DESIGN OF A STEEL PLATE ROLLER MACHINE WITH A 10.

5 HP MOTOR

A Study/Design Report
Presented to

DR. JAMES JAIME P. HONRA

Professor at the School of Mechanical and Manufacturing Engineering

In Partial Fulfilment of the

Submitted by:

Arabis, John Andrei P. – 2018100793

Aves, Derrick James V. – 2016141995

Drueco, Juan Miguel – 2016144128

Evangelista, Ryan Jason P. – 2018104109

February 5, 2022

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 TABLE OF CONTENTS

CHAPTER 1: INTRODUCTION ....................................................................................... 1

1.1 Overview and Background ................................................................................. 1

1.2 Statement of the Problem .................................................................................. 2

1.3 Objectives of the Study .......................................................................................... 2

1.3.1 General Objective ........................................................................................... 2

1.3.2 Specific Objective ............................................................................................ 2

1.4 Significance of the Study ....................................................................................... 3

1.5 Scope and Limitations ........................................................................................... 3

CHAPTER 2: REVIEW OF RELATED LITERATURE ..................................................... 4

2.1 Transmission on Roll Forming Equipment (Shanghai MTC Industrial Co, 2012) ... 4

2.2 Roll Bending Machine Working Principle and Rolling Process (Artizuno, 2018) .... 4

2.3 Hot Rolled vs Cold Rolled Steel (Reliance Steel, 2016) ........................................ 6

2.4 Types of Rolled Steel Sections .............................................................................. 7

2.5 The Fabricator: For high productivity in plate rolling, it helps to have latest
technology (Davis, 2020) ............................................................................................. 9

2.6 Safety Precaution and Tips to follow when working with Sheet Metal Rolling
Equipment (Woodward, 2020) ................................................................................... 10

CHAPTER 3: METHODOLOGY .................................................................................... 11

3.1 Design Calculations ............................................................................................. 11

3.1.1 Chain Drive Selection .................................................................................... 11

3.1.2 Gear Specifications ....................................................................................... 17

3.2 Design Layout ...................................................................................................... 20

3.2.1 Plate Roller.................................................................................................... 20

3.2.2 Chain Drive ................................................................................................... 21

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 3.2.3 Gear Drive ..................................................................................................... 22

3.2.4 Steel Plate Rolling Machine .......................................................................... 23

3.3 Design Considerations ......................................................................................... 24

3.4 Description of Machine ........................................................................................ 27

3.5 Description of Machine Utility............................................................................... 27

CHAPTER 4: RESULTS AND DISCUSSION ................................................................ 28

CHAPTER 5: CONCLUSION AND RECOMMENDATION ............................................ 29

REFERENCES .............................................................................................................. 30

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CHAPTER 1: INTRODUCTION

1.1 Overview and Background

Steel is one of the most used materials in the industries such as in construction,

infrastructure, mechanical equipment, electronics and automotive due to its tensile

strength, ductility, malleability, and it is a good conductor of electricity as well as heat.

Steel can now be molded into a wide range of shapes thanks to modern technologies.

Steel can be cut with better precision and is even lighter than wood in some cases. Its

amazing strength, even in little amounts, means it takes up far less room on construction

sites than concrete. Steel is a great material for design software because of its

predictability. Steel is used in everything from bridges, buildings, and tunnels to cars,

ships, and planes for these reasons (Burns, 2020). One equipment that could reform and

mold steel into a different shape is a steel roller machine. Henry Cort, who improved on

prior basic attempts to employ this process, brought rolling to steel production in 1783.

There has been continual advancement of the process and mill size since Cort's early

rolling mill, which used grooved rollers. Steel plate rolling machine is a type of metal

forming machine that produces sheet of steel and round forming of steel using its working

rollers. This machine is a sort of machine tool that is used to bend metal sheets in

continuous points by passing the metal between opposing-rotating rollers, it is plastically

deformed. The primary goal of rolling is to reduce the metal's thickness. In most cases,

the gain in width is insignificant, therefore the decrease in thickness leads in an increase

in length (Mari, 2017). In the sheet metal business, the plate rolling machine is particularly

1
important. This piece of machinery can be used to make cylindrical, conical, and other

arc-shaped pieces (Barton, 2020).

