Make A Metal Bender || Homemade Roller Bender

 Suthar Sandeep  35932 View  September 19, 2018  Comments (41 )

Introduction

The roller bender is a mechanical device or jig having three rollers used to form a metal bar or rod into a circular arc. The rollers are freely rotate about three parallel axes, which are arranged with uniform horizontal spacing. Two outer rollers, cradle the bottom of the material while the inner roller, whose position is adjustable, presses on the topside of the material.

In this mechanism, after the bar is initially inserted into the jig, the middle roller is manually lowered and forced against the bar or rod with a screw arrangement. This causes the bar or rod to undergo plastic and elastic deformation.

The main problem that people, doing various metallic projects, face is the bending of metallic pieces. The reason that this problem is arisen during these projects is because the metallic pieces need a lot of pressure, strength as well as accuracy to be bent. There are many machines to be used to achieve this but the cost is very high. Therefore, I decided to make for my own. The construction of this roller bender is more user-friendly to everyone, is relatively affordable, is extremely useful and it will fill with feelings of joy and satisfaction the people who want to spend their time productively.

Parts Used :-

  • L-Section channel 1.25”*1.25” width (5mm thickness) 9” length for base
  • L-Section channel 1.25”*1.25 width (5mm thickness) 5” length
  • L-Section channel 1.25”*1.25” width (5mm thickness) 2” length
  • 2 Nos. metal pieces 2”*7” (10mm thickness)
  • Metal piece 2”*2” (10mm thickness)
  • Metal piece 5”*2” (10mm thickness)
  • Metal piece 5”*1” (5mm thickness)
  • 4 Nos. 6301-2RS bearings
  • M12 Bolt (5” length) with 2 nuts
  • M10 Bolt (3” length) with nut
  • 3 Nos. M12 allenky bolts (3” length) with nuts
  • 5 Nos. M8 allenky bolts (1” length)
  • 2 Nos. M4 allenky bolts (1” length)
  • Cylindrical metal piece (1.5” diameter)12.5mm hole
  •  

How To Make :-

Step 1 :- Cutting of parts

First step to make roller bender is cutting of all metal parts to its desired dimension. You can see all the dimension of cutting parts in “parts used”. In this metal bender machine, I have used 4 bearings to use as a roller, also one cylindrical metal piece of 1.5” diameter. This cylindrical metal piece is middle roller and it is manually lowered and forced against the bar or rod with a screw arrangement.

Step 2 :- Assembly of all cutting parts

This is the second step to make roller bender, assembly of all cutting parts. For assembly of parts I have used allenky bolts, I have not doing any type of weld for assembly of cutting parts. 4 bearings are attached with base (L-Section channel 1.25”*1.25” (5mm thickness) 9” length for base), Metal piece 5”*2” (10mm thickness) and 2 Nos. metal pieces of 2”*7” (10mm thickness) by using of M12 allenky bolts (3” length).

Also attach the L-Section channel 1.25”*1.25 width (5mm thickness) 5” length on other side of the metal pieces of 2”*7” by using of 4 Nos. M10 allenky bolts.

Next step is assembly of M12 Bolt (5” length) with 2 nuts and middle roller (Cylindrical metal piece (1.5” diameter) and 12.5mm hole).

This M12 bolt is provide the screw arrangement to manually lowered and forced the middle roller against the bar or rod, and at the last attach the handle to rotate the middle roller.

Handle is attached with middle roller by using of 2 Nos. M4 allenky bolts (1” length). I have used M10 Bolt (3” length) with nut, metal piece 5”*1” (5mm thickness) and wooden cylindrical piece to make handle.

Step 3 :- Ready to use

Now the roller bender is ready to use. In this mechanism, after the bar is initially inserted between the three rollers, the middle roller is manually lowered and forced against the bar or rod with a screw arrangement. This causes the bar or rod to undergo plastic and elastic deformation.

The bar between the three rollers will take on the shape of a cubic polynomial, which approximates a circular arc. The three rollers are then rotated moving the bar along with them. For each new position, the portion of the bar between the three rollers takes on the shape of a cubic modified by the end conditions imposed by the adjacent sections of the bar. When either end of the bar is reached, the force applied to the centre roller is incrementally increased, the roller rotation is reversed and as the rolling process proceeds, the bar shape becomes a better approximation to a circular arc, gradually, for the number of passes required to bring the arc of the bar to the desired radius.

For better to understand, watch the video given below.

Comments (41)

Amit chheda,   Mumbai

Give contact no I want machine bender

RePly  November 10, 2019
Matthew wong,   Lagos

Is it possible to get a mathematical model of this

RePly  October 3, 2019
Abdul rehman,   Mumbai thane

I want this product urgently, if anyone is having please let me know my cellphone number is 9595597320

RePly  September 28, 2019
Manish yadav,   Vashi

I hav made dis machine and it will only cost u 7000 rs.mob-9920654859

 October 4, 2019
om patel,   visnagar

I am sale this product in rs:-5000₹ my mobile number:-9723798896

RePly  September 2, 2019
Abdul rehman,   Thane

5000 is much more i will give you 1500 , my mobile number is 9595597320

 September 28, 2019
Mohammad asib,   Kalyan, ulhasnagar

How much cost it will take to make metal bender of your video incuding machining cost also, and can already cutted parts and dimensioned part for easiness.

RePly  July 28, 2019
David Webster,   Sandbach, England

Excellent video on your metal bender do you make and sell this machine, we are looking for a machine that will roll 2-3 mm brass strip up to 40 mm wide and 4-5 mm brass rod. Would appreciate your help. Kind regards David

RePly  July 13, 2019
Otto Wenninger,   Wiesbaden

Super gemacht, nur die Rolle zum Absenken ist problematisch zu bekommen.

RePly  June 20, 2019
Marve,   Cebu, Philippines

Hello May i know how much would it cost to make bender machine of the following dimensions and ship to Cebu, Philippines -17.7cmDia -12.2cmDia -26.8cmDia Thanks Marve

RePly  June 20, 2019
Sergei Kapooski,   Kansas City,KS

Your project is great. The part of the dimensions are metric. What would you recommend the thickness of material I should use. The closest to 5mm can be 3/16 (or 4.762mm) and the 10mm could be 3/8 (or 9.525mm) . What about the bearings? Will the 6301-2RS bearings still work if use standard bolts as 1/2 inch and 3/8 bolts?

RePly  June 13, 2019
MRITUNJAY KUMAR,   Bokaro

Where is the calculation of machine????? Can you please give it...

RePly  June 4, 2019
Nitish kumar,   Bokaro

Can you send me the calculation part of this . Please it's very urgent

RePly  June 3, 2019
Nitish kumar,   Bokaro

Can you send me the full calculation of this ....

RePly  June 3, 2019
Abhishek Yadav,   Varanasi

Sir I want project report on this machine ,immediately. Please sir.

RePly  May 16, 2019
Санёк,   Tambov

Собрал на закалённых от болгарки штивтов на которые закрепляют отрезные круги и повесил на них по три подшипника гнёт 4 мм стали шириной 25 мм. Но уголок сделал из 5 мм и пришлось по покам приварить треугольные косынки жёсткости без них уголок начал сгинатся который двигается по серидини в центре.И ещё почему-то когда выкручиваю винт м 16 из него выкручивается в него вкрученный маленький м 5 винт который поднимает тот уголок. Спасибо за внимание.

RePly  May 15, 2019
Ankit kumar,   Muzaffarnagar

Sir hme ye machine project ke liye kharidni he hamne bnai thi lekin glat ban gai or ab time nahi he bnane ka isliye hme aapse kharidni he plz help me

RePly  May 10, 2019
,   

i can not find a 11/2 clindrical roller. if you have two send me an email of how nuch it cost and i"ll send you the money. my email is mama.luz@att.net my home address is 2604 Salinas ave. laredo, tx 78040

RePly  April 30, 2019
Dinesh ,   Trichy

I want a report of this project any one send report to my email. www.dineshrainababu@gmail.com

RePly  March 30, 2019
Yilma tilahun,   Ethiopia/arbaminch

Good house made project

RePly  March 24, 2019
,   

Bro project report ketaikuma...?

RePly  March 16, 2019
hanse,   seoul korea

I am gaining knowledge and inspiration through video about your homemade. Thank you for this. I wanted to know the limit of the material through the production of the vendor. I hope that your work develops and thrives.

