johnson :-In their paper, The bending of plate using
a three roll pyramid type plate bending machine, J. strain Analysis Process
manual, maintenance manual, machine capacity chart and technical specification
of rolling machine, M/s Larsen& Toubro ltd, Hazira, Surat, India.

Dr. C. C. Handaet. al :-This paper gives a review and Discussed about the
productivity analysis of manually and power operated sheet bending machine
considering time required to complete one pipe, total expenditure required to
manufacture one pipe, number of operators and labors required during both
operations, etc. Limitations of the manually operated sheet bending process over
power operated sheet bending machine is also discussed.

P.G. Mehar:- In his M. Tech Thesis studied the manually operated and
power operated sheet bending machine. Experimentations were conducted on
sheet in order to measure actual no. of passes, time required to complete bending
process etc. Also, productivity of sheet bending process is analyzed in depth.
Design of various components of power operated sheet bending machine
considering various theories of failure in elastic region and values for bending
force, power required, spring back radius etc. for different diameters, thicknesses
and width of sheet metal has been determined.
 CHAPTER 3

BLOCK DIAGRAM
 CHAPTER 3

PURPOSE OF THE PROJECT

Coil springs are a spiral thick metal wire that is made of steel. Used in a
car’s suspension system to hold the weight, keep the ride height and control the
ride of the vehicle.

There are many factors as to why coil springs are replaced. Some are by
choice and other because they need replacing. Below are some of the reasons coil
springs are replaced.

Sagging

Coil springs support a car’s body; over time coil springs will weaken and
sag causing the ride height to lower. As the coilsprings sag, on side of the car
may be lower than the other and case the car to tilt.

Tyrewear

While stabilising the car’s body, coil springs and shocks keep a car’s tyres
firmly on the ground, keeping the axles at the correct angles. Warn coil springs
and shocks can misalign tyres and/or track abnormally, causing early tyre wear.
Noise

When a car is driven over large bumps, pot holes and/or around tight
corners if a noise occurs, this often is a sign of worn coil springs and/or shock
absorbers.

Bounce

When driving if you car is bouncing or feels like you’re in a boat, you
need to replace your coil springs and/or shock absorbers.

Swaying
Coil springs and shocks work together to keep a car centered and stabilized while
going around tight corner. Worn coil springs and shock absorbers loose their
stabilising capabilities and cause a car to sway excessively.

Height

By replacing the coil springs you can choose the ride height. There is
typically three options for most cars these being:
* Standard height

Restore the car to its formal ride height

* Lowered height

There are options of 20mm to 60mm lower than original height. When
lowering a car remembers the car will be closer to the road, tyres and suspension
bump stops. Depending on how lowered you choose, you may also need to
replace your shock absorbers.

* Raised height

Options are 20mm to 50mm raised above original height of the car. Why
raise the ride height? For many reasons for example towing, LPG tank, 4WDing,
load carrying and for increased ground clearance.
 CHAPTER 4

SPRING

Spring is an elastic object used to store mechanical energy. Springs are

usually made out of spring steel. Small springs can be wound from pre-hardened
stock, while larger ones are made from annealed steel and hardened after
fabrication. Some non-ferrous metals are also used including phosphor bronze
and titanium for parts requiring corrosion resistance and beryllium copper for
springs carrying electrical current (because of its low electrical resistance).

When a spring is compressed or stretched, the force it exerts is

proportional to its change in length. The rate or spring constant of a spring is the
change in the force it exerts, divided by the change in deflection of the spring.
That is, it is the gradient of the force versus deflection curve. An extension or
compression spring has units of force divided by distance, for example lbf/in or
N/m. Torsion springs have units of force multiplied by distance divided by angle,
such as N·m/rad or ft·lbf/degree. The inverse of spring rate is compliance, that is:
if a spring has a rate of 10 N/mm, it has a compliance of 0.1 mm/N. The stiffness
(or rate) of springs in parallel is additive, as is the compliance of springs in
series.

Depending on the design and required operating environment, any material

can be used to construct a spring, so long as the material has the required
combination of rigidity and elasticity: technically, a wooden bow is a form of
spring.

