Hydraulic Rod Bending Machine Design

This project focused on designing and constructing a low-cost hydraulic rod bending machine to increase the production rate of stirrups. The project involved researching hydraulic systems, overcoming design challenges like team conflicts and equipment faults, and utilizing mechanical engineering skills for fabrication. The successful machine achieved a production rate of 1000-1250 stirrups in 8 hours, demonstrating the effectiveness of the hydraulic system and the team's problem-solving abilities.

CE 3.1 Project Information
Name of the project: Development of Hydraulic Rod Bending Machine
Location of the project: [Please fill]
Project Duration: [Please fill]
Organization: [Please fill]
Role and Designation during the time: Project Team Leader
CE 3.2 Project Background
CE 3.2.1 Characteristics of the project
The Development of Hydraulic Rod Bending Machine project has applied the principle of
hydraulic system for bending rods at specified dimensions. Power of hydraulic load is
comparatively more than the electric as well as the pneumatic loads. The process of manual
stirrups has several disadvantages and this project was undertaken to overcome these drawbacks.
This project proposed a system of bending circular and square Stirrups. In this project, the rod
was bent by using hydraulic force. The equipments and components that were used in this project
for developing a rod bending machine based on hydraulic system are hoses, pump, rack, pinion,
cylinder, control valve, fixture and free wheel. The rod was being bent by the piston of the
hydraulic cylinder. The overall benefit of this project was that there was no need for
repositioning of rod while bending the square Stirrups.

CE 3.2.2 Objectives developed for the project
This project was undertaken to apply the principle of hydraulic systems in developing
and fabricating a rod bending machine in order to utilize the benefits of hydraulics and fluid
mechanics. The main objectives of this project were:
 To incorporate the principle of hydraulics in the design and construction of the
rod bending machine
 To implement hydraulic based rod bending system in construction sites at a low
cost
 To increase the productivity of stirrups
 To improve the accuracy
 To prevent the labours from injuries and musculoskeletal disorder by automating
the process
CE 3.2.3 My area of work
I was the team leader of this project. I had to report to the project manager. My area of
work was to supervise and monitor the activities of the project team members. Being the team
leader, I had a significant role in all the various phases of the project. My main area of work was
to carry out a proper plan and schedule for the completion of the project. I had to interpret the
specification of the tasks. My leadership qualities had helped me to manage and lead the project
team in a systematic manner.

Project Manager
Project Team Leader
(Myself)
Team Member Team Member Team Member
CE 3.2.4 Project Group
Figure 1: People involved in the project
CE 3.2.5 My responsibilities throughout the project
I had numerous responsibilities throughout the project. My main responsibility was to
give a clear direction to the team members for the successful completion of the project. I had
promoted the idea of creative thinking and encouraged my team members to solve complex
problems and issues. I was responsible for monitoring the performance of the team members and
the progress of the project work. I was responsible for distributing the tasks among the entire
team members. I had to identify the loopholes in the design and rectify them. I had to review the
quality of the selected components and equipments, and replace the components if there were
any faults and defects. I was responsible for preparing the weekly plans and reports for carrying

out the tasks in an effective and efficient manner. Being the team leader, I was also responsible
for motivating my team members and maintaining a healthy work environment.
CE 3.3 Distinctive Activity
CE 3.3.1 Comprehending the Theory of the project
Hydraulic machines are based on the principle that states that greater force must be
generated by using less force. Hydraulic systems are able to multiply the force in the process.
Rod bending machines make use of cylinders for bending operations. Automating the
mechanism of rod bending will help to increase the processing rate. Hydraulic systems are
reliable and simple to operate. Hydraulic systems contain two pistons and a pipe that is filled
with oil. This pipe is known for connecting the pistons. Hydraulic machines use two cylinders:
master and slave cylinders. Pascal’s law forms the basis of the working mechanism of the
hydraulic machines and systems. The principle of hydraulic systems states that when a force is
applied at a single place or point of a fluid then it gets transmitted equally in all the direction.
According to the Pascal’s law, a small piston will feel small force and a large piston will feel
large force. The force exerted by the fluid is equal to area X pressure. The construction of
hydraulic machines is simple and needs less maintenance. The RAM force of the hydraulic
system is able to reduce the human efforts.
The main focus of this project was to bend square as well as circular stirrups. Hydraulic
force has been applied to increase the productivity and bend 3 to 6 rods based on its diameter. It
has been able to reduce the faults in the older machines. The system which was designed by us
did not require repositioning of rods for bending purpose. The components that were required in
this project are filter, vane pump, pressure gauge, hoses, valve for direction control and pressure