1.2 Statement of the Problem

Steel plates are hard to manufacture without a proper and right equipment. When the

plates are improperly manufactured it may cause a glitch, wrinkles, and scratches in the

steel plates itself. Steel plates are manufactured using the steel plate roller machine. The

steel plate roller machine is needed to be designed precisely and accurately so that

machine members of the equipment will not experience wear and tear due to the loads

and stresses induce in the machine while operating. The design of the drives must also

be precise since it transfers power from the motor to the working rollers. Inappropriate

design in the gears may result to the wear of teeth which destroys the gear drive and

improper design belt drive may result to sagging and worn out of belt due to the loads

applied which may lead malfunction of the machine and the drive itself.

1.3 Objectives of the Study

In this section the general and specific objectives for the design of the steel plate

rolling machine are stated.

1.3.1 General Objective

The general or the primary objective of this paper is to design a steel plate

roller machine driven by a gear and chain drive.

1.3.2 Specific Objective

a) Design and Compute for the chain Drives.

b) Design and compute for the gearing system.

c) Finalizing the design of the steel plate rolling machine using Fusion 360.

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1.4 Significance of the Study

This paper discusses the design of a simple steel roller plate that may be used in

metal industry. The obtained data in this study may aid hardware stores to design their

own steel roller plate. This paper may also help further research in designing more

efficient and economical steel roller plates.

Furthermore, this paper maybe adds to additional source to a designer if they are

planning to design a specific drive specially gears and selection of chains and sprocket

that will drive the mechanism also if they are planning to produce a steel plate at a specific

thickness for their compliance use. As well as this may aid people some idea on how

useful the steel plates in the engineering.

1.5 Scope and Limitations

This paper will focus on designing a simple steel plate rolling machine that will

produce a thin sheet of metals that may be used in a hardware shop. The design will be

based on the concepts and application that is learned in machine design course. The

focus of the design is the power transmitting elements which is the gear drive and the

chain drive that will transmit power to the components of the machine. The design will

also be based on this design consideration: Health, Safety, and Welfare Factors, Social

Factors and Global and Cultural Sensitivity and Awareness.

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CHAPTER 2: REVIEW OF RELATED LITERATURE

2.1 Transmission on Roll Forming Equipment (Shanghai MTC Industrial Co, 2012)

Suppliers typically use chain-sprocket transmission in roll forming equipment to

produce thin metal sheets (less than 3mm) at a regular speed, depending on the technical

requirements, such as corrugated sheet roll forming machine, roll forming machine, and

stud and track roll forming machine. Gear boxes and universal joint shafts will be mounted

in most roll forming equipment handling materials over 3mm thickness or working at a

speed over 20m/min, such as a highway guardrail roll forming machine; in high precision

or accuracy roll formers, such as some stud and track roll forming machines,

manufacturers will also apply gearbox and universal joint shaft to drive the machine.

The shafts of the gearbox and universal joint are sturdy and massive. With this

type of transmission, roll formers may be given a lot of power, allowing them to work

steadier and ensuring the precision or correctness of the finished roll formed goods.

Chain-sprocket transmission, on the other hand, is a more cost-effective way of

transmission. A clean working environment is not required; even dust will not prevent its

operation. However, chain-sprocket transmission is not suited for high-precision or

accuracy applications since it does not allow for the control of cutting length tolerances.

2.2 Roll Bending Machine Working Principle and Rolling Process (Artizuno, 2018)

Known as a rounder and roller machine, a roll bending machine is universal

forming equipment for rolling metal plates into cylinders, cones, curved shapes, and other

shapes. The relative position change and rotating motion of the working roll, according to

the three-point forming circle concept, cause the metal sheet to produce continuous

plastic deformation to get the predetermined shape of the workpiece. The plate is put

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between the higher and lower rollers while rolling steel plate, and the three cutting places

exposed to the metal sheet by three rolls can bend the plate into a curved or closed circle.

Sheet metal forming can be thought of as a three-roll bending machine that produces a

continuous three-point bending operation.

Figure 1. Drawing of Symmetrical 3 roll Bending Machine

In the figure above the plate is put between the higher and lower rollers while rolling

steel plate, and the three cutting places exposed to the metal sheet by three rolls can

bend the plate into a curved or closed circle. Sheet metal forming can be thought of as a

three-roll bending machine that produces a continuous three-point bending operation.

If the workpiece does not meet the desired curvature after rolling, the top roller can

be correctly decreased, and the reverse rolling can be repeated until the desired shape

is achieved. The three rollers of the symmetrical three roller bending machine are

positioned in an isosceles triangle, as shown above, thus the two ends of the workpiece

are bound to leave a straight line during the rolling operation.

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2.3 Hot Rolled vs Cold Rolled Steel (Reliance Steel, 2016)

Steel is available in a variety of grades, standards, shapes, and finishes, with the

World Steel Association listing over 3,500 different grades, each with its own set of

attributes. Steel may be found in a wide range of applications, including infrastructure,

appliances, cars, wind turbines, and many others. However, optimizing steel's

characteristics for each application entails more than just adjusting the chemical makeup.

Even when the grades and standards are the same, steel production processing can have

a considerable impact on steel products. The difference between hot rolled and cold rolled

steel is an important distinction among prefabricated steel products.

Steel that has been roll-pressed at extremely high temperatures over 1,700

degrees Fahrenheit, which is higher than the re-crystallization temperature for most

steels—is known as hot rolled steel. This allows the steel to be formed more easily,

resulting in easier-to-work-with products. Manufacturers begin with a huge, rectangular

length of metal called a billet to process hot rolled steel. The billet is heated before being

flattened into a big roll during pre-processing. It is then held at a high temperature and

rolled to its final proportions. Steel strands that are white hot are sped through the rollers.

Rolled steel is formed into coils and allowed to cool before being used to make sheet

metal. As steel cools, it shrinks slightly. Hot rolled steel has less control over its final

shape because it is cooled after processing, making it less appropriate for precise

applications. Hot rolled steel is frequently utilized in applications where precise

dimensions are not required. Hot rolled steel is frequently used in railroad tracks and

construction projects.

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 Hot rolled steel that has been processed further is known as cold rolled steel. After

cooling, hot rolled steel is re-rolled at room temperature to get more precise dimensions

and improved surface qualities. Although "cold rolled" steel is commonly used to

represent a variety of finishing methods, it technically only refers to sheets that are

compressed between rollers. Steel forms, such as bars or tubes, are "drawn" rather than

"rolled." Other cold finishing operations include turning, grinding, and polishing, which are

all used to refine hot rolled stock.

2.4 Types of Rolled Steel Sections

There are various forms of rolled steel sections that are used in steel construction and

are manufactured based on their usage. They are casted in continuous casting molds

without any joints.

The following are the different shapes or forms of rolled steel sections

1. Angle sections – They are manufactured in "L” shape. It contains two legs. It can

also be categorized as equal and unequal angle sections based on the dimensions

of the legs if they are equal or not. They are widely used for roof truss constructions

and for filler joint floors.

2. Channel Sections – Also known as C-section and consists of equal flanges

connected to web at both ends. They are extensively used in framed structures

3. T-sections – It consists of flange and web design in "T” shape. Two angle sections

can also be joined to get a T-section. They are used in steel roof trusses to form

built-up sections.

4. I -sections – Also known as steel beams. It consists of two flanges and a web

connected forming a “I” shape.

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5. Round bars – Contains circular cross sections and are used in reinforcement in

concrete and steel grill work

6. Square bars – Contains square cross sections and are widely used for gates,

windows, and grill works.

7. Flat bars - They are designated with width of the bar which varies from 10 mm to

400 mm. They are commonly used for gates, window, and grill works.

8. Corrugated sheets – They are produced by passing plain steel sheets through

machines which produces bends called corrugations and are commonly used for

roof coverings.

9. Expanded metal - They are made from mild steel sheets which are cut through

machine and expanded. Generally, Diamond shaped mesh is appeared in this type

of sheets.

10. Steel Plates - They are well used items in steel structures. They are used for

connecting steel beams, tensional member in roof truss etc.

