Plate rolling machine: a powerful assistant for metal sheet processing

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Plate rolling machine: a powerful assistant for metal sheet processing 14 Jan 2025

Plate rolling machine: a powerful assistant for metal sheet processing

In the field of metal processing, plate rolling machine is a vital mechanical equipment that can bend plates into various shapes. It is widely used in many industries such as metal processing, shipbuilding, boiler manufacturing, aerospace, hydropower, chemical industry, machinery manufacturing, etc. Its main function is to accurately bend the plate into O-shape, U-shape or multi-segment R-shape through continuous three-point bending.Types of CNC plate rolling machines

Three-roller plate rolling machine

Symmetrