1. Rolling & Bending Steel Section and Tube Sam Hastwell Dan Lauthier Jaime Sanchez Product Design Technology 1 (GRAP 1025) 2012 Assessment 1 - Analysis and Design

2. What is Steel Lesko, Jim; Industrial Design: materials and manufacturing guide; (2nd edition, John Wiley & sons, Inc.; 2008), page 13

3. Carbon Steel

4. Stainless Steel http://www.flickr.com/photos/pcw/4840894857/http://www.flickr.com/photos/pcw/4840894857/ (accessed 4th May 2011)

5. Austenitic (300 Series)

6. Ferritic (400 Series) http://media.supercheapauto.com.au/sca/images/143227.jpghttp://media.supercheapauto.com.au/sca/images/143227.jpg (accessed 4th May 2012)

7. Martensitic (400 Series)

8. Precipitation-Hardened (Alloys: 13-8,15-5,15-7,17-4,17-7) http://www.crankbrothers.com/eggbeater.phphttp://www.crankbrothers.com/eggbeater.php (accessed 4th May 2012)

9. Tool Steel http://image.made-in-china.com/4f0j00YvNtrboGODpq/1-2083-Tool-Steel-Round-Bars.jpghttp://image.made-in-china.com/4f0j00YvNtrboGODpq/1-2083-Tool-Steel-Round-Bars.jpg (accessed 4th May 2012)

10. Mould Steels (type P) http://en.wikipedia.org/wiki/Injection_moldinghttp://en.wikipedia.org/wiki/Injection_molding (accessed 4th May 2012)

11. Shock Resistant Steels (type S)

12. Hot Work Steels (type H) http://www.airliners.net/photo/1116891/L/http://www.airliners.net/photo/1116891/L/ (accessed 4 th May 2012)

13. High Speed Tool Steels (type TIM)

14. How Steel is Made - Reduction Oxygen burns the Coke to create Carbon Monoxide; This process removes the Oxygen from the Iron Ore to produce Iron and Carbon Dioxide: Fe 0 +C 0 ≥ Fe+ C0 2

15. How Steel is Made images: http://www.bluescopesteel.com/about-bluescope-steel/student-information/ingredients-of-steel (accessed 20th March 2012)http://www.bluescopesteel.com/about-bluescope-steel/student-information/ingredients-of-steel

16. Basic Oxygen Steelmaking process http://www.bluescopesteel.com/images/BOS_001.jpghttp://www.bluescopesteel.com/images/BOS_001.jpg (accessed 20th March 2012)

17. http://www.bluescopesteel.com/images/BOS_003.jpghttp://www.bluescopesteel.com/images/BOS_003.jpg (accessed 20th March 2012) Basic Oxygen Steelmaking process

18. http://www.bluescopesteel.com/images/BOS_005.jpghttp://www.bluescopesteel.com/images/BOS_005.jpg (accessed 20th March 2012) Basic Oxygen Steelmaking process

19. http://www.bluescopesteel.com/images/BOS_004.jpghttp://www.bluescopesteel.com/images/BOS_004.jpg (accessed 20th March 2012) Basic Oxygen Steelmaking process

20. Image: Guidot, Raymond (ed.); Industrial Design Techniques and Materials; (Paris, Flammarion, 2006), page 182 Electric Arc Furnace Image: Guidot, Raymond (ed.); Industrial Design Techniques and Materials; (Paris, Flammarion, 2006), page 182

21. http://www.bluescopesteel.com/images/ACF1CFB.gifhttp://www.bluescopesteel.com/images/ACF1CFB.gif (accessed 20th March 2012) Casting http://www.bluescopesteel.com/images/Caster008.gif (accessed 20th March 2012)

22. Rolling http://www.bluescopesteel.com/images/Rolling. jpghttp://www.bluescopesteel.com/images/Rolling. jpg (accessed 20th March 2012) http://www.bluescopesteel.com/images/Shaping. jpghttp://www.bluescopesteel.com/images/Shaping. jpg (accessed 20th March 2012) Lesko, Jim; Industrial Design: materials and manufacturing guide; (2nd edition, John Wiley & sons, Inc.; 2008), page 46.

23. Guidot, Raymond (ed.); Industrial Design Techniques and Materials; (Paris, Flammarion, 2006), page 187 Rolling

24. Guidot, Raymond (ed.); Industrial Design Techniques and Materials; (Paris, Flammarion, 2006), page 187 Rolling

25. DEFINITION: To form sheet metal strip along straight, longitudinal, parallel bend lines with multiple pairs of contoured rolls without changing the thickness of the material at room temperature.

