A Metal Plate Roll Bending Machine, also known as a Sheet Metal Rolling Machine, is a mechanical device that uses work rolls to bend sheet metal into various shapes such as cylindrical, conical, and other forms. This equipment plays a crucial role in sheet metal fabrication.
The machine consists of a set of rollers that apply pressure to the plate as it passes through, gradually reducing its thickness and shaping it into the desired form. These machines are technologically advanced products capable of bending plates of varying thicknesses with maximum precision, high productivity, and long-term reliability.
There are different types of plate bending machines to cater to various application requirements. For instance, Faccin produces models suitable for bending thin plates like HCU (a high-speed two-roll bending roll), ASI (a three-roll initial pinch bending roll), and 3HEL (an electronic three-roll pyramid bending roll with double pinch). For rolling thicker plates, they offer models like 4HEL (a four-roll pyramid electronic bending roll), and HAV (a three-roll variable geometry bending roll).
Automation is a strong point of these machines. They can include features like plate loading systems, feeding tables, supports, ejectors, conveyors, and many other custom-made solutions.
Please note that the exact specifications and features can vary based on the manufacturer and the specific model of the machine.
Metal Plate Roll Bending Machines, also known as Plate Rolling Machines or Roll Bending Machines, operate based on the principle of three-point forming circles. Here's a step-by-step explanation of how these machines work:
Placement of Metal Plate: The metal plate is placed between the upper and lower rollers.
Application of Pressure: The top roller applies downward pressure on the metal plate, causing it to undergo plastic bending deformation due to compression.
Roller Rotation: The rotation of the lower rollers, driven by friction between the plate and the rollers, causes the plate to move back and forth along its longitudinal direction.
Continuous Deformation: As the plate passes through the roller deformation zone, plastic deformation occurs when stress exceeds the yield limit. This results in the plate undergoing plastic bending deformation along its entire length and being shaped into the desired form.
There are different types of Plate Rolling Machines, such as three-roller machines (variable pitch aka variable geometry) and four-roller machines. In a typical three-roller machine, two lower rolls function as active rolls and can rotate in both positive and reverse directions, while the upper roller serves as a follower roll, which can move up and down vertically. The advantage of having a variable three-roll machine is its ability to roll many thicknesses and diameters of cylinders.
Plate rollers can be powered and controlled in multiple ways. Older plate mills are driven by electric motors and newer ones are directed by programs that are loaded into the CNC controller.
Please note that this is a general explanation and the exact working mechanism can vary based on the specific model and manufacturer of the machine.
There are several types of Metal Plate Roll Bending Machines, each designed to cater to different requirements and applications. Here are some of the main types:
Two-Roll Plate Bending Machine: This machine features an upper roller made of rigid metal and a lower roller covered with high strength polyurethane material that can be adjusted vertically. When the roller rotates, the upper roller and the feed plate are subjected to pressure, causing the elastic layer of the lower roller to deform. These machines are mainly designed for metal plates with a width of 2000mm and a thickness of less than 2mm for round rolling, making them ideal for batch production of thin containers in the household appliance industry.
Three-Roll Plate Bending Machine: There are two main types of three-roll machines: symmetrical and asymmetrical. In a typical three-roll machine, two lower rolls function as active rolls and can rotate in both positive and reverse directions, while the upper roller serves as a follower roll, which can move up and down vertically.
Four-Roll Plate Bending Machine: These machines are suitable for bending plates in a variety of thicknesses. They are technologically advanced products capable of bending varyingly thin or thick plates offering maximum precision, high productivity, and long term reliability.
Variable Geometry Plate Bending Machine: These machines have three rolls that can be adjusted to form different geometries. They are ideal for bending heavy plates.
CNC Plate Bending Machines: These machines use Computer Numerical Control (CNC) for precise control over the bending process. They are specifically designed for bending circular cans for applications like wind tower production and also complex shapes for applications like tank production.
Each type of machine has its own advantages and is used for specific applications based on factors such as the thickness and width of the metal plate, the desired shape, and production volume.