relief. Hydraulic oil was stored in a 40 litres tank. A 2HP electrical motor was coupled to a vane
pump for driving the fluid. Coupling that connected the pump and motor caused the pump to
rotate. A valve was connected in a parallel manner to relief pressure. The pressure was measured
by using pressure gauge. After this, the oil was then transferred to a control valve. P-40 DCV
was used in this project and it was connected to an acting cylinder. The bending operation was
carried out by the extension force of the double acting cylinder after the activation of left spool.
After the completion of bending operation, the right spool was activated. This was causing the
cylinder to retract. This entire process was repeated for bending the stirrups. Our set up required
rack and pinion to for turning the table to 90 degree. The frame was considered to be the base
and main part of the machine.
CE 3.3.2 Engineering Knowledge and Skills applied in the project
I have comprehensive knowledge in the field of fluid mechanics. I have utilized my
mechanical engineering skills for designing the hydraulic rod bending machine. I have also
applied my critical thinking ability to prioritize various activities to carry out the plan in an
effective manner. I had undertaken significant research regarding on the design and working
principle of the hydraulic systems. My interpersonal skill has helped me to maintain harmony in
the team.
CE 3.3.3 Accomplishment of the project
My leadership skill has played a significant role in the accomplishment of the project. My
team was able to complete the tasks within the given deadline of the project and without any
delay. We were successfully able to find a solution to overcome the issues regarding manual
stirrup. The fixture of the table was being changed for obtaining different sizes of stirrups. The
design was complicated but yet we were able to use kinematic systems. The hydraulic machine

that was fabricated had a production rate of 1000-1250 stirrups in every 8 hours per working day.
The system that was developed can be operated in a simple manner. The hydraulic rod bending
machine had a simple design and was produced at a low cost.
CE 3.3.4 Identified issues and their solutions
CE 3.3.4.1 Issues
The main issue that occurred during the designing of the hydraulic machine was conflict
among the team members. This issue had stopped the production work for few days. Later on I
had discovered that there were faults in the design of the machine and faulty equipments were
selected by the team members.
CE 3.3.4.2 Solution
I had applied my problem solving skills to overcome all the issues. My mechanical
engineering skills had played a significant role in overcoming the design related issue. I had also
applied my exemplary designing skills to rectify the faults in the initial design of the hydraulic
rod bending machine. I had reviewed the features and characteristics of all the equipments to find
its faults. I had formulated a new strategy to purchase new equipments at a low cost. I had taken
the initiative to conduct weekly meetings and group discussions for sorting out the differences
among the team members.
CE 3.4 Project review
CE 3.4.1 Project overview
This project was undertaken to design a rod bending machine based on hydraulic systems
at a low cost. This project was successful in developing a rod bending machine and in increasing

the productivity of stirrups. The project team was able to incorporate the principle of hydraulics
for producing an effective system.
CE 3.4.2 My contribution to work
I was the team leader of this project. I had several roles from the start till the completion
stage of the project. I had obediently followed the instructions of my project manager and
conveyed all the information to the team members. I had kept the track record of all the team
members and had motivated them to perform better. I had applied my mechanical engineering
skills and knowledge at the correct time for getting the desired results. My hard work and
dedication played a significant role in the success of this project.