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Rolling machine for rails. Rolling mill - how to give the metal the desired shape? Homemade pipe bender for a profile pipe

The rolling machine is special equipment, which is used in metallurgical industry and is intended for processing a metal workpiece by pulling it through special rolls.

With the help of a rolling mill, products such as rolled metal sheets, square or round beams, and wire are obtained. In the future, complex mechanisms and machines are created from these materials.

Rolling machines for sheet metal

Rolling machines, with the help of which sheet metal is obtained, belong to the so-called section mills.

Such machines can be:

high-grade;

mid-range;

rail rolling.

Sheet rolling mills can be operated by hot or cold forming, and can produce metal plates with a thickness of 50 to 350 mm, sheet metal from 3 to 50 mm, and metal strips from 1.2 to 20 mm. After the product is ready, the products are wound with standard rolls weighing 50 tons.

Rolling machines for profile pipes

Rolling machines, with which you can get profile pipes, experts divide into three types.

Roller bender- a machine that is used to deform sheet metal. Most often, this unit is used for the manufacture of thin-walled parts. For example, ebbs or gutters.

Three-roller machines- these devices allow you to deform not only the sheet, but also the pipes. With the help of the equipment, profile rolled products are also processed. The power of this equipment is determined by the downforce generator. If the machine is powered by a hydraulic drive, then it can even deform T-rails.

Machines with four rollers- the most powerful unit of this type. Such equipment makes it possible to produce even an annular profile. These machines are used in industrial enterprises with mass production.

Manual rolling machines

Manual rolling machine allows you to get specific metal blanks, wire or, for example, straighten metal plates at home.

The design of the manual rolling machine includes:

two gears;

two racks;

gear;

springs;

bushings;

bearings.

The manual rolling machine can be universal due to the fact that shafts can be used on the machine different designs. So, if you put shafts with special grooves, you can make wire, and installing circular knives allows you to cut metal.

Production of rolling machines

Rolling machines are manufactured by many companies in different countries peace.

The rolling line includes equipment such as:

the main line of the rolling mill;

heating furnaces;

systems that allow descaling;

equipment for cutting, transporting, winding, marking, packaging.

Modern rolling equipment must have characteristics that allow you to receive products required quality, while it should be sufficiently compact, versatile, economical and energy-intensive.

An important factor in classy equipment is its production flexibility, ability to quickly change to another product, durability and ease of maintenance.

Manufacturers and suppliers of rolling machines

Rental equipment for metallurgical complex is a complex system, the production of which uses the most modern technologies. Among the global brands producing rolling machines, the following companies stand out.

OAO Elektrostal Heavy Machinery Plant is the only Russian enterprise, which manufactures fluid friction bearings for rolling mills.

BORA Group is a major manufacturer of lines and other automated equipment for thin sheet metal processing in Russia.

NPP Mekhatronika is a Russian company that designs rolling mills and manufactures rolling mills to individual orders.

If we talk about global manufacturers, we can note the companies:

MS COSTRUZIONI SRL, Italy. This enterprise is engaged in the production of complex equipment and machine tools for the metallurgical industry. Among other things, the company is engaged in the production of rolling mills of various capacities.

ELEKTROMASHSTAN, Spain. The plant produces rolling machines that allow the production of metal sheets, pipes, profiles. The company has a developed network for the sale of its equipment and is well known in many countries around the world.

Luoyang Sennuo Precision Bearing Co., Ltd China. This enterprise develops and manufactures machine tools for various purposes, including a rolling mill. It should be noted that despite good quality The company sells its equipment at very reasonable prices.

Where can I buy a rolling machine

You can get acquainted with manufacturers of rental equipment for further cooperation at specialized events (exhibitions, fairs). You can buy rolling machines from supplier companies and on the Internet.

Among the most famous sites offering such equipment, experts note the following trading platforms:

prostanki.com. On the site you can find offers for the sale of rolling machines of various capacities, from manual to powerful industrial equipment;

kovkapro.com. On this resource you can order rental equipment for small businesses and private use;

pulscen.ru. This site offers a wide range of rolling machines. On the site you can choose equipment for equipping a large plant or a small factory.

Rolling machines at the exhibition

Industrial companies have the opportunity to get acquainted with the most modern models of rolling equipment at specialized exhibitions.

Usually well-known foreign and domestic manufacturers demonstrate their products at such events.

In addition, here you can get acquainted with the most advanced technologies in the field of metalworking. For example, not only Russian companies but also representatives of other countries.

Read our other articles:

Rolling machines are the most important equipment in obtaining metal in the form in which it is needed. They will be discussed in the article.

General information

Today, metal is the most common material from which a huge variety of things are made, from small household parts to large industrial facilities. However, there is a very important point that not everyone knows about. Simply smelting the metal and then turning it into an ingot is not enough. After the formation of the ingot, any metal is transferred to the rolling shop. The only equipment that is available in such workshops is rolling machines. It is these devices that give the desired shape, which is suitable for the subsequent use of metal. It is worth noting that this equipment is one of the oldest today. However, over the years of its use, the machine has proven itself from such a good side, has such good characteristics and productivity that it is still used today.

Machine device

As such, the rolling machine apparatus is not complex or difficult to maintain, assemble, or repair. The sole purpose of this device is to give shape to ingots of metal. In other words, large ingots enter the rolling mill, and as they pass through the rolling mill, they are shaped into more familiar sheet metal. In order to achieve this effect, the design of the rolling machine has two rollers that constantly rotate towards each other. From point of view technological process this work is considered quite simple. In addition, the constant improvement of technology has made it possible to make many improvements and modifications to the operation of this device. Thanks to these changes, all equipment of this type is now able to operate in a fully automatic mode.