A plate rolling machine, also known as a roll bending machine or plate bending machine, is a type of metal forming machine that uses work rollers to produce sheet metal round processing and forming. Here are the key components of a plate rolling machine:
Rollers: The machine typically consists of three parallel steel rollers arranged similar to the vertices of an isosceles triangle. The types of rollers include:
Top Roller: This is mainly composed of the main oil cylinder, bearings, and upper roll. The upper roll is an important part of this plate rolling machine.
Lower Rollers: These are driven by the final reduction gear of the main reducer, which creates a rotary motion that provides the torque necessary for the rolling of plates in the machine.
Rolling Machine Structure: This includes frames, base plates, and support beams that provide stability and rigidity during the bending process.
Main Oil Cylinder: This is part of the upper roller device and plays a crucial role in the functioning of the machine.
Bearings: These are used in both the upper roller and lower rollers to reduce friction and ensure smooth operation.
Double Row Self-Aligning Bearing: This is used in the upper roller device for better alignment and efficiency.
The working principle of a plate rolling machine involves passing a sheet of metal between the lower and upper rollers to change its shape and undergo a curvature, known as the radius of curvature. The entire process results in permanent plastic deformation of the sheet metal workpiece.
When considering a Metal Plate Roll Bending Machine, there are several key features to take into account:
Machine Type: The type of machine is crucial as it determines the kind of bending application that can be performed. The general machine styles include three-roll initial-pinch, three-roll double-pinch, four-roll double pinch, three-roll variable translating, three-roll pyramid, and two-roll systems.
Machine Capacity: The machine's capacity should match your material. Plate roll manufacturers commonly rate their machines according to baseline material yield strengths of 36,000 to 38,000 pounds per square inch (PSI). However, you need to realize that steel mills are producing materials with ever-increasing yields.
Prebending and Rolling Capacities: You often will see capacities for both prebending and rolling for any plate rolling machine. It's important to note that the maximum rolling capacity is usually expressed with the basic requirement of multiple rolling passes and very long unbent flats.
Material Thickness and Width: The thickness and width of the material you intend to bend will determine the type of machine you need.
Control Method: Plate rollers can be powered and controlled in multiple ways. Older plate mills are driven by electric motors and newer ones are directed by programs that are loaded into the CNC controller.
Working Length of the Roller: This refers to the maximum length of plate that the machine can handle.
Top Roll Diameter Size: This is another critical component to disclose to machinery companies when looking for a plate roller.
Minimum Thickness of the Material: This refers to the thinnest plate that the machine can handle.
Material Yield: The yield strength of the material you intend to bend is another critical component to consider when looking for a plate roller.
Remember, it's always a good idea to consult with plate or sheet metal rolling equipment experts directly for more in-depth information and application engineering expertise.
Metal Plate Roll Bending Machines offer several benefits that make them a valuable asset in many industries. Here are some key advantages:
Efficiency: These machines are known for their efficiency when producing large-diameter cylinders. They can achieve high precision shaping in a single stroke.
Speed: They offer fast processing speed as there's no need for end bending.
Quality: Metal plates will not crack or have irregular warping even after punching, cutting, and rolling. This ensures the quality of the final product.
Versatility: These machines can bend metal sheets into various shapes such as large arcs, cylinders, ellipses, squares, and multi-sectional arcs.
Automation: Many of these machines come equipped with automatic feeding and discharging systems, offering high levels of automation and increased efficiency.
Cost-Effective: Some types of these machines are known for their low cost, making them an affordable solution for many businesses.
Durability: The machines are designed to handle heavy-duty tasks and can withstand the rigors of industrial use.
Minimal Surface Damage: The process does not cause wrinkles or scratches on the surface of the parts.
These benefits make Metal Plate Roll Bending Machines an essential piece of equipment in various industries including home appliances, pressure vessels, wind power, shipping, aerospace, military, and automobile refurbishment.
Plate rolling machines and other fabricating machinery like press brakes, shears, and laser cutters, all have their unique roles in the metal fabrication industry. Here's a comparison:
Plate Rolling Machines:
Plate rolling machines are used to roll flat metal sheets into a round or conical shape.
These machines use three or four rolls in various configurations to bend the metal.
The capacity of these machines is often rated based on baseline material yield strengths.
The process involves multiple forces and directions of inertia as the forming takes place.
Plate rolling requires a lot of skill and comprehensive knowledge about materials and rolling practices.
Other Fabricating Machinery:
Press Brakes: These are used to bend sheet and plate material. They provide high precision but are limited to producing one bend at a time.
Shears: Shears are used to cut sheet metal along straight lines.
Laser Cutters: These use a high-powered laser to cut precise shapes out of sheet metal.
The choice between a plate rolling machine and other fabricating machinery depends on the specific requirements of your project, such as the type of material, yield, tensile strength, width, thickness, and diameter of the part. Each machine has its own strengths and is best suited for certain types of jobs. Therefore, understanding your project needs will help you select the right equipment for your metal fabrication tasks.
Choosing the right Metal Plate Roll Bending Machine for your needs involves considering several factors. Here are some key points to guide your decision:
Machine Type: The type of machine is crucial as it determines the kind of bending application that can be performed¹. The general machine styles include three-roll initial-pinch, three-roll double-pinch, four-roll double pinch, three-roll variable translating, three-roll pyramid, and two-roll systems.
Machine Capacity: The machine's capacity should match your material. Plate roll manufacturers commonly rate their machines according to baseline material yield strengths of 36,000 to 38,000 pounds per square inch (PSI). However, you need to realize that steel mills are producing materials with ever-increasing yields.
Prebending and Rolling Capacities: You often will see capacities for both prebending and rolling for any plate rolling machine.
Material Thickness and Width: The thickness and width of the material you intend to bend will determine the type of machine you need.
Control Method: Plate rollers can be powered and controlled in multiple ways. Older plate mills are driven by electric motors and newer ones are directed by programs that are loaded into the CNC controller.
Working Length of the Roller: This refers to the maximum length of plate that the machine can handle.
Top Roll Diameter Size: This is another critical component to disclose to machinery companies when looking for a plate roller.
Minimum Thickness of the Material: This refers to the thinnest plate that the machine can handle.
Material Yield: The yield strength of the material you intend to bend is another critical component to consider when looking for a plate roller.
Scalability: Do you have a special shape for bending? For example, do you need a Plate roller that has a metal cylinder with almost no straight edges?
Productivity Factor: Consider your production volume and how quickly you need tasks completed.
Remember, it's always a good idea to consult with plate or sheet metal rolling equipment experts directly for more in-depth information and application engineering expertise.
Operating a Metal Plate Roll Bending Machine requires adherence to certain safety precautions and operational guidelines to prevent accidents and ensure efficient operation. Here are some key points to consider:
Avoid Entanglement: Severe injuries, amputations, and even death can occur if a worker is caught and drawn into the counter-rotating infeed rolls. Wearing gloves with fingertips and loose clothing can increase the risk of entanglement.
Use Safety Devices: Devices such as safety trip cables (emergency stop) and hold-down controls can provide some protection for the operator and anyone near the machine. These safety devices do not directly prevent entanglement or entrapment but are intended to help prevent or minimize injury by stopping the machine quickly.
Maintain Adequate Distance: Maintain adequate distance from the workpiece being formed to prevent being struck by it.
Use Feed or Roller Tables: Whenever practical, use feed or roller tables.
Wear Appropriate Clothing: Consider wearing gloves without fingertips or palm protection only. Prohibit loose-fitting clothing.
Follow Operational Guidelines: The machine should be used as per the operational guidelines provided by the manufacturer.
Emergency Stop Button: An emergency stop button should be provided at the machine control console and at any remote workstation.
Training: Ensure that all operators are properly trained on how to use the machine safely and efficiently.