RePly  March 2, 2019
Barathkumar C,   hosur

How much diameter a circular rod can be bent?

RePly  February 28, 2019
Sunil,   Bhiwandi

Very well explained and put on text. Kindly help me as How can I buy a ready one. Sunil 9920695585

RePly  February 24, 2019
Anburaj,   Coimbatore,Tamil nadu,india

Sir can you give me the calculations for the roller bender please

RePly  February 21, 2019
s.ashkar ali,   dindigul,tamil nadu, India

we need a calculations related to home made metal bender for our project , please kindly request for a give calculations for us

RePly  February 11, 2019
,   

Расчёт толщины металла диаметр трубы умножаем на давление и делим на запас прочности .

 May 15, 2019
,   

Bro project report iruntha whatsapp bro 7540070885

 March 16, 2019
Vijay,   Madurai

Bro ethum calculation kututhangala..

 March 16, 2019
Sanjay,   Jaipur, rajasthan

Metal bender price

RePly  February 7, 2019
Colin J Niehus,   Conder

Brilliant work, I must try this for myself,would be very handy tool in my workshop. Many thanks for taking the time to make the video for us, Col

RePly  January 8, 2019
Charlie,   Las Vegas

Always wanted to do a few of these being a welder ..what about a diy plate bender using hinges and the end of a metal table or something? Love your work.thanx

RePly  January 7, 2019
B.r.enterprises ,   ANAKAPALLI. A.P

Metal bender price .From. 09849966043

RePly  December 22, 2018
om patel,   meshana

Only 6000₹

 September 2, 2019
,   

 December 29, 2018
,   

Please send metal bender price list sir. From. B.r.enterprises. ANAKAPALLI. A.P. phone. 09849966043

RePly  December 22, 2018
,   

RePly  December 22, 2018
Swinder Singh ,   Jagraon, punjab

Sir! I want to purchase your roller bender machine. I want to know about price and some other details. My no. 09465471449

RePly  December 18, 2018
,   

 August 20, 2019
mücahit,   turkey

iyi günler.inanılmaz kanal.benim bu projenin bitmiş haline ihtiyacım var.turkiyede yasıyorum.en kısa sürede sizden haber bekliyorum.lütfen gmail hesabıma mesaj verin. mucahitozdemir2023@gmail.com

RePly  December 18, 2018
Javier,   Brownsville

Mamalon👍🍺🍺🍺

RePly  November 26, 2018
Khademul Masum ,   Dhaka

I want hitachi cordless drill machine. Please contact with me

RePly  October 26, 2018
joe bochi,   Nairobi

Amazing channel... Thank you a million times. Just starting and definitely will save on tools I thought were impossible to buy at this time. Cheers

RePly  October 22, 2018
Ruben Gonçalves,   porto salvo

pode mandar as medidas exata de cada peça para que eu possa fazer igual

RePly  October 15, 2018
Sujit kuila,   Mechada

Subject

RePly  October 10, 2018
V.Ramakrishnan,   Coimbatore/Tamilnadu

Dear Sri.Suthar, I need the finished product of this metal bender and the Metal Drill press vice. Please forward the amount and your bank account so that i can send the payment for them. i have provided my address below: V.Ramakrishnan, U-15, Kovaipudur Housing Unit, Kovaipudur, Coimbatore - 641042. My mobile:8105843368 A message from your side is highly appreciated.

RePly  October 10, 2018
Ryan,   Bangkok

Sam you can get the 1.5" piece at metal supply shop

RePly  October 2, 2018
Carlos Arias,   San Miguel de Tucumán -Argentina

Si es posible la dimensión del angulo y brocas.exelente saludos

RePly  October 1, 2018
Sam,   Layton

I appreciate your very informative article and video. Thank you so much for putting all this together. Just one question if you allow me. Where can I get the 1.5 inch Cylindrical metal pieces? Again, I thank you so much!!!

RePly  September 20, 2018
jack monico,   FRANKLIN

steel tubing you can get it at your local metal supply shop

 March 1, 2019
Vikram Panchal,   Pune

Whats the Length of solid round bar of 38mm O.D and 12.5MM ID??

 January 7, 2019
Dan,   East Tennessee

Cylindrical pieces. This is sold as "round bar". Its solid, you drill out the center for desired diameter.

 November 3, 2018

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