26. Dobrev, Atanas; George T. Halmos (1993). Roll forming into the 21st century. Society of Manufacturing Engineers.

27. Halmos, George T. Roll Forming Handbook, CRC Press, 2005. ISBN 0824795636ISBN 0824795636

28. #Halmos, George T. Roll Forming Handbook, CRC Press, 2005. ISBN 0824795636ISBN 0824795636

29. Halmos, George T. Roll Forming Handbook, CRC Press, 2005. ISBN 0824795636ISBN 0824795636

30. Forms and Shapes Kula, D; Ternaux, E; Hirsinger, Q; Materiology: The Creative Industry's Guide to Materials and Technologies; (Basel, Birkhäuser Architecture and Amsterdam, Frame Publishers, 2008) ; page 48.

31. Different Complexity

32. Forms and Shapes

35. Rotary Draw Bending Heng, 2007. 'Role of mandrel in NC precision bending process of thin-walled tube', International journal of machine tools & manufacture, 0890-6955, vol. 47, Issue 7, p 1164,

36. Rotary Draw Bending Heng, 2007. 'Role of mandrel in NC precision bending process of thin-walled tube', International journal of machine tools & manufacture, 0890-6955, vol. 47, Issue 7, p 1164,

37. Rotary Draw Bending

43. http://youtu.be/fwUleWqEeWs Uni Workshop tube bending

44. Mandrel Bending http://www.allbend.com.au/bending-rolling.phphttp://www.allbend.com.au/bending-rolling.php (accessed 12th April 2012)

45. http://www.allbend.com.au/bending-rolling.phphttp://www.allbend.com.au/bending-rolling.php (accessed 12th April 2012) Mandrel Bending

46. http://www.allbend.com.au/bending-rolling.phphttp://www.allbend.com.au/bending-rolling.php (accessed 12th April 2012) Mandrel Bending

47. http://www.allbend.com.au/bending-rolling.phphttp://www.allbend.com.au/bending-rolling.php (accessed 12th April 2012) Mandrel Bending

48. http://www.bendpro.com.au/basemedia/content/images/cnc-mandrel-bending-customised-tooling.jpghttp://www.bendpro.com.au/basemedia/content/images/cnc-mandrel-bending-customised-tooling.jpg (accessed 17th April 2012)

49. Mandrel Bending Heng, 2007. 'Role of mandrel in NC precision bending process of thin-walled tube', International journal of machine tools & manufacture, 0890-6955, vol. 47, Issue 7, p 1

50. Press Brake

51. Kula, D; Ternaux, E; Hirsinger, Q; Materiology: The Creative Industry's Guide to Materials and Technologies; (Basel, Birkhäuser Architecture and Amsterdam, Frame Publishers, 2008) ; page 245.

52. Press Brake Todd, Robert (1994). Manufacturing Processes Reference Guide. New York: Industrial Press inc.. ISBN 0831130490.ISBN0831130490

53. Rolling/ Curving Coils and Spirals Lefteri, Chris; Making It: Manufacturing Techniques for Product Design; (London, Laurence King, 2007); page 86.

54. Rolling/ Curving Coils and Spirals http://www.bolnar.com.au/DCP00425.JPGhttp://www.bolnar.com.au/DCP00425.JPG (accessed 12th April 2012)

55. Rolling/ Curving Coils and Spirals http://www.bolnar.com.au/large%20section%20rolling.JPGhttp://www.bolnar.com.au/large%20section%20rolling.JPG (accessed 12th April 2012)

56. Rolling/ Curving Coils and Spirals http://www.bolnar.com.au/Steam%20coils.JPGhttp://www.bolnar.com.au/Steam%20coils.JPG (accessed 12th April 2012)

57. Rolling/ Curving Coils and Spirals http://www.bendcraft.com/images/image_8_l.jpghttp://www.bendcraft.com/images/image_8_l.jpg (accessed 17th March 2012)

58. Rolling/ Curving Coils and Spirals http://www.bendcraft.com/images/image_9_l.jpghttp://www.bendcraft.com/images/image_9_l.jpg (accessed 17th March 2012)

59. http://youtu.be/k-WU24_D-ro Rolling and Bending - Steel Section and Tube

60. Advantages and Disadvantages

61. Environment and Safety http://www.bluescopesteel.com/files/dmfile/SteelforLife07.pdfhttp://www.bluescopesteel.com/files/dmfile/SteelforLife07.pdf (accessed 4th May 2012)

62. 9 Pictures of examples of rolled and bent steel sections and steel tube

66. Authors Photo

78. Green Steel Supplies 23 Manton Street Hindmarsh 5007 (08) 8241 5566 http://www.greensteelsupplies.com.au sales@greensteelsupplies.com.au

79. Ackland Stainless Steel 45 Phillips Street, Thebarton, SA 5031 (08) 8234 5288 http://www.acklandstainless.com.au sales@acklandstainless.com.au

80. Atlas Steels 9 Capelli Road Wingfield SA 5013 (08) 8359 1100 http://www.atlassteels.com.au/ sasales@atlassteels.com.au