Remember, these are general guidelines, and specific safety measures may vary based on the type of machine and its manufacturer. Always refer to the user manual or consult with the manufacturer for specific safety instructions.
Maintaining a Metal Plate Roll Bending Machine is crucial for its longevity and optimal performance. Here are some steps and guidelines for the maintenance of these machines:
Regular Inspection: Regularly inspect the machine for any residue post-rolling, broken parts, or cut-down sections of the steel plate that you would have rolled earlier.
Lubrication: Ensure that all moving parts are well lubricated to reduce friction and prevent wear and tear.
Cleaning: Keep the machine clean. Remove any debris, dust, or residue that could interfere with its operation.
Check for Damage: Regularly check for any signs of damage or wear on the machine parts. Replace any damaged parts as soon as possible to prevent further damage.
Follow Manufacturer's Guidelines: Always follow the manufacturer's guidelines for maintenance. This includes recommended cleaning methods, lubrication types, and maintenance schedules.
Training: Ensure that all operators are properly trained on how to maintain the machine safely and efficiently.
Safety Devices: Check the safety devices regularly to ensure they are working correctly. These include emergency-stop buttons, safety trip wires, and hold-down controls.
Remember, regular maintenance not only extends the lifespan of your Metal Plate Roll Bending Machine but also ensures its optimal performance and safety.
Metal Plate Roll Bending Machines are versatile and find applications in a variety of industries. Here are some key industries and applications:
Boiler Manufacturing: These machines are used to bend metal plates into cylindrical shapes for boiler shells.
Shipbuilding: In shipbuilding, these machines are used to form various parts of the ship, including the hull and other structural components.
Petroleum and Chemical Industries: These machines are used in the petroleum and chemical industries for creating storage tanks and other equipment.
Hydraulic Industry: In the hydraulic industry, these machines are used to form various components like cylinders.
Metal Structure: These machines are used in the construction of metal structures for buildings, bridges, towers, etc.
Wind Power: In the wind power industry, these machines are used to form the tower sections of wind turbines.
Automobile Refurbishment: These machines are used in automobile refurbishment for bending and forming various parts.
Home Appliances: These machines are often equipped with automatic feeding and discharging systems, offering high levels of automation and increased efficiency, making them ideal for batch production of thin containers in the household appliance industry.
The plate rolling machine has the capability to bend metal sheets into large arcs, cylinders, ellipses, squares, and multi-sectional arcs. This versatility makes them a crucial piece of equipment in these industries.
Choosing the right supplier for a Metal Plate Roll Bending Machine is a crucial decision that can significantly impact your operations. Here are some factors to consider:
Quality of Machines: The quality of the machines is the most critical factor to consider when choosing a plate rolling machine manufacturer. You want a machine that is well-engineered, durable, and reliable.
Customer Service and Support: Good customer service and support are essential when purchasing a plate rolling machine. The supplier should be able to provide prompt and effective support in case of any issues or queries.
Price and Value for Money: Price is always a factor to consider when making a purchase. However, it's important to ensure that the price aligns with the value you're getting in terms of machine quality, features, and after-sales service.
Reputation: Consider the reputation of the manufacturer in the industry. Look for manufacturers who have a proven track record of providing quality equipment and exceptional customer service.
Range of Products: The manufacturer should offer a diverse range of products to cater to different requirements.
Here are some top manufacturers known for their quality plate rolling machines:
Akyapak: Founded in 1962, Akyapak has been providing metal bending, drilling, cutting machines, and welding solutions to 110 countries across six continents.
AMB Picot: Founded in 1964, AMB Picot has more than 150 years of experience in machine tool manufacturing.
Carell Corporation: Carell Corporation was founded in 1992 and offers products including plate roll, angle roll, vertical roll, tube & pipe bending, metal forming, and organic equipment.
Davi: Davi is the world's largest manufacturer of heavy-duty plate roll, heavy-duty angle roll, high productivity lines, and customized rolling machines.
Remember to do your research and consult with experts before making a decision.
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