Rolling

The rolling machine for metal performs another very important function. It doesn't just shape the leaf. As the ingot passes through this machine, the metal becomes more uniform and denser in structure. This is due to the fact that the rollers completely overwrite or close any cracks or voids that could well be formed on the ingot.

Another important point- the process of turning or rolling metal into a sheet form takes place in several stages and with the participation of several types of machines. Primary rolling is carried out by blooming and slabbing devices. It is worth noting that before sending the ingot to rolling on these machines, it needs to be slightly warmed up. Raising the temperature of the metal will increase the plasticity of the material during its rolling. If we talk about the performance of such machines, then it is huge. One machine is capable of producing about 6 million tons of metal per year. This is taking into account the fact that the weight of the ingots coming for hire can be in the region from 1 to 18 tons.

Blooming or slabing

Before entering the rental, ingots are heated in special wells. The temperature maintained in such devices can reach 1800 degrees Celsius. After passing the well, an electric car is used, which, in fact, gives out the heated ingot for rental of blooming or slabing. The difference between these machines is that blooming has only two rollers, while slabing has four. It is important to understand that the passage of this stage and the processing process itself are only primary, since at the exit from blooming or slabbing the ingot still does not have a full-fledged form of sheet material. These units are designed to form bars. Depending on its shape and size, the resulting material is divided into blooms or slabs. An important note - the use of blooming or slab rolling machines is carried out only at those industrial facilities where the metal will later be poured into molds.

General characteristics of the machine

Rolling mills - devices having smooth rollers through which metal is passed in order to give it a sheet shape. Currently, there is a huge range of these devices. The biggest difference between the machines is in the shape of the rollers. For example, there is a unit that was originally made for the production of rails. The shape of its rollers was prepared precisely for this task during the production of the machine. It is also important to understand that the machine has several pairs of rollers through which the metal passes. Constant progress has led to the fact that all types of devices are able to work in a constant automatic mode. The speed at which the stands pull the ingot through the machine can reach a record speed of 290 km/h. The annual capacity of such a rolling mill reaches several million tons. To date, such units as casting and rolling are gaining great popularity. The advantage is that they can act as a separate complete production line, unlike conventional rolling mills.

Currently, there are such types of machines as blanks, sheet, strip, sectional, and some types are capable of producing wire or beams.

pipe rental

Another large category of rolling machines is intended for the production of metal pipes, not sheet metal. There are only three main types of pipe rolling machine that are currently in use. These include piercing, rolling and finishing machines.

If we talk about piercing mills, then they can have three different types of rollers used for rolling. There are barrel-shaped, mushroom-shaped and disc rollers. The device of the first type, i.e. barrel-shaped, is characterized by the fact that these machine elements have a double-tapered shape with a diameter of 450 to 1000 mm. Both parts are located in the horizontal plane, but along the vertical axis, you can adjust the feed angle from 5 to 18 degrees or more.

Screw rolling

Rolling machine for profile pipe also can perform metal screw processing. This type of operation in double-cone rolls creates tensile and shear stresses in the metal. It is important to note that the radial stress of the workpiece can reach quite large values, which creates a cavity of small diameter, which has uneven walls. In order to obtain a hole with the required diameter and at the same time avoid the presence of irregularities, and make even walls, it is necessary to roll on a mandrel. A mandrel is understood as a cone-shaped tool, which is located at the end of the rod between the rolls along the path of movement of the metal workpiece. There is a special stop for fastening the rod with such a mandrel. As the metal moves forward, it is pierced by this bezel which passes through the hole, expanding and flattening it.

It is rather problematic to collect reviews about a rolling machine for a profile pipe, since such units are mainly used only by large enterprises. However, here the very use of these particular units already indicates that they work stably and well. In other words, conclusions can be drawn based on the fact that for a huge period of time all metalworking factories use such machines. And this means that the presence of an automatic mode and huge performance do their job. The disadvantages include the fact that the dimensions of such devices are quite large, and their stop and new launch- it's very problematic.

Thin tubes

It should be noted that thick-walled sleeves are obtained during the passage of rolled products on piercing machines. After processing on this device, the workpiece is transferred to thin-tube rolling on a device such as:

pilgrim;
auto;
continuous;
three-roller.

The name of each of these units is determined by the type of rolling mill that is used on this equipment.

Rolling punching machine

The most famous manufacturer of this unit is Kadzama. This device is also called a roller press. The device of this thing is very simple, and it is intended for cutting cardboard, paper or plastic boxes for confectionery.

The advantages of this device include the fact that it pays off pretty quickly. The first 10,000 boxes - this is the approximate cost of one such machine. Cost price finished products, that is, boxes, is also very small. You have to pay only for the source material itself - cardboard. It is very easy to work with this type of machine. All it takes is just two things. First, a sheet of cardboard is placed on the punching knives, and then the feed handle is turned. The dimensions of such a device are also quite small. You can even install it on a regular table.

How to make a rolling machine?

In order to make a rolling machine for the production of profiles, you will need 3 mandatory things - this is metal, bearings and a lathe. The very same design of the machine is also quite simple. The constituent parts of a one-piece rolling machine is a table to which a worm gear motor is attached. In addition, it is necessary to fix 7 additional receiving stands on the table. It is important to know here that each cage consists of several constituent parts, and all of them are linked to each other. That is, each cell is connected to the next. One more nuance concerns rollers. In this model of the machine, they are removable, and their fastening is carried out on the shafts. This type of arrangement and the type of rollers itself opens up wide opportunities for the production of various profiles in terms of their dimensions, as well as the type of product. If there is such a desire, then you can put a new type of rollers that will make it possible to produce an LSTC profile. In order not to be mistaken in manufacturing, it is best to make a drawing of a rolling machine before proceeding with its assembly.

