Abstract
The use of a bending machine acquired a high level of importance as a consequence of increasing the level of the industry. This paper aims to develop a more accurate and precise bending machine. The proposed bending machine has achieved brilliant output products, in which three main manufacturing parameters have been examined for the production of an equilateral triangle, which are flange length, bending angle and bending radius. The main point depends on the proposed algorithm, which has been developed based on separating the process, in which the central controller is responsible mainly for controlling the sub-controller, where the sub-controllers are programmed using PID to control the entire mechanisms of feeding and bending separately and ensure that the outcomes of these mechanisms are compatible with the input data from the central controller. Ten different dimensions of an equilateral triangle design sample with ten tries for each dimension (variable flange length, fixed bending angle equals to 60 degrees and bending radius equals to 3 mm) have been selected being produced using the bending machine, and the products have been formed two times. Firstly, using the proposed bending machine, in which the proposed algorithm is applied. Secondly, using the bending machine implemented without applying the proposed algorithm. The results have been compared in terms of error rates with respect to the standard design of products designed using CAD/CAM application. An enhancement has been recorded in terms of product accuracy and precision for the parameters of flange length, bending angle and bending radius. The overall accuracy level reaches up to 98.85228 % for a product manufactured using the proposed machine by applying the proposed algorithm compared with a product made with the machine designed without the proposed algorithm
Highlights
In different sectors of industries and medical fields, auto mated machines spread widely nowadays [1]
The current study has proven that the development of a bending machine is necessary in the field of forming industries and this study proved that this machine is able to produce a product of any design
Design and development of wire bending machine have been achieved successfully, in which the machine is able to create any frame shapes such as hexagonal, recant angular and circular frames depending on the set point of the structure
Summary
In different sectors of industries and medical fields, auto mated machines spread widely nowadays [1]. The industries are still considered to be seriously, more expensively and erroneously manufacturing complex engineering products with hand machines, though incorporating automation has made them simpler and more economically effective [6]. Challenges in the global economy and the industrial section developments exacerbated as a result of a lack in the machine industry, especially the use of bending machines during different processes of manufacturing due to the problems of automated machine systems growing [7,8,9,10]. It has proven that the use of bending machines is necessary to include during a linear or rotating movement with different industrial processes [11]. Studies that are devoted are important in the process of bending machine in the forming industries nowadays
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