Design and Fabrication of a Manually Operated Pipe Bending Machine

This study presents the design, fabrication, and performance evaluation of a manually operated pipe bending machine developed as a low-cost and energy-independent alternative to electrically powered systems. The machine was designed and constructed at the Centre for Space Innovation and Development of the National Space Research and Development Agency (NASRDA) Abuja, Nigeria. The aim of the project is to produce a manually operated pipe bending machine to meet the fabrication needs of the centre for space innovation and development mechanical workshop. The machine was produced using locally sourced material to promote affordability and ease of maintenance for small-scale workshops and educational laboratories. The machine incorporated a rigid steel frame, a manually driven lever mechanism, adjustable bending dies, and support rollers to ensure uniform force distribution during operation. The machine consists of a 90mm round steel pipe frame welded to a 10mm steel flat bar,10 x 630mm mild steel plate manually driven lever mechanism. 305mm, 315mm, 465mm mild steel adjustable die and 150mm mild steel support rollers to ensure uniform force distribution during bending operations. Engineering design calculations were carried out to determine the required length lever, shaft diameter, bending force, torsional resistance, and structural integrity of the frame. Standard manufacturing processes include cutting, machining, welding, and assembly. Performance testing was carried out by bending the following gauge of metal square pipes,1x1mm,1.5 x 1.5mm, 2 x 2mm to predetermined angles. The results showed smooth bends with minimal wrinkling, cracking and cross-sectional distortion. The bending accuracy repeatedly confirms the machines suitability for fabricating structural frames such as gates, furniture and tricycle components. The developed manual pipe bending machine offers an economical, efficient and easy to operate alternative to conventional bending equipment.