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Rolling machine - equipment for bending sheet metal

The rolling machine (rolling machine, rollers) is a versatile equipment used in the field of construction and repair for bending various metals.

Such machines are used at any modern enterprise for the production of conical, oval and cylindrical products from sheet metal. The procedure for manufacturing such structures is called rolling. It makes it possible to obtain any pipes, blanks for subsequent stamping, various finished metal products.

Simple rolling equipment also used in everyday life when it is required to make gutters, chimneys, pipes, air ducts, other products for roofing and construction works. Modern roller machines allow you to work with almost any metal. They easily bend sheets of stainless steel, alloy and carbon alloys, aluminum, cast iron.

There are also models of rolling equipment that work with polycarbonate blanks.

All the units described by us for bending sheet metal are divided into the following groups:

manual;
electromechanical;
hydraulic.

The manual machine can be mounted on a stand (floor) or on a workbench (table). It does not have a mechanical drive, therefore, to perform work on it, it is required to apply muscular strength. Manual machines are very easy to use. Their elementary design ensures high reliability of equipment operation for a long time.

Manual rollers are designed to produce pipes and other sheet metal products with a thickness of up to 1.5–2 millimeters. They are light and compact, which allows them to be carried and used directly at the facility for performing certain works (roofing, repair). Best of all, they don't need electricity. For the price, a desktop and floor-standing manual unit is always preferable to an electromechanical one.

Machine tools with an electric motor equipped with a gearbox are more efficient in operation. They facilitate and significantly speed up the process of bending pipes. The electromechanical unit is installed permanently in the corresponding workshop of the enterprise and is used for processing metal with a thickness of up to 4 millimeters.

Hydraulic equipment belongs to the heavy class. It is used for the manufacture of pipes and other structures on an industrial scale at power engineering, shipbuilding and machine-building plants. In terms of its technical potential, the hydraulic machine is several times superior to the electromechanical and manual ones. Hydraulics can produce pipes from metal sheets up to 8 millimeters thick. Often hydraulic equipment is equipped with program control.

The main unit of the described machines is a cast bed. It is made from steel or cast iron. A special deformation mechanism is mounted on the frame, consisting of several (3–4) rolls. Two rolls are stationary, rotation in the process is made by the third and, if any, the fourth. The movable shafts can also move vertically.

The upper roll is fixed on the frame according to the scheme, which makes it possible to quickly remove it if necessary, or quickly adjust it for the production of pipes with different sections. Adjustment of this structural element is carried out by a single wing-type screw. In the presence of grooves on the work rolls, not only pipes, but also rods or thick wire can be bent on them. A manual metal bending machine usually has three rolls, an electromechanical machine has 3–4. But hydraulic installations are always produced with four rolls.

The process of manufacturing pipes on any unit is really simple:

first, a sheet of metal is clamped between the middle and outer shaft by means of a special handle on the machine;
then the workpiece is pressed against them by the third roll;
start manually rotating the rolls or start the electric motor.

Passing through the shafts at a certain speed, the metal is bent at the right angles. To make pipes or gutters of quite decent quality with your own hands, you can purchase a manual machine. By and large, you don’t even need to buy it (although they are inexpensive), since you can assemble a home-made unit and use it effectively to perform small jobs. For information on how to do this, see the next section of the article.

Anyone who sets himself such a task can make such a machine with his own hands. We will very briefly describe what materials and how exactly a home-made unit can be made. First you need to take a frame made of pipes or a curved profile that will serve as a bed.

Then we prepare a U-shaped profile (ideally, when the material for it is hardened steel) for the manufacture of a vertical support for our equipment. The deforming unit of the rolling machine is located in the open (upper) part of the profile. You can fix it with a clamp, which is threaded. Under the bed, the lower part of the U-profile is fixed.

After that, we take the transmission chain, without which the roller device will not work, and mount it on the sprockets. Here it is important to pull the chain well and be sure to check the ease of its movement.

Then we install the feed handle and fasten the entire mechanism to the frame using rolling bearings. You have made the simplest manual rolling machine with your own hands! It is desirable to provide in its design a special mechanism that allows you to adjust the gap between the shafts. Then you can process metal of different thicknesses.

It is easy to make a more complex rolling mechanism with your own hands. There are a lot of materials on the Internet on this issue. Find a site with relevant information, look at the drawings of homemade installations and make your own equipment that is perfect for you.

The modern market for metalworking equipment is able to satisfy any request. Everyone can find the machine he needs at a very reasonable cost. It is easy to purchase an inexpensive compact do-it-yourself pipe bending machine, and a professional outdoor unit for a large production workshop or a modest private workshop.

Rolls of the following manufacturers are popular:

You can also buy equipment from other manufacturers - SAHINLER, JET, SCHWARTMANNS, PRINZING. The machines vary in their price, but they all do their main task well.

The range of mechanical rolling machines with an electric motor is no less impressive. Demanded electromechanical roller machines are produced by the already mentioned companies, as well as by Russian factories. We describe several popular models of such equipment:

As you can see, the choice of rolling equipment is currently very good. You can easily purchase both professional machines for use in production, and amateur units for domestic use.

tutmet.ru

Rolling mills - main types and design

It is difficult to name an industry where metal and products from it are not used, for the production of which a rolling mill is actively used. Metallurgical enterprises today make rather high demands on equipment. That is why modern industrial machines, in particular rolling mills, differ significantly from the models that were produced earlier.

