In the manufacturing and metal industry, many tools and advancements have been created to make the job that much more efficient. One of those advancements includes the plate rolling machine.
You may be asking, &#;What is a plate rolling machine?&#; or &#;What is it used for?&#; You will learn all about the plate rolling machine definition and its working principle in this article.
Plate rolling is a crucial part of any metal-working job and is essential to ensuring that the job is done correctly. From rolling metal sheets into pipes or creating buckets and more, the plate rolling machine is a valuable and technologically advanced tool used by many manufacturers and workers.
While there are many different types of metal plate rollers that result in different sizes of metal cylinders, they all have their uses and qualities that make it an irreplaceable machine, especially in the metalworking industry.
Now, let&#;s take a look at what a plate rolling machine is and what it can do.
Let us first start with a plate rolling machine definition. While the plate rolling machine may look intimidating, the usage is really quite simple.
Definition:
A plate rolling machine is a machine that is used to roll metal into a cylindrical shape using hydraulics or mechanics. This can include anything from pipes, buckets, pressure vessels, and more.
While most plate rolling machines are used to roll flat metal pieces into a cylindrical shape, there are some that can also do the opposite, though they aren&#;t used as often. You may hear plate rolling also referred to as roll bending or plate bending, though they all mean the same thing.
Plate rolling machines are most often seen in industries such as gas and oil, home, automobile, appliances, and more. Along with it being used in many different industries for various purposes, there are also a variety of types.
These different types of machines include two roll machines, three roll initial, three roll double pinch, three roll variable translating geometry, four roll double pinch, vertical rolls, and automated cycle and specialty rolls.
Each different type of plate rolling machine has a different purpose depending on what you are using it for. While some are used for bigger cylinders and less arc, some of used for tighter cylinders with a high arc.
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A plate rolling machine works by using hydraulic or mechanical power along with three to four hardened metal rollers.
Normally, there is four rollers total, two of which are adjustable for size and cylinder shape. Three of the four rollers are found on the bottom with a bigger roller that goes on top. The two outer rollers are adjustable in order to change the shape and size of the roll that you are creating.
One of the most common types of metal plate rollers is the standard four roller because it can produce the biggest variety of metal cylinders.
While there are many different types of plate rolling machines that will all change the usage slightly, this is how you can use a standard four-roll type.
Plate rolling machine working principle and operation:
To use the machine, you first raise the lower roll to the punch plate, meaning that it is now above the other two rollers. Then, you slide the metal sheet into place between the rollers, stopping when it is square against the pinch plate that you raised.
Once it is firmly in place, you can lower the initial roller back down and bring the third and potentially fourth roller into the correct position to roll the metal while moving the metal to the center of the punch plate. You then raise the side roll that the metal is on the create the &#;pre-bend&#;, or the initial bend, in the metal.
Roll the metal through the machine until it is on the other side of the upper roller, lower the pre-bend roller, and raise the opposite bending roller until it is in position to roll.
From there, the machine pulls the metal through the rollers, creating an arc or cylindrical shape by pinching the metal between them. The two edges are then welded together to complete the cylindrical shape and merge the two edges.
While there are many different types of plate rolling machines that are slightly different in the shape or size of the cylinder that they make, they all follow generally the same steps and procedures and will all result in the round, cylinder shape. The only difference between the machines would be the size of the cylinder it creates.
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To break it down more, here are some simplified steps you can follow If you are using a four-roller bending machine:
- Raise the lower roll to the punch plate
- Place the metal sheet until it is square against the lower roll
- Lower the roll and pull the metal sheet until it is centered with the punch plate
- Create the pre-bend by raising the first roller or pre-bend roller and pull the metal through
- Lower the pre-bend roller and raise the opposite roller the create an arc in the metal
- Pull the metal all the way through until it creates a complete cylinder
- Weld the two edges together
While these steps may vary if you are using a two roller or three roller, this is the general idea and usage of a plate rolling machine and how it works.
Overall, the plate rolling machine working principle is immensely valuable in many industries or the manufacturing field of work. Because it is used to create cylindrical shapes such as pipes, buckets, and more, it can be used in any industry from military to homes and beyond. Its usage is extremely valuable and is used across the manufacturing workforce.
From pipes to housing appliances and more, the technologically advanced plate rolling machine is irreplaceable in the metalworking industry. Because of its many uses and possibilities, it is not going away anytime soon.
Click here to know: How To Bend Cone Workpiece With Plate Rolling Machine
Ever wondered how the metal around you is getting its shape? Be it an automobile part, a ship, or a large metal container. It's not magic, but a machine breathing life into metal and turning it into breathtaking art.
Plate rolling is an incredibly essential part of any metal industry. The task of these rolling machines is simple: shaping metal plates into cones, cylinders, and curved shapes.