81. G&L Bolnar Engineering 28 Phillis St, Wingfield SA 5013 (08) 82683655 http://www.bolnar.com.au sales@bolnar.com.au

82. Rowlands Metalworks Unit 13/19 Heath Street Lonsdale South Australia 5160 (08) 8329 6700 http://www.rowlandsmetal.com.au/ metal@rowlandsmetal.com.au

83. Lakeside Engineering Pty Ltd 69 Cavan Rd Gepps Cross SA 5094 (08) 8262 9177 lakesideeng@adam.com.au

84. Bibilography All photos by the author except where noted. (Guidot, Raymond; ed. Industrial Design Techniques and Materials P172) http://www.bluescopesteel.com/about-bluescope-steel/student-information/ingredients-of-steel (accessed 20th March 2012)http://www.bluescopesteel.com/about-bluescope-steel/student-information/ingredients-of-steel http://elibrary.steel.org.au/asi/index.cfm?070CBAFC-1E4F-17FA-CD13-196EF2865903 (accessed 20th March 2012)http://elibrary.steel.org.au/asi/index.cfm?070CBAFC-1E4F-17FA-CD13-196EF2865903 http://www.bluescopesteel.com/about-bluescope-steel/student-information/steelmaking (accessed 20th March 2012)http://www.bluescopesteel.com/about-bluescope-steel/student-information/steelmaking Guidot, Raymond (ed.); Industrial Design Techniques and Materials; (Paris, Flammarion, 2006), page 182 http://elibrary.steel.org.au/asi/index.cfm?070CBAFC-1E4F-17FA-CD13-196EF2865903 (accessed 20th March 2012)http://elibrary.steel.org.au/asi/index.cfm?070CBAFC-1E4F-17FA-CD13-196EF2865903 http://www.bluescopesteel.com/about-bluescope-steel/student-information/steelmaking(accessed 20th March 2012)http://www.bluescopesteel.com/about-bluescope-steel/student-information/steelmaking Lesko, Jim; Industrial Design: materials and manufacturing guide; (2nd edition, John Wiley & sons, Inc.; 2008), page 13 http://www.worldsteel.org/faq/about-steel.html (accessed 20th March 2012)http://www.worldsteel.org/faq/about-steel.html http://www.worldsteel.org/media-centre/multimedia/steel-production (accessed 20th March 2012)http://www.worldsteel.org/media-centre/multimedia/steel-production http://www.bluescopesteel.com/about-bluescope-steel/student-information/properties-of-steel (accessed 20th March 2012)http://www.bluescopesteel.com/about-bluescope-steel/student-information/properties-of-steel http://www.bluescopesteel.com/about-bluescope-steel/student-information/glossary-of-terms (accessed 20th March 2012)http://www.bluescopesteel.com/about-bluescope-steel/student-information/glossary-of-terms Lesko, Jim; Industrial Design: materials and manufacturing guide; (2nd edition, John Wiley & sons, Inc.; 2008) http://www.bluescopesteel.com/about-bluescope-steel/student-information/steelmaking (accessed 20th March 2012)http://www.bluescopesteel.com/about-bluescope-steel/student-information/steelmaking Ashby, Mike and Johnson, Kara; Materials and Design: The Art and Science of Material Selection in Product Design; (Oxford, Elsevier Butterworth-Heinemann, 2005); page 250 Guidot, Raymond (ed.); Industrial Design Techniques and Materials; (Paris, Flammarion, 2006), page 187 Lesko, Jim; Industrial Design: materials and manufacturing guide; (2nd edition, John Wiley & sons, Inc.; 2008) Kula, D; Ternaux, E; Hirsinger, Q; Materiology: The Creative Industry's Guide to Materials and Technologies; (Basel, Birkhäuser Architecture and Amsterdam, Frame Publishers, 2008) http://www.allbend.com.au/bending-rolling.php (accessed 12th April 2012)http://www.allbend.com.au/bending-rolling.php http://www.bendpro.com.au/basemedia/content/images/cnc-mandrel-bending-customised-tooling.jpg (accessed 17th April 2012)http://www.bendpro.com.au/basemedia/content/images/cnc-mandrel-bending-customised-tooling.jpg Lefteri, Chris; Making It: Manufacturing Techniques for Product Design; (London, Laurence King, 2007); page 86. http://www.bolnar.com.au/DCP00425.JPG (accessed 12th April 2012)http://www.bolnar.com.au/DCP00425.JPG http://www.bendcraft.com/images/image_8_l.jpg (accessed 17th March 2012)http://www.bendcraft.com/images/image_8_l.jpg http://www.bendcraft.com/images/image_9_l.jpg (accessed 17th March 2012)http://www.bendcraft.com/images/image_9_l.jpg Kula, D; Ternaux, E; Hirsinger, Q; Materiology: The Creative Industry's Guide to Materials and Technologies; (Basel, Birkhäuser Architecture and Amsterdam, Frame Publishers, 2008) ; page 245. Lefteri, Chris; Making It: Manufacturing Techniques for Product Design; (London, Laurence King, 2007); page 87. Kula, D; Ternaux, E; Hirsinger, Q; Materiology: The Creative Industry's Guide to Materials and Technologies; (Basel, Birkhäuser Architecture and Amsterdam, Frame Publishers, 2008) ; page 48.