Rolling mill for the production of corrugated board

What is this equipment for?

The need for such a durable and reliable material as metal is constantly growing, which leads to the need to open new metallurgical enterprises and modernize existing ones. The list of industries in which the use of metal is simply indispensable can be continued indefinitely. These are mechanical engineering, automobile and shipbuilding, the construction industry and many others.

In order for metal ore to turn into rolled metal of a certain grade, it is necessary to perform a lot of basic and auxiliary operations, for each of which special equipment is used. One of the main types of metallurgical equipment, on which, as a result of plastic deformation, a sheet of metal is obtained from a hot billet, is a rolling mill. It is on it that the bulk of the work carried out by metallurgical enterprises is carried out.

Varieties of rolling mills

As we have already found out, a rolling mill is equipment on which, due to sequentially performed operations, a metal billet is converted into rolled products with the required geometric parameters. Depending on parameters final product, these machines can be of several types. Blanking and swaging (slabings and bloomings) are designed to produce a billet from a large ingot of metal, which is fed for further processing to a special rolling device. The equipment of the latter type, which already produces rolled metal of the required configuration, includes section, pipe and wire mills.

Section mills include equipment for the production various kinds rental. So, these can be mills for the production of sheet steel, angles, channels, rails, etc. Depending on their functionality, such mills can be large- and medium-section, rail-rolling and MPS categories, on which profiles of various sections are obtained. Sheet rolling mills capable of processing blanks by cold or hot deformation are used to produce metal plates (thickness 50–350 mm), sheet metal (3–50 mm) and strips (1.2–20 mm). Finished products after production are wound into rolls weighing up to 50 tons.

The classification of rolling mills, which produce various types of seamless pipes, divides them into the following categories:

continuous extension, which produce pipes with a cross section of up to 110 mm;
short straightening mills required for the production of pipes with a diameter of 60–450 mm;
equipment of a three-roll type - for the manufacture of thick-walled pipes with a diameter of 35–200 mm (pipes obtained on such equipment are distinguished by a reduced degree of wall difference);
pilgrim mills used for the manufacture of seamless pipes of significant diameter (400–700 mm).

Rolling stand of sheet rolling mill

At modern enterprises, mills of a part-rolling or special type are also used. They are used for the production of profile and pipe blanks, the length of which does not exceed 3 meters. In addition, the capabilities of such equipment make it possible to produce blanks in the form of balls, bent profiles, gear wheels, screws, pipes with a ribbed section, etc. Finalization of blanks is already carried out at enterprises that use them to manufacture their products.

Components of a rolling mill

The design of any rolling mill includes three main elements: the so-called working stands, transmission devices and drive motors. Rolls along which sheet or profile metal moves are part of the working stands. They also include installation mechanisms, beds, plates and wiring. The movement of all working parts of the rolling mill is provided by powerful electric motors, which are connected to them through the elements of the transmission device: couplings, spindles and gears.

You should know that the main characteristic of billet and reduction type rolling mills is the diameter of the work roll. If several working stands are used at once in the process of processing the workpiece, then the diameter of the roll on which the finishing operation is performed is used as such a characteristic.

A section rolling mill, where products of complex shape and with fairly accurate geometric parameters are obtained, includes several stands at once, through which the rolled product passes sequentially during its processing.

Modern enterprises today use universal rolling mills equipped with 3 or 5 working stands. Part of the rolls of such mills (2-3) has a diameter of 1350 mm, the rest - 800 mm. Equipment for producing sheet products of considerable thickness, as a rule, is equipped with one or two working stands. The working width of such mills, formed by the length of the rolls, is in the range of 3.5–5.5 meters. The sheet metal mill is most often equipped with additional working stands with vertical rolls, which provide compression of the side edges of the metal sheet being formed. Sheet metal in the form of strips is produced on a device equipped with 10–15 working stands, equipped with horizontal rolls with a length of 1.5–2.5 meters and vertical rolls for end reduction.

The rolling mill, as can be seen from its design, can be of considerable length. The most noteworthy in this regard is the pipe-rolling equipment, which includes three mills at the same time. On the first of them, a hole is pierced in a metal workpiece, on the second - the workpiece is drawn into a pipe, on the third - calibration, which is carried out to give finished product required diameter. On part-rolling mills, the workpiece is subjected to both helical and transverse processing.

Rolling mill device

Making a rolling mill with your own hands

If you need a low-power rolling mill for use in your home workshop, then it is quite possible to do it yourself. Despite the simplicity of its design, such equipment can be used to perform various types of work. So, with its help, it will be possible to independently produce wire of various diameters, straighten or cut sheet metal, the thickness of which does not exceed 0.5 mm.

In order to manufacture such rolling equipment, the following structural elements will be needed: two powerful racks, a steel bar with a diameter of 5 cm, a top plate, bolts with nuts (M10), two gears and a gear wheel, bronze bushings and bearings, springs and stops.

The design of such a home-made rolling mill is assembled in the following sequence:

from racks and a steel plate, by connecting them with bolts and nuts, a semblance of a cage is created;
two working shafts are mounted on the racks, which are previously machined from a steel bar and hardened to give them increased hardness;
the lower shaft is installed between the racks using bushings with bearings, and the upper shaft, which is movable, is mounted on special sliders, the upward movement of which is limited by stops;
constant compression of the two working shafts will be provided by springs, which should be fixed simultaneously on the base plate and the upper shaft.