Springs can be classified depending on how the load force is applied to

them:

• Tension/Extension spring – the spring is designed to operate with a

tension load, so the spring stretches as the load is applied to it.
• Compression spring – is designed to operate with a compression load,
so the spring gets shorter as the load is applied to it.
• Torsion spring – unlike the above types in which the load is an axial
force, the load applied to a torsion spring is a torque or twisting force,
and the end of the spring rotates through an angle as the load is applied.
• Constant spring - supported load will remain the same throughout
deflection cycle
• Variable spring - resistance of the coil to load varies during
compression

They can also be classified based on their shape:

• Coil spring – this type is made of a coil or helix of wire

• Flat spring – this type is made of a flat or conical shaped piece of
metal.
• Machined spring - this type of spring is manufactured by machining bar
stock with a lathe and/or milling operation rather than coiling wire.
Since it is machined, the spring may incorporate features in addition to
 the elastic element. Machined springs can be made in the typical load
cases of compression/extension, torsion, etc.

3.2 Types of Spring

• Cantilever spring – a spring which is fixed only at one end.

• Coil spring or helical spring – a spring (made by winding a wire around
a cylinder) and the conical spring – these are types of torsion spring,
because the wire itself is twisted when the spring is compressed or
stretched. These are in turn of two types:
• Compression springsare designed to become shorter when loaded.
Their turns (loops) are not touching in the unloaded position, and they
need no attachment points.
• A volute spring is a compression spring in the form of a cone, designed
so that under compression the coils are not forced against each other,
thus permitting longer travel.
• Tension or extension springsare designed to become longer under load.
Their turns (loops) are normally touching in the unloaded position, and
they have a hook, eye or some other means of attachment at each end.
• Hairspring or balance spring – a delicate spiral torsion spring used in
watches, galvanometers, and places where electricity must be carried to
partially rotating devices such as steering wheels without hindering the
rotation.
• Leaf spring – a flat spring used in vehicle suspensions, electrical
switches, and bows.
 • V-spring – used in antique firearm mechanisms such as the wheellock,
flintlock and percussion cap locks.

Other types include:

• Belleville washer or Belleville spring – a disc shaped spring commonly

used to apply tension to a bolt (and also in the initiation mechanism of
pressure-activated landmines).
• Constant-force spring — a tightly rolled ribbon that exerts a nearly
constant force as it is unrolled.
• Gas spring – a volume of gas which is compressed.
• Ideal Spring – the notional spring used in physics: it has no weight,
mass, or damping losses.
• Mainspring – a spiral ribbon shaped spring used as a power source in
watches, clocks, music boxes, windup toys, and mechanically powered
flashlights
• Negator spring – a thin metal band slightly concave in cross-section.
When coiled it adopts a flat cross-section but when unrolled it returns
to its former curve, thus producing a constant force throughout the
displacement and negating any tendency to re-wind. The commonest
application is the retracting steel tape rule.[7]
• Progressive rate coil springs – A coil spring with a variable rate,
usually achieved by having unequal pitch so that as the spring is
compressed one or more coils rests against its neighbour.
 • Rubber band – a tension spring where energy is stored by stretching the
material.
• Spring washer – used to apply a constant tensile force along the axis of
a fastener.
• Torsion spring – any spring designed to be twisted rather than
compressed or extended. Used in torsion bar vehicle suspension
systems.
• Wave spring – a thin spring-washer into which waves have been
pressed.

3.3 History

Simple non-coiled springs were used throughout human history e.g., the
bow (and arrow). In the Bronze Age more sophisticated spring devices were
used, as shown by the spread of tweezers in many cultures. Ctesibius of
Alexandria developed a method for making bronze with spring-like
characteristics by producing an alloy of bronze with an increased proportion of
tin, and then hardening it by hammering after it is cast.

Coiled springs appeared early in the 15th century, in door locks. The first
spring powered-clocks appeared in that century and evolved into the first large
watches by the 16th century.

In 1676 British physicist Robert Hooke discovered the principle behind

springs' action, that the force it exerts is proportional to its extension, now called
Hooke's law.
3.3.1 Types

Fig 3.1 A spiral torsion spring, or hairspring, in an alarm clock

3.2 Avolute spring. Under compression the coils slide over each other, so
affording longer travel
 Fig 3.3Vertical volute springs of Stuart tank

Fig 3.4 Tension springs in a folded line reverberation device

Fig 3.5 A torsion bar twisted under load

Fig 3.6 Leaf spring on a truck

Springs can be classified depending on how the load force is applied to them:

 Tension/Extension spring – the spring is designed to operate with a tension

load, so the spring stretches as the load is applied to it.