11. Ribbed Bars (HYSD) - They are made of high yield strength steel. Ribs are nothing

but projections produced on bars by cold twisting of bar in hot rolled condition. The

twist is made according to the standard requirements. They are extensively used

as main reinforcement materials in all concrete works like bridges, buildings,

precast concrete works, foundations, roads

12. Ribbed Bars (mild steel) - These are look-alike HYSD ribbed bars but these bars

are not recommended by any code and they also have very less strength

compared to HYSD bars.

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 13. Thermo-mechanically Treated bars – They are also known as TMT bars and are

manufactured by a special technique in which the red-hot steel bars are suddenly

quenched by spraying water on it. So, surface of bar gets cooled down and inner

side or core of the bar still in hot condition. The core helps the outer surface to be

tempered. By this combination of different temperature, the bar gains more yield

strength and exhibits good elongation at ultimate failure. Copper, phosphorus and

chromium etc. are added in manufacturing process of TMT bars which improves

its corrosion resistance.

14. Wielded Wire Fabrics - They are nothing but a series of mild steel bars which are

arranged perpendicular to each other and welded at all intersection. Commonly

used for loor slabs, small canal linings, and pavements.

2.5 The Fabricator: For high productivity in plate rolling, it helps to have latest

technology (Davis, 2020)

The operators who guide the process on older plate rolling machines are only as

effective as the equipment themselves. It takes great care and patience to ensure that

the plate isn't rolled too tightly, or the entire item may end up in the scrap bin. The plate

must also have a narrow unbent flat section on its leading edge for the rollers to pinch it

to start the forming sequence with older plate rolling technologies. The length of this

unbent flat part is reduced by pre-bending this leading edge.

Lates roller machines today were equipped with CNC technology, manufacturing

was made simple. It uses the BENDtronic control software on a machine to handle all

parts of the bending process. A capacity calculator calculates the load supplied to the

9
machine during the forming cycle and the expected spring back, as well as whether the

workpiece can be bent, and the desired form achieved. Whether it's a single pass work

or a more intense multi pass project, a bend calculator determines the required roll

positions to produce the desired radius. Beyond cylinders, the control software also aids

with shapes other than cylinders. It's made to move the rollers in a regulated manner,

resulting in ovals, cones, and even S-shaped shapes.

2.6 Safety Precaution and Tips to follow when working with Sheet Metal Rolling

Equipment (Woodward, 2020)

Sheet metal rolling is an industrial metal casting technique that requires the use of

sophisticated machinery. Hot rolling, cold rolling, transversal rolling, and partitioned rolling

may all be used in the process. Even though sheet metal rolling is a simple process, it

still necessitates the use of complicated machinery.

The following are the safety precautions with metal rolling equipment that must be

taken by the operator.

• Installing Emergency Controls

• Skilled and experienced operator

• Conduct Regular Maintenance and Repair

• Use of Personal Protective Equipment (PPE)

• Safe Working Distance

• Environmental Safety

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CHAPTER 3: METHODOLOGY

3.1 Design Calculations

3.1.1 Chain Drive Selection

Motor: 10.5 HP

Driver RPM: 200 rpm

Driven RPM: 75 rpm

Pitch: 1 inch

Lubrication: Type II Lubrication (Drip Lubrication)

Diameter of Driver: 6.7095 in.

Diameter of Driven: 17.8347 in.

Number of Links: 82 links

Chain Speed: 350 fpm

Sprocket specification (small): RS80 A-Type – 21T

Sprocket specification (large): RS80 A-Type – 56T

Calculations:

Design Horsepower:

𝑆𝑒𝑟𝑣𝑖𝑐𝑒 𝐹𝑎𝑐𝑡𝑜𝑟 = 1.2

𝐷𝑒𝑠𝑖𝑔𝑛 𝐻𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 = 𝐼𝑛𝑝𝑢𝑡 𝐻𝑃 𝑥 𝑆𝑒𝑟𝑣𝑖𝑐𝑒 𝐹𝑎𝑐𝑡𝑜𝑟

11
 𝐷𝑒𝑠𝑖𝑔𝑛 ℎ𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 = 10.5 ℎ𝑝 𝑥 1.2