Version of the manual rolling mill

In order for such a rolling mill to work, it is necessary to ensure the synchronous rotation of the working shafts. This problem is solved by a gear train that transmits torque from a gear mounted on the lower shaft to a gear mounted on the same axis as the upper shaft. To set in motion the entire mechanism, it is necessary to turn the handle rigidly connected to the lower gear. What is convenient, the gap between the working shafts of such a mill can be adjusted.

The versatility of such equipment is ensured by installing shafts of various designs on it. Thus, the use of shafts in the form of circular knives makes it possible to cut sheet metal, and working elements with grooves of the required size make it possible to produce wire. You can use such simple equipment and in order to form stiffeners on the workpiece. To do this, it is necessary to install working shafts on it, which will be in contact with their surfaces according to the “groove-comb” principle.

met-all.org

Rolling sheet metal and making rolls with your own hands

Such a technological operation as sheet metal rolling has been common for quite a long time. Of course, the rollers used for sheet metal processing have undergone major changes since their invention, but the principle of their operation has not changed much. The development of modern technologies has led to the fact that today on the market you can easily find equipment that allows you to perform such a complex technological operation as rolling, even at home.

Sheet metal rolling on an electromechanical machine

Technology features

Rolling, which can be subjected to products not only from metal, but also from other plastic materials (rubber, plastic, etc.), is a process necessary to give sheet blanks the required configuration. Despite the fact that rolling of sheet metal is the most common, pipe products can also be subjected to such a technological operation.

In this case, special equipment is used, the main working elements of which are shafts that act on the workpiece from sheet metal. If it is necessary to give it a cylindrical shape, the technological operation is called rolling (or rolling). When it is required to increase the diameter of the pipe, the procedure is called flaring.

Working principle of 3 roll bending machine

In industrial enterprises, equipment with electric or hydraulic drives is used to perform rolling or flaring operations, and at home, manual machines are used for this, which can be both serial and home-made. Several factors contribute to the high popularity of such technological operations as rolling and expanding, which involve the deformation of metal in a cold state.

The steel or other metal from which the workpieces are made is not exposed to temperature and, accordingly, does not change its original characteristics.
In the structure of the material that is subjected to such processing, internal cracks do not form.
The workpiece is deformed evenly over its entire surface.
With the help of cold deformation, the process of which can be controlled, products are made with the most accurate geometric parameters.

Due to these advantages, these technological operations are used to process not only large-sized, but also miniature products made of steel and other metals (such as, for example, parts jewelry).

Used equipment

The equipment that is used for rolling is distinguished not only by its versatility, but also by its simple design, so it is easy to make it yourself. Of course, homemade rolling machines are best suited for home use, and to equip the production workshop, where the load on such equipment is quite large, it is best to purchase serial models of rollers, presented on the modern market in a wide variety.

Both serial and home-made models of machines, with the help of which rolling is carried out, work on the principle of rolling sheet material around the main roll located on top. This process also involves side rolls, which can be moved, thereby adjusting the diameter of the formed shell.

The rolls of this machine are rotated manually, and the approach of the upper roller is carried out using two handles.

Important characteristics of rollers are the radius of their working elements - rolls, as well as the greatest thickness and width of the workpiece. The radius of the rolls, in particular, affects such a parameter as the minimum bending radius of the workpiece. The larger the rolls in their diameter, the greater the value of the minimum bending radius of the sheet metal workpiece. The thickness of the sheet itself also affects the value of the minimum bending radius. As a general rule, for rollers, the minimum bending radius of the sheet stock should be 5-10 times its thickness.

Taking into account the high loads that rolls experience during operation, only high-strength steel is used for their manufacture, which can significantly improve their performance characteristics. By the number of working elements, two-, three- and four-roll machines are distinguished, with the last two types being the most popular.

Main differences between 3 and 4 roll machines

3-roll sheet bending rolls, the working elements of which can be arranged symmetrically and asymmetrically, although they differ in an acceptable price, have such disadvantages as:

low rolling speed (no more than 5 m/min);
the difficulty of processing workpieces with a thickness of less than 6 mm, which can simply slip between the rolls;
lack of exact coordinates at the clamping point of the workpiece.

All such shortcomings are devoid of rollers, on which an additional - fourth - shaft is installed. Due to the reliable clamping, the sheet metal blank does not slip between the rolls during processing. This ensures a high rolling speed of 6 m/min or more.

The machine with 4 rolls is able to produce, in addition to cylindrical, oval and polycentric workpieces

Rollers of this type are usually equipped with automated systems control, which has a positive effect not only on their productivity, but also on the accuracy of the processing performed. The biggest and, perhaps, the only disadvantage of such a device is its high cost.

Classification of rollers by type of drive

According to the type of drive used, equipment for rolling sheet metal blanks is divided into the following categories:

manual;
electrical;
hydraulic.

The simplest in design are hand-operated rollers; it is their home craftsmen who most often assemble them with their own hands for their own needs.

On simple three-roll rollers, the clamping of the workpiece, the rotation of the shafts and the formation of the bending radius are performed manually

Significant advantages of such a device, which does not require any additional power for its operation, are:

compactness and, accordingly, high mobility;
reliability;
ease of operation and maintenance;
low cost (especially if the rollers are assembled by hand).

Of the minuses of machines of this type, it should be noted:

low productivity;
the impossibility, especially in the case of home-made machines, to perform rolling of sheet metal products of great thickness (more than 2 mm);
the need to apply significant physical effort to bend sheet steel blanks.

Electromechanical double-sided rollers with program control

Machines equipped with an electric drive are more productive and efficient in operation. Of course, their cost, even if they are made by hand, is higher than the price of manual rollers, but they allow you to process sheet products of considerable thickness.