 Compression spring – is designed to operate with a compression load, so

the spring gets shorter as the load is applied to it.

They can also be classified based on their shape:

• Coil spring – this type is made of a coil or helix of wire

• Flat spring – this type is made of a flat or conical shaped piece of
metal.
• Machined spring - this type of spring is manufactured by machining bar
stock with a lathe and/or milling operation rather than coiling wire.
Since it is machined, the spring may incorporate features in addition to
the elastic element. Machined springs can be made in the typical load
cases of compression/extension, torsion, etc.

3.4The most common types of spring are:

• Cantilever spring – a spring which is fixed only at one end.

• Coil spring or helical spring – a spring (made by winding a wire around
a cylinder) and the conical spring – these are types of torsion spring,
because the wire itself is twisted when the spring is compressed or
stretched. These are in turn of two types:
 • Compression springsare designed to become shorter when loaded.
Their turns (loops) are not touching in the unloaded position, and they
need no attachment points.
• A volute spring is a compression spring in the form of a cone, designed
so that under compression the coils are not forced against each other,
thus permitting longer travel.
• Tension or extension springsare designed to become longer under load.
Their turns (loops) are normally touching in the unloaded position, and
they have a hook, eye or some other means of attachment at each end.
• Hairspring or balance spring – a delicate spiral torsion spring used in
watches, galvanometers, and places where electricity must be carried to
partially rotating devices such as steering wheels without hindering the
rotation.
• Leaf spring – a flat spring used in vehicle suspensions, electrical
switches, and bows.
• V-spring – used in antique firearm mechanisms such as the wheellock,
flintlock and percussion cap locks.

3.5 Other types include:

• Belleville washer or Belleville spring – a disc shaped spring commonly

used to apply tension to a bolt (and also in the initiation mechanism of
pressure-activated landmines).
• Constant-force spring — a tightly rolled ribbon that exerts a nearly
constant force as it is unrolled.
• Gas spring – a volume of gas which is compressed.
• Ideal Spring – the notional spring used in physics: it has no weight,
mass, or damping losses.
• Mainspring – a spiral ribbon shaped spring used as a power source in
watches, clocks, music boxes, windup toys, and mechanically powered
flashlights
• Negator spring – a thin metal band slightly concave in cross-section.
When coiled it adopts a flat cross-section but when unrolled it returns
to its former curve, thus producing a constant force throughout the
displacement and negating any tendency to re-wind. The commonest
application is the retracting steel tape rule.[7]
• Progressive rate coil springs – A coil spring with a variable rate,
usually achieved by having unequal pitch so that as the spring is
compressed one or more coils rests against its neighbour.
• Rubber band – a tension spring where energy is stored by stretching the
material.
• Spring washer – used to apply a constant tensile force along the axis of
a fastener.
• Torsion spring – any spring designed to be twisted rather than
compressed or extended. Used in torsion bar vehicle suspension
systems.
• Wave spring – a thin spring-washer into which waves have been
pressed.
3.6 Physics

3.6.1 Hooke's law

As long as they are not stretched or compressed beyond their elastic limit,
most springs obey Hooke's law, which states that the force with which the spring
pushes back is linearly proportional to the distance from its equilibrium length:

where

x is the displacement vector – the distance and direction the spring is

deformed from its equilibrium length.

F is the resulting force vector – the magnitude and direction of the

restoring force the spring exerts

k is the rate, spring constant or force constant of the spring, a constant

that depends on the spring's material and construction.

Coil springs and other common springs typically obey Hooke's law. There
are useful springs that don't: springs based on beam bending can for example
produce forces that vary nonlinearly with displacement.

3.6.2 Simple harmonic motion

Since force is equal to mass, m, times acceleration, a, the force equation

for a spring obeying Hooke's law looks like:
 Fig 3.7 Simple harmonic motion

The displacement, x, as a function of time. The amount of time that passes

between peaks is called the period.