𝐷𝑒𝑠𝑖𝑔𝑛 ℎ𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 = 12.6 ℎ𝑝

Initial Chain Selection:

@ 𝐷𝑒𝑠𝑖𝑔𝑛 𝐻𝑃 = 12.6 ℎ𝑝 𝑎𝑛𝑑 𝑁 = 200 𝑟𝑝𝑚 (𝑠𝑖𝑛𝑔𝑙𝑒 𝑠𝑡𝑟𝑎𝑛𝑑)

𝐶ℎ𝑎𝑖𝑛 = 𝑅𝐶80

𝐹𝑟𝑜𝑚 𝑡ℎ𝑒 𝑃𝑖𝑡𝑐ℎ 𝑇𝑎𝑏𝑙𝑒 @ 𝑅𝐶80

12
 𝑃𝑖𝑡𝑐ℎ = 1 𝑖𝑛𝑐ℎ. (𝑆𝑖𝑛𝑔𝑙𝑒 𝑠𝑡𝑟𝑎𝑛𝑑)

𝑑𝑒𝑠𝑖𝑔𝑛 ℎ𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 12.6 𝐻𝑃

𝐹𝑟𝑜𝑚 𝑡ℎ𝑒 𝑅𝐶80 𝐻𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 𝑟𝑎𝑡𝑖𝑛𝑔, @ 200 𝑟𝑝𝑚 𝑎𝑛𝑑 12.6 ℎ𝑝

𝑇1 = 21 𝑡𝑒𝑒𝑡ℎ, 𝑡𝑦𝑝𝑒 𝐼𝐼 𝑙𝑢𝑏𝑟𝑖𝑐𝑎𝑡𝑖𝑜𝑛 (𝐷𝑟𝑖𝑝 𝐿𝑢𝑏𝑟𝑖𝑐𝑎𝑡𝑖𝑜𝑛)

13
 An RS80 chain with a 21-teeth sprocket is acceptable base from the horsepower

rating table since the power transmission from the table and the design horsepower is

12.6 hp.

Checking for determination whether the number of teeth and the pitch selected will a

sprocket large enough to be mounted on the shaft with due allowance for a keyway:

𝑝 1
𝑑𝑚𝑎𝑥 = (𝑇1 − 5) × = (21 − 5) ( )
4 4

𝑑𝑚𝑎𝑥 = 4 𝑖𝑛.

Diameter of Smaller Sprocket:

180° 180°
𝐷1 = 𝑝 (csc ( )) = (1) csc ( )
𝑇1 21

𝐷1 = 6.7095 𝑖𝑛.

Velocity Ratio:

𝑁1 𝑇2
=
𝑁2 𝑇1

200 𝑇2
=
75 21

𝑇2 = 56 𝑡𝑒𝑒𝑡ℎ

Diameter of Larger Sprocket:

180° 180°
𝐷2 = 𝑝 (csc ( )) = 1 (csc ( ))
𝑇2 56

𝐷2 = 17.8347 𝑖𝑛.

Recommended Center Distance:

𝐷1 6.7095
𝐶 = 𝐷2 + = 17.8347 +
2 2

14
 𝐶 = 21.1895 𝑖𝑛.

Length of Chain in links:

𝑇1 + 𝑇2 2𝐶 𝑇2 − 𝑇1 2 𝑝
𝐾= + +( ) ( )
2 𝑝 2𝜋 𝐶

21 + 56 2(21.1895) 56 − 21 2 1
𝐾= + +( ) ( )
2 1 2𝜋 21.1895

𝐾 = 82.34 ≈ 82 𝑙𝑖𝑛𝑘𝑠 (𝑛𝑒𝑎𝑟𝑒𝑠𝑡 𝑒𝑣𝑒𝑛 𝑛𝑢𝑚𝑏𝑒𝑟)

Chain Speed:

𝑣 = 𝑇𝑝𝑁

1𝑓𝑡
𝑣 = 21 × 1 𝑖𝑛 × × 200 𝑟𝑝𝑚
12 𝑖𝑛

𝑣 = 350 𝑓𝑝𝑚

15
Chain Drive Specifications

Sprocket number (Small): RS80 A-Type – 21T

Sprocket number (Large): RS80 A-Type – 56T

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 3.1.2 Gear Specifications

The specifications of the gear are selected based on the requirements of the

Steel Roller Machine to operate smoothly.