The most powerful are the rollers, powered by a hydraulic drive. The capabilities of such machines, which are large in size, make it possible to successfully roll sheet metal blanks, even of very considerable thickness. Devices of this type, as a rule, are installed in industrial enterprises, where high demands are made on the power, reliability and functionality of the equipment.

Industrial rollers with hydraulic drive

Do-it-yourself bending rolls

Due to the simplicity of the design of manual rollers, it is not difficult to make them yourself. Naturally, in order to assemble a workable homemade machine, on which sheet metal processing will be performed, you must have certain skills and have at your disposal all necessary tools And Consumables. In addition to getting acquainted with the recommendations for performing such a procedure, it is advisable to watch the video on this topic.

Drawing of homemade manual rollers for rolling wide billets (click to enlarge)

The first thing you need to make your own rollers is drawings that you can find on the Internet or make your own. Having made the drawings, you can begin to prepare materials and assemble the structural units that will make up your home-made machine. These nodes include, in particular:

roller frame, on which all other elements of them are fixed;
side racks, in the bearing units of which rolls will be installed;
the rolls themselves, made of high-strength steel (the number and diameters of these elements depend on what technical capabilities you want to endow your device with);
a handle that will rotate the lower rolls;
a drive assembly (chain or gear) that ensures synchronous rotation of the lower rolls (it should be borne in mind that such rolls must rotate in one direction);
spring-type pressure unit, due to which the upper roll is pressed against the surface of the sheet metal blank.

Compact homemade rollers for processing narrow workpieces

Main parts of compact rollers

The assembly of the rollers begins with the manufacture of a frame, which can be welded with your own hands from steel billets of great thickness. The dimensions of this element, of course, must be checked against the drawing you have. As side racks, which are also fixed to the frame by welding, powerful low-carbon steel channels can be used.

The elements of the drive unit are fixed on one of the racks, for which special holes are provided on it. After the side racks with the drive unit are completely mounted, the rolls themselves are installed in their bearing units, which must be aligned and only after that the final fixation of all other units is performed.

Do-it-yourself plate bending roll option

Before starting work on a machine that you have assembled with your own hands, you should perform trial bending on it in order to immediately detect all existing shortcomings and eliminate them.

The video can help you figure out how to work properly with the rollers, but the process is actually pretty straightforward. Rolling, no matter what equipment it is performed on, is carried out in the following sequence.

The sheet of metal to be processed is placed on the two lower rolls.
With the help of the upper roll, equipped with a pressure unit, the sheet is pressed against the lower working bodies.
By turning the handle of the machine, rolling is started.

A rolling machine, which many experts call a roll machine or simply rolls, is a device that allows you to bend blanks made of sheet metal. Rolling machines are highly efficient and versatile, which allows them to be successfully used in a wide variety of areas, including construction and repair.

Rolling machine W12-4×2500 rolls mild steel up to 4 mm thick

Purpose and main varieties

Rolling devices, the versatility of which was mentioned above, today can be found on almost any manufacturing plant. It is with the help of such a machine (which, if desired, can be made with your own hands) that conical, cylindrical and even oval-shaped products are obtained from sheet metal. The technological operation that allows solving such problems is called rolling. At the same time, it should not be confused with flaring, through which changes in the configuration and dimensions of tubular products are achieved.

Rolling machines of the simplest design are also actively used by home craftsmen. With the help of such equipment, various gutters, air ducts, elements of roof structures, as well as many products for other purposes are produced. Rolling machines produced by modern industry can effectively process sheets made of various metals.

Thus, devices of this type, represented by a wide variety of models, can successfully cope with sheet blanks made of carbon and alloy steels, aluminum, copper and cast iron. Separate models of such machines, the rollers of which have a special design, can bend polycarbonate sheets.

Among the rolling equipment, the following categories are distinguished:

manual machine;
electromechanical machine;
sheet metal machine equipped with a hydraulic drive.

A manually driven roller mill is the simplest type of equipment that can be produced in floor (mounted on a rack) or desktop (mounted on a workbench) version. This rolling machine is easy to use, but requires considerable physical effort. Meanwhile, the simplicity of the design of the machine ensures the preservation of its reliability for a long time.

The classic manual three-roll bending machine is suitable for rounding metal blanks up to 3.5 mm thick.

Manual three-roll rollers (namely, with such a number of working bodies they are mainly manufactured) make it possible to process pipe and sheet products with a wall thickness of up to 1.5–2 mm. Such a manual bending machine is the easiest to make with your own hands. It has such advantages as:

compact dimensions;
small mass;
high mobility, which makes it easy to move such machines to those places where their use is most in demand;
savings on electricity bills (rolling manual machine does not require its use);
low cost (when compared with the price of electromechanical type machines).

Electromechanical three-roll sheet bender FormRoller is used for series production workpieces of various geometries

An electrically driven device (rolling electromechanical machine) has a special gearbox in its design, which significantly increases the efficiency of such equipment. The electromechanical rolling machine can be used both for processing sheet metal and for changing the configuration of shaped tubes. With regard to sheet metal processing, the three-roll machine with electromechanical drive can be used for processing sheet metal, the thickness of which does not exceed 4 mm.

The most powerful type of equipment is a hydraulic rolling machine, which is actively used in energy, shipbuilding and machine-building enterprises. A hydraulic three-roll machine or a device with a large number of working bodies differs significantly more power when compared with manual or electromechanical devices. On rolling equipment of a hydraulic type, which is often equipped with CNC systems, it is possible to successfully bend metal sheets with a thickness of up to 8 mm.