The mass of the spring is assumed small in comparison to the mass of the
attached mass and is ignored. Since acceleration is simply the second derivative
of x with respect to time,

This is a second order linear differential equation for the displacement as

a function of time. Rearranging:
 the solution of which is the sum of a sine and cosine:

A and B are arbitrary constants that may be found by considering the

initial displacement and velocity of the mass. The graph of this function with
(zero initial position with some positive initial velocity) is displayed in the
image on the right.

3.7 Theory

In classical physics, a spring can be seen as a device that stores potential

energy, specifically elastic potential energy, by straining the bonds between the
atoms of an elastic material.

Hooke's law of elasticity states that the extension of an elastic rod (its
distended length minus its relaxed length) is linearly proportional to its tension,
the force used to stretch it. Similarly, the contraction (negative extension) is
proportional to the compression (negative tension).

This law actually holds only approximately, and only when the
deformation (extension or contraction) is small compared to the rod's overall
length. For deformations beyond the elastic limit, atomic bonds get broken or
rearranged, and a spring may snap, buckle, or permanently deform. Many
materials have no clearly defined elastic limit, and Hooke's law can not be
meaningfully applied to these materials. Moreover, for the superelastic materials,
the linear relationship between force and displacement is appropriate only in the
low-strain region.

Hooke's law is a mathematical consequence of the fact that the potential

energy of the rod is a minimum when it has its relaxed length. Any smooth
function of one variable approximates a quadratic function when examined near
enough to its minimum point as a result of the Taylor series. Therefore, the
force—which is the derivative of energy with respect to displacement—will
approximate a linear function.

Force of fully compressed spring

where

E – Young's modulus

d – spring wire diameter

L – free length of spring

n – number of active windings

 – Poisson ratio

D – spring outer diameter

3.8 Zero-length springs

"Zero-length spring" is a term for a specially designed coil spring that

would exert zero force if it had zero length. That is, in a line graph of the spring's
force versus its length, the line passes through the origin. Obviously a coil spring
cannot contract to zero length because at some point the coils will touch each
other and the spring will not be able to shorten any more. Zero length springs are
made by manufacturing a coil spring with built-in tension, so if it could contract
further, the equilibrium point of the spring, the point at which its restoring force
is zero, occurs at a length of zero. In practice, zero length springs are made by
combining a "negative length" spring, made with even more tension so its
equilibrium point would be at a "negative" length, with a piece of inelastic
material of the proper length so the zero force point would occur at zero length.

A zero length spring can be attached to a mass on a hinged boom in such a

way that the force on the mass is almost exactly balanced by the vertical
component of the force from the spring, whatever the position of the boom. This
creates a horizontal "pendulum" with very long oscillation period. Long-period
pendulums enable seismometers to sense the slowest waves from earthquakes.
The LaCoste suspension with zero-length springs is also used in gravimeters
because it is very sensitive to changes in gravity. Springs for closing doors are
often made to have roughly zero length so that they will exert force even when
the door is almost closed, so it will close firmly.

3.9 Hooke's Law

Springs are fundamental mechanical components which form the basis of many
mechanical systems. A spring can be defined to be an elastic member which
exerts a resisting force when its shape is changed. Most springs are assumed
linear and obey the Hooke's Law,

where F is the resisting force, D is the displacement, and the k is the spring
constant.

For a non-linear spring, the resisting force is not linearly proportional to its
displacement. Non-linear springs are not covered in depth here.

3.8 Basic Spring Types

Springs are of several types, the most plentiful of which are shown as follows,
 Fig 3.8 Basic Spring Types

Circular cross section springs are shown. If space is limited, such as with
automotive valve springs, square cross section springs can be considered. If
space is extremely limited and the load is high, Belleville washer springs can be
considered. These springs are illustrated below,

Fig 3.9 Belleville Washer

3.9 PAC Racing Springs

The world's Premier Valve & Suspension Spring Manufacturer
www.racingsprings.com

Leaf springs, which are illustrated below in a typical wheeled-vehicle

application, can be designed to have progressive spring rates. This "non-linear
spring constant" is useful for vehicles which must operate with widely varying
loads, such as trucks.