Larger Gear

Specifications Formula Value

Module 6

Pressure Angle 20 deg

Number of Teeth 64 T

Dedendum 1.157/DP 0.2554 in

Circular Pitch 𝜋/DP 0.6935 in

Pitch Diameter 14.7 in

Gear Thickness 3.15 in

Clearance 2 mm

Addendum 1/DP 0.2208 in

Whole Depth A+D 0.4762 in

Diametral Pitch Number of Teeth/PD 4.53 in

Bore Diameter 3.94 in

Working Depth 2/DP 0.4415 in

Circular Thickness 1.57/DP 0.3466 in

Outside Diameter PD+2A 15.14 in

Root Diameter PD-2D 14.19 in

Base Circle PD cos PA 13.81 in

17
 Smaller Gear

Specifications Formula Value

Module 6

Pressure Angle 20 deg

Number of Teeth 56 T

Dedendum 1.157/DP 0.2684 in

Circular Pitch 𝜋/DP 0.7289 in

Pitch Diameter 13 in

Gear Thickness 3.15 in

Clearance 2 mm

Addendum 1/DP 0.2320 in

Whole Depth A+D 0.5004 in

Diametral Pitch Number of Teeth/PD 4.31 in

Bore Diameter 2.36 in

Working Depth 2/DP 0.4640 in

Circular Thickness 1.57/DP 0.3643 in

Outside Diameter PD+2A 13.46 in

Root Diameter PD-2D 12.46 in

Base Circle PD cos PA 12.22 in

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Equipment Selection

10.5HP AC 2 Speed Otis Electric Motor

19
3.2 Design Layout

The 3D model of the designed steel plate rolling machine was made from Fusion

360. The model is divided into three parts. The first is the plate roller where the rolling

pins, table as well as the adjusting screw is located. Next is the roller chain drive which

is connected to the motor. And lastly is the gear drive.

3.2.1 Plate Roller

Isometric View of the Plate Roller

20
3.2.2 Chain Drive

Top View Front View

Isometric View Right Side View

21
 3.2.3 Gear Drive

Top View Front View

Isometric View Right Side View

22
3.2.4 Steel Plate Rolling Machine

Isometric View

23
3.3 Design Considerations

A. Health, Safety, and Welfare Factors

The design of the (semi-compact) steel plate roller machine has necessary elements

to consider particularly the size of the machine itself, durability, efficiency, and the energy

consumption. These factors will ensure that the (semi-compact) steel plate roller machine

will function properly without compromising the safety of the operator. Safety is one of the

important factors to consider, especially when working with machines. A machine guard

is installed to protect the chain drive and also in order to minimize possible accidents.

Another thing to consider is the safety trip control feature of the machine. This safety trip

control will automatically stop the steel plate roller machine once it detects something

other than the steel in the rollers. This will greatly ensure the safety of the operator of the

machine since the steel is manually inserted by the operator to the steel plate roller

machine. The utilization of hazard signs and lights around the machine will also be

considered. This is for additional precautions as when the steel plate roller machine is

operating, there may be some people in the workplace that wanders around. This feature

will make them aware that the steel plate roller machine is operating and refrain them

from going near the machine. Aside from safety measures to consider, the parameters

of the steel plate roller machine are also considered. The size of the materials should be

considered for the steel plate roller machine to function properly. The size of the material

must complement the capacity of the steel plate roller machine can accommodate.

Safety hazards in steel plater rolling machines include:

• Dust

• Unintentionally getting into the rollers of the machine.

24
 • Contact with the chain drives of the machine.

• Rust

• Chain failure

• Contact with steel coming out from the machine.

In order to ensure the health, safety, and welfare of the people around the steel plate

roller machine, here are some things to consider when operating a steel plate roller

machine:

• Regularly check the chain and the drive of the machine.

• Operators of the steel plate roller machine must be well-informed and professionally

trained.

• Always adjust the rollers in proportion with the material (steel) that is going to be

inserted into the machine.

• When a chain failure occurs, ensure that the machine is turned off before going near

the drive and inspecting.