The hydraulic drive of this machine easily moves shafts of impressive dimensions, and the CNC controls their location and the degree of deformation of the sheet.

Design and principle of operation

The supporting element of the rolling machine, including the one made by oneself, is the base frame. It is on this bed, which can be made of cast iron or sheet steel of considerable thickness, that the deforming body of the machine is mounted, which can include two, three or even four rolls. The overwhelming majority of such devices, including those made by hand, are equipped with three working bodies, since two-roll rollers are not very efficient.

The rotational movement during the operation of a three-roll machine is communicated only to the two lower working bodies, which, meanwhile, can only move linearly in a horizontal plane, which is necessary to change the distance between them. The upper roll of such a device, which is called a thrust roll, rotates due to the friction forces created between its surface and the surface of the workpiece being processed.

The upper roll, which is equipped with a rolling machine, has the ability not only to move in the vertical direction, which allows it to be pressed with the required force to the surface of the workpiece being processed, but also to lean to the side. The latter is necessary in order to quickly replace it with a roll designed for processing workpieces with other geometric parameters.

The machine, whose work rolls are equipped with special grooves, can be used to bend pipes, bars and even large wire. It should be borne in mind that an additional fourth roll, the use of which significantly increases the load on the drive mechanism of the equipment, can only be installed on an electromechanical or hydraulic rolling machine.

The sheet bending machine, whose main working bodies are rollers, works according to the following principle.

A sheet of metal from which it is necessary to form a product of a cylindrical or conical shape is placed on two lower rolls separated from each other at a certain distance.
By lowering the upper roll using a special mechanism, the metal sheet is securely clamped between the three working bodies.
When the two lower rolls rotate, which is provided by a manual or electromechanical drive, the processed sheet of metal is set in motion and begins to go around the working bodies of the rolling machine clamping it, gradually assuming the required configuration.

Moving at a certain speed between the rolls, a flat sheet of metal gradually turns into a product of a cylindrical, conical or oval shape. Obviously, this type of machine does not work like a flaring machine, the working body of which rolls out the end of the tubular product, expanding it to the required geometric parameters.

A rolling machine, on which you can effectively bend not only sheet metal products, but also tubular products, is not at all necessary to buy. A rolling apparatus, if it does not require high performance, is easy to make with your own hands. Of course, the easiest way is to make such a machine with a manual drive, but the power and functionality of this equipment is quite enough to perform construction and repair work on it.

DIY rolling machine: drawings and videos

To manufacture a manual rolling machine, you must first find its drawings or develop them yourself, taking as a basis the design of any serial model.

As an example, consider a set of drawings of a USG rolling machine, which are presented below.

Assembly drawing of a serial rolling machine USG (click to enlarge)

So, in order to make a rolling manual machine with your own hands, you must follow the algorithm below.

From metal sheets, cutting them according to a previously prepared drawing, a device frame is made, in special grooves of which its lower shafts will be fixed. Between themselves, the structural elements of the bed are connected using stiffeners, which can be used as metal pipes or corners.
To accommodate the upper roll, support posts are welded to the frame of the device. For their manufacture, it is best to use a powerful U-shaped profile. Bearing assemblies are mounted in the support post, into which the upper roll of the machine is installed.
A drive mechanism is mounted on the side of the bed, which includes three sprockets, a chain and a device for tensioning it.
The final stage in the manufacture of a home-made rolling machine is the installation of a drive mechanism handle, chain tension and adjustment of all structural elements.

Naturally, after the final assembly, the home-made machine must be tested (and the operation of all its mechanisms should be adjusted, if necessary).

Popular models of manual rolling equipment

Manual rolling machines, presented on the modern domestic market, allow you to effectively solve technological problems of any degree of complexity. So, for a reasonable price, you can purchase a small-sized table-top rolling device or stationary equipment, the power and productivity of which is quite enough to solve the problems facing a small production or repair enterprise.

Among specialists and home craftsmen who prefer to perform, manual rolling equipment of the following brands is very popular.

Stalex

This company produces reliable and efficient equipment designed for processing sheet blanks. different widths and thickness.

metal master

Under this trademark, reliable, functional and easy-to-use equipment for rolling is produced. On many models from Metalmaster, due to the presence of special grooves on the rolls, it is possible to bend pipes and bars.

Encore Corvette

This is a domestic brand, under which an inexpensive, but fairly reliable product is produced in China. sheet bending equipment. Using such machines, it is possible to bend sheet metal, the thickness of which does not exceed 1.5 mm.

Sheet bending machines of electromechanical type

Rolling electromechanical machines are presented on the domestic market in an equally wide range. So, from the most popular brands of devices of this type, it is worth noting the following.

VEM

This is a functional rolling equipment, which, due to its high reliability, rarely needs repairs and expensive maintenance. Due to the equipment with additional structural elements, the technical capabilities of the machines of this trademark can be greatly expanded.

Stalex

Under this trademark, roller electromechanical machines of a professional level are produced. Design feature such machines is the asymmetric arrangement of the work rolls, as well as the ability to quickly retract the upper working body, which allows you to quickly remove the workpiece from the processing area.

Electromechanical rolling machine Stalex ESR-1300×2.5 (the width and thickness of the metal being processed is reflected in the designation of the machine)

metal master

This is a powerful and reliable equipment with convenient foot control, which can be used not only for bending sheet metal, but also for processing tubular products and reinforcing bars.

Regular readers of our magazine and viewers of the television program “You Can Do It” are familiar with the name of the craftsman from the city of Troitsk near Moscow, Yuri Mikhailovich Orlov. The machines and fixtures designed and made by him are distinguished by their well-thought-out design, reliability in operation and the wide possibilities inherent in a universal tool. All these requirements are met by the table rolling rolls offered to your attention.

Table rollers outwardly resemble a two-roll stand of a rolling mill. They differ from their factory counterpart not only in size, but also in capabilities - due to the installation of interchangeable tools. With the help of cylindrical rollers with shaped grooves, it is possible to obtain wire of a wide variety of sections: round, triangular, square, diamond-shaped. It is convenient to straighten (roll stiffeners) metal plate parts with rollers with a symmetrically located crest and groove. And by installing instead of them two steel discs with sharpened conical edges, it is easy to cut sheet materials - from paper to stainless steel with a thickness of 0.5 mm. Even the gear wheels of the roller drive mechanism are used to form wave-like parts: wire zigzags or corrugated plates. It is also not difficult to roll a wire ring or a cylindrical sleeve on this machine: it is enough to have a pair of cylindrical rollers of the corresponding diameters and, when rolling, press the workpiece with a wedge to one of them.

Table rolling rolls are arranged as follows. The base, top plate and two side posts are made of thick steel bar. With the help of four M10 screws and four M10 bolts, they are connected into a strong supporting frame-cage. The top and bottom rollers are machined from a steel bar d 50 mm and hardened to obtain a high surface hardness. Bronze bushings-bearings of the lower roller are mounted in the holes of the racks, and the upper one - in sliders that can move along the vertical guide grooves of the racks. From below, the sliders are pressed by small springs, tending to push the rollers apart; from above, their travel is limited by stops installed in the threaded holes of the upper plate. The synchronous rotation of both stops, necessary for the parallel movement of the upper roller, is provided by a gear mounted on the upper plate of the core. It is formed by a wide gear wheel of the regulator, freely mounted on an axle pressed in the center of the plate, and two narrow gears, seated through keys on the shanks of the stops. By turning the knob attached to the central wheel, you can change the position of the stops and, at the same time, the size of the working gap.

The rollers are driven into rotation by a handle put on the square shank of the lower roller. The rotation is transmitted to the top by means of a gear train. This not only makes the work of the rollers more efficient, but also allows the design to be used for cutting sheet metal with the help of circular knives mounted on their axis.

Rice. 1. The device of universal rolling rollers:

1 - regulator gear (m = 1, Z = 50), 2 - threaded stop gear (m = 1, Z = 50), 3 - M10 bolt (4 pcs.), 4 - top plate, 5 - interchangeable tool: shaped rollers, circular knives, 6 - plain bearing (bronze), 7 - stand (steel 20), 8 - M10 screw (4 pcs.), 9 - upper roller (steel 40X), 10 - base (steel 20), 11 - lower roller (40X steel), 12 - roller gear (40X steel, m = 2, Z = 25), 13 - bushing, 14 - spring, 15 - upper roller slider (steel 20), 16 - threaded stop (40X steel) , 17 - axis of the regulator gear, 18 - regulator knob, 19 - handle, 20 - M8 screw, 21 - handles, 22 - roller handle.

1 - shaped rollers, 2 - circular knives, 3 - toothed rollers, 4 - a set for rolling the workpiece into a ring (cylinder), 5 - rollers for straightening.

The assembly of the rollers consists in connecting the frame elements and parallel installation of the rollers. To perform additional operations, you do not need to disassemble the machine: the tools are quickly mounted cantilevered on the shanks of the roller axles. To do this, they are provided with axial holes with M8 thread, and outside - dowels for transmitting rotation. There are mounted on threaded mandrels and circular knives. If you want to cut a strip with a width of more than 35 mm, use an elongated mandrel, which will move the knives away from the rack for a greater distance.

According to the catalog of the Internet portal, the site offers to purchase equipment for rolling production at enterprises of various levels. Rolling equipment and tools are used for plastic deformation of metal by moving it through rotating rolls, rolling is supplemented by cutting, winding and other technological operations. If you need equipment for the production of rolled metal, on our website you will find the latest offers from manufacturers, importers and other business representatives.

Types of rental equipment

The site catalog contains rolling machines and apparatus for metalworking, which can be used in enterprises of various industries. It is used for the manufacture of metal siding, metal tiles, steel pipes and hundreds of other types of products; properly selected production equipment is guaranteed to pay back all purchase costs.

Using the website portal, you can buy at a low cost the following types of equipment for metalworking and the production of finished products:

Ready-made lines for the production of metal profiles. They will allow in a short time to equip the enterprise with everything necessary and start producing products in large quantities. Automated lines provide high precision metalworking.
Lines for the production of profiled sheets. This material is actively used in the construction of fences and railings, roofing, wall cladding, profiled sheet is in constant demand, and its popularity continues to grow. The finished line for the production of profiled sheets will become a guaranteed source of profit.
Manual profile benders designed for bending profiles of various sizes and thicknesses. Equipment can be part of automated line, this technique allows you to simultaneously work with three workpieces.
Separate accessories for rolling mills. Any breakdown of equipment leads to a stoppage of work and losses, so it is important to take care of quality spare parts. Suppliers offer various details, the catalog contains detailed description each position.

On our site you can easily find everything you need to equip a modern production complex, the purchased equipment will last for years and bring considerable profit. To clarify the price and terms of sale, you can directly communicate with suppliers and find permanent partners.

Conditions for the supply of equipment

The site site offers modern equipment for enterprises producing metal products, you can modernize production with minimal cost. Buy the selected application and contact the suppliers directly to discuss the terms of cooperation and choose reliable equipment. Technique is accompanied complete set documents. when buying new equipment, you will receive a manufacturer's warranty.