Fig 3.10 Laminated Leaf Spring

 CHAPTER 4

MECHANISM

4.1 Spring Mechanism

Like most other fundamental mechanisms, metal springs have existed

since the Bronze Age. Even before metals, wood was used as a flexible
structural member in archery bows and military catapults. Precision springs first
became a necessity during the Renaissance with the advent of accurate
timepieces. The fourteenth century saw the development of precise clocks
which revolutionized celestial navigation. World exploration and conquest by
the European colonial powers continued to provide an impetus to the
clockmakers' science and art. Firearms were another area that pushed spring
development.

The eighteenth century dawn of the industrial revolution raised the need
for large, accurate, and inexpensive springs. Whereas clockmakers' springs
were often hand-made, now springs needed to be mass-produced from music
wire and the like. Manufacturing methodologies were developed so that today
springs.
4.2 Risk Factors

Compression spring bucking refers to when the spring deforms in a non-axial

direction, as shown here,

Fig 4.1 Non-axil Direction

Buckling is a very dangerous condition as the spring can no longer provide the
intended force. Once buckling starts, the off-axis deformation typically continues
rapidly until the spring fails. As a result, it is important to design compression
springs such that their likeliness to buckle is minimized.

Buckling of compression springs is similar to buckling for vertical structural

columns. When the free height of the spring (Lfree) is more than 4~5 times the
nominal coil diameter D, the spring can buckle under a sufficiently heavy load.

The maximum allowable spring deflection Dmax that avoids buckling depends on
the free length, the coil diameter, and the spring ends (pivot ball, ground &
squared, etc.).
4.3 Buckling Thresholds

One quick method for checking for buckling is to compute the deflection to free
height ratio (D/Lfree) and use the following chart to check if the ratio exceeds the
maximum allowable value:

Fig 4.2 Buckling Thresholds

 CHAPTER -5

CONCLUSION

The new change in the design will reduce the crushing stress in the handle
of the rolling machine on which the upper roller is mounted .The addition in the
change of material will reduce the contact stress in the support end where the
roller rolls which result in frictional wear. Thus, the rolling machine will have a
less maintenance which will directly in reduce the maintenance cost.
REFERENCES

[1] Mr. Nitin P. Padghan,” Force Analysis of Metal Sheet in Bending Operation
on Sheet Bending Machine”

[2] Himanshu V. Gajjar, Anish H. Gandhi, Tanvir A Jafri, and Harit K. Raval”
Bendability Analysis for Bending of C-Mn Steel Plates on Heavy Duty 3-Roller
Bending Machine”

[3] Y. H. Lin, M. Hua, “Mechanical analysis of edge bending mode for four-roll
plate bending process”, Computational Mechanics, Springer-Verlag 1999, pp
396-407

[4] P. S. Thakare1 , P. G. Mehar ,“PRODUCTIVITY ANALYSIS OF

MANUALLY OPERATED AND POWER OPERATED SHEET BENDING
MACHINE : A COMPARATIVE STUDY”

[5] K. L. Elkins, R. H. Sturges, “ Spring back analysis in Air bending”, Tran,

ASME, J. Manufacturing science and engineering, 121, Nov. 1999, PP. 679-688

[6] Aniruddha Kulkarni Mangesh Pawa “SHEET METAL BENDING

MACHINE” VOLUME 2, ISSUE 3, March.-2015

[7] Jong Gye Shin, Tac Joon Park & Hyunjune Yim ― Roll Bending‖, Tran,
ASME, J. Mechanical Design, 123 May 2001, PP 284-290
[8] Yiljep, T. P. 1999. Characterization of major Agricultural Tools
manufacturing Artisans in Northern Nigeria. Journal of agric. Eng. & Tech. 7:
45-52.

[9] George, L. 1983. The theory and practice of metal work. 3rd edition. PTF low
price edition. Longman, London

[10]R. S. Bello “Development and evaluation of metal rolling machine for small-
scale manufacturers” Vol. 15, No.3

[11]M.B. Bassett, and W. Johnson ― Design of machine elements‖, Tata mc-

Graw Hill Publication

[12]Gandhi, A. A. Shaikh& H. K. Raval, “Formulation of springback and

machine setting parameters for multipass three-roller cone frustum bending with
change of flexural modulus”, Springer/ESAFORM 2009, pp 45-57