• Always wear the proper protective equipment when operating the steel plate roller

machine.

B. Social Factors

• The design can provide a steel plate roller machine that is efficient, durable, and

long-lasting.

• The simple operating design of the steel plate roller machine was designed for the

convenience of the operator.

• The design of the steel plate roller machine uses quality parts that can be found

locally resulting in low-cost maintenance.

25
 • The design allows steel plates to be rolled in the least time possible which is perfect

for businesses involving steel fabrication.

• The steel plate rolling machine is designed to give stability in work application

particularly in steel fabrication.

C. Global & Cultural Sensitivity and Awareness

• The drive of the steel plate roller machine was designed to be able to operate at

longer time maximizing efficiency.

• The machine’s design was done in the most straightforward manner possible for

the convenience of the operator in operating the machine.

• The steel plate roller machine's design matches the standard and compliance of

every component to ensure the manufacturer and customer's safety and

protection.

• The materials of the steel plate roller machine are cost efficient and

environmentally friendly.

D. Economic Factors

• The steel plate rolling machine is designed to use the least raw material components

possible while still attaining the minimum standards, reducing manufacturing costs.

• The (semi compact) steel plate rolling machine performs on far with large steel

rolling machines but built with more affordable quality parts.

26
3.4 Description of Machine

A steel plate rolling machine is a piece of equipment that is used to roll various types

of sheet metal into round, semi round, round with varying radii or conical shapes. The

rolling machine boasts a working mechanism that allows it to bend flat sheet metal into a

large arc or cylinder or even a square, an ellipse shape, and a multi-section arc. Utilizing

a series of precise and strong hardened rolls powered by either hydraulic or mechanical

methods, the rolls are brought into a pitching position with the material desired to be

shaped.

3.5 Description of Machine Utility

The steel plate rolling machine that was designed by the proponents is a 3-roll

bending machine. The plate roller itself has one top roller and two bottom rollers. The

bottom rollers are attached to the shaft which is driven and attached to the spur gears.

The chain drive, which is attached to the motor, transmits power directly to the spur gears.

The top roller has an adjustment screw for the purpose of adhering to the desired bend

and thickness of the steel plate.

The (semi compact) steel plate roller machine is designed suitable for small steel

fabrication businesses. It has a simple operating design which makes it straightforward

for the operator to operate. There are two adjustment screws on the steel plate roller

machine wherein the user or the operator can manually adjust according to the thickness

and the width of the steel plate for a fine outcome.

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CHAPTER 4: RESULTS AND DISCUSSION

A steel plate roller machine is designed to be able to produce steel sheets in

smaller scales. Since most of the design of steel plate roller machines have been massive

to fit adequately enough in a standard sized room, the design of this steel plate roller

machine will be perfect for (small) businesses related in fabrication using steel plates.

The proposed design of the steel rolling machine is composed of gear and chain

drives. The steel rolling machine is equipped with a horizontal chain drive which is being

powered by a 10.5 hp motor. For the sprockets of the chain drive, they are measured with

a diameter of 13 in for the smaller gear and 14.7 in for the larger gear which has an rpm

of 200 and 75 respectively. The length of chain in links is determined to have a

measurement of 82.34 which is approximately 82 links (nearest even number) with

350fpm of chain speed.

The specifications of the horizontal chain drive were computed by using the power

transmission table. The researchers have selected the RC80 in the transmission table

with a pitch of 1 that is selected from the pitch table. An RS80 chain with a 21-teeth

sprocket is acceptable base from the horsepower rating table since the power

transmission from the table and the design horsepower is 12.6 hp. Therefore, it can

transmit a power of 10.5hp which makes the design acceptable.

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CHAPTER 5: CONCLUSION AND RECOMMENDATION

After the rendering of the design, the group was able to implement the theoretical

calculations and concepts of a chain drive and gear drive learned in the subject in the

design of the machine. The group was able to design a machine with a simple system

that regular people can easily understand. The group was able to design a machine that

is of small scale compared to the ones used in big industries. With this, the machine can

have higher reliability. The group recommends that the machine be improved by adding

a feature that can roll other types of steel sections without increasing or changing the

power used in the machine.

29
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