The definition looks simple, but the plate bending/rolling machines deliver sophisticated, cutting-edge, unique products. Different types of plate rolling/bending machines are available in the market. This blog will have a detailed view of a 3-roll plate rolling/ bending machine's working principle and rolling process.
What is a Plate Bending/Rolling Machine?
A Plate Rolling machine, also known as a roller machine, is a metal rolling equipment. Its main purpose is to shape metals into conical, cylindrical, or curved shapes. Industries worldwide require different machines according to their needs.
Plate rolling is a complex process but crucial for expanding the bending options available to your customers. Moreover, it depends on the precision levels and skill set of operators.
What Are the Types of Roll Plate Bending Machines?
There are three types of plate rolling/bending machines that individual industries need:
2-roll Plate Bending/Rolling machine
3-roll Plate Bending/Rolling machine
4-roll Plate Bending/Rolling machine
As mentioned above, each machine has its individual use, but here we will have a look at the 3-roll Plate Bending/Rolling machine.
What is the Working Principle of a 3-Roll Plate Rolling/Bending Machine?
Before understanding the working, let's have a brief look at a 3-Roll Plate Rolling/Bending Machine.
Industries of all sizes, from shipping to metal fabrication, need 3-roll plate bending/rolling machines. The process/task of the machine remains the same: bending metal sheets into the desired shape.
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A 3-roll bending machine has three rolls: two side rolls that move back and forth, while the upper roll stays fixed but rotates. You can interchange this upper roll to fit shells of varying sizes.
Images 1, 2, and 3 show how a 3-roll plate bending machine uses rollers A, B, and C to shape metal plates. This is a pre-pinching/pre-bending process in plate bending.
The manufacturer can control the amount and speed of the rollers to achieve the desired shape. As you can see, the plate smoothly and uniformly bends/rolls using the three rollers. The engineer can also bend or roll the desired location to achieve the required shape during the pre-bending process.
Let&#;s have a look at the mechanism in detailed steps.
Step 1: Placing the Plate
The first step for rolling a plate is placing the plate between the upper (I) and lower rollers (II and III). This process bends the plate into an arc or closed circle. As the metal sheet passes through the three cutting points created by the rollers, the plate will mold into the desired shape.
(Have a look at Diagram 1 of the working principle of a 3-roll rotating/ bending machine.)
Step 2: Plastic Bending Deformation
After the insertion of the metal plate, the top roller applies downward pressure on the plate. As a result, the plate undergoes a plastic bending deformation process due to compression.
Plastic bending deformation of metals occurs when an object's shape and size change due to applied force. Deformation happens when the shape of a material or object changes due to pressure. Plastic deformation occurs when the applied force is enough to cause a permanent deformation.
Step 3: Rotation & Friction
Due to the friction between the rollers and the plates, the lower rollers begin rotating, causing the plate to move back and forth along its longitudinal direction.
The plate moves back and forth as the lower roller alternatively does a forward and reverse rotation. At the same time, the upper roller continuously exerts vertical pressure or downward pressure on the plate.
The stress will exceed the yield limit during this process. Now the plastic deformation will occur. You can see the plate going through a plastic bending deformation. This entire process lets the plate take the required shape.
Key Factors of a 3-Roll Plate Bending/ Rolling Machine
To bend the plate to a radius no longer than the upper roller, you can modify the relative position of the upper and lower rollers.
A motor and a reducer power the lower roller (II and III), making them rotate in a similar momentum and the same or opposite direction.
To vary the curvature of the desired plates, you can adjust the position of the upper rollers.
You can change the position of the upper rollers to vary the curvature of the desired plates. Moreover, you can readjust the upper roller if you do not receive the desired curvature after a single rolling process. Then, you can redo the process until you achieve the desired shape.
There is one disadvantage of this machine. When you look at the above diagram, you can notice that the three rolls of the 3-roll bending/rotating machine form an isosceles triangle.
During the process, this triangle-forming shape forces the two ends of the machine to leave a straight part. The straight part of the machine is half the distance between the centers of the two lower rollers. This is the part where the rollers cannot roll.
Despite this one disadvantage, there are several benefits and features of a 3-roll plate bending machine. The main benefits of this plate rolling machine are structure, ease of operation, and low cost.
Wrapping Up!
3-roll plate bending machines have played an important role in history and continue to do so. You can rely on our plate-bending machines across various industries, including shipping, oil tanks, metal structures, tubes, and pipes. Be it 2-roll bending, 3-roll bending, or 4-roll bending machines.
We hope this blog helped you understand the working principle of our 3-roll bending machine. Feel free to contact us for all your plate-bending machinery needs. Our team at Himalaya Machinery would love to help you.
The company is the world’s best Sheet Metal Rolling Machine supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.