85. Bibilography Ercolina USA YouTube channel http://www.youtube.com/user/ErcolinaUSA (accessed 12th April 2012)http://www.youtube.com/user/ErcolinaUSA Kottler Metal Products YouTube channel http://www.youtube.com/user/KottlerMetalProducts (accessed 12th April 2012)http://www.youtube.com/user/KottlerMetalProducts Simulación de la Fabricación mediante Perfilado de Chapa de un Guardarraíl ; http://youtu.be/jW3QDwU8cag; (accessed 23 rd April 2012)http://youtu.be/jW3QDwU8cag Jem Melts Rock Using Sunshine - Bang Goes The Theory - Series 3, Episode 5 Preview - BBC One; http://youtu.be/z0_nuvPKIi8; (accessed 23 rd April 2012)http://youtu.be/z0_nuvPKIi8 Melting steel with solar power – James Mays Big Ideas; http://youtu.be/8tt7RG3UR4c; (accessed 23 rd April 2012)http://youtu.be/8tt7RG3UR4c http://elibrary.steel.org.au/asi/index.cfm?070CBAFC-1E4F-17FA-CD13-196EF2865903 (accessed 20th March 2012)http://elibrary.steel.org.au/asi/index.cfm?070CBAFC-1E4F-17FA-CD13-196EF2865903 http://elibrary.steel.org.au/asi/index.cfm?070CBAFC-1E4F-17FA-CD13-196EF2865903 (accessed 20th March 2012)http://elibrary.steel.org.au/asi/index.cfm?070CBAFC-1E4F-17FA-CD13-196EF2865903 http://www.flickr.com/photos/pcw/4840894857/ (accessed 4 th May 2011)http://www.flickr.com/photos/pcw/4840894857/ http://www.crankbrothers.com/eggbeater.php (accessed 4th May 2012)http://www.crankbrothers.com/eggbeater.php http://image.made-in-china.com/4f0j00YvNtrboGODpq/1-2083-Tool-Steel-Round-Bars.jpg (accessed 4th May 2012)http://image.made-in-china.com/4f0j00YvNtrboGODpq/1-2083-Tool-Steel-Round-Bars.jpg http://en.wikipedia.org/wiki/Injection_molding (accessed 4th May 2012)http://en.wikipedia.org/wiki/Injection_molding http://www.airliners.net/photo/1116891/L/ (accessed 4th May 2012)http://www.airliners.net/photo/1116891/L/ http://www.bluescopesteel.com/files/dmfile/SteelforLife07.pdf (accessed 4th May 2012)http://www.bluescopesteel.com/files/dmfile/SteelforLife07.pdf Halmos, George T. Roll Forming Handbook, CRC Press, 2005. ISBN 0824795636ISBN 0824795636 Dobrev, Atanas; George T. Halmos (1993). Roll forming into the 21st century. Society of Manufacturing Engineers. Todd, Robert (1994). Manufacturing Processes Reference Guide. New York: Industrial Press inc.. ISBN 0831130490.ISBN0831130490 http://www.worldsteel.org/faq/about-steel.html (accessed 20th March 2012)http://www.worldsteel.org/faq/about-steel.html http://www.worldsteel.org/media-centre/multimedia/steel-production (accessed 20th March 2012)http://www.worldsteel.org/media-centre/multimedia/steel-production http://www.bluescopesteel.com/about-bluescope-steel/student-information/steelmaking (accessed 20th March 2012http://www.bluescopesteel.com/about-bluescope-steel/student-information/steelmaking Ashby, Mike and Johnson, Kara; Materials and Design: The Art and Science of Material Selection in Product Design; (Oxford, Elsevier Butterworth-Heinemann, 2005); page 250 Metal Forming Practice, 2006, ISBN 9783540332169, pp. 194 - 211 Heng, 2007. 'Role of mandrel in NC precision bending process of thin-walled tube', International journal of machine tools & manufacture, 0890-6955, vol. 47, Issue 7, p 1164, http://www.sciencedirect.com.ezlibproxy.unisa.edu.au/science/journal/09240136; Journal of Materials Processing Technologyhttp://www.sciencedirect.com.ezlibproxy.unisa.edu.au/science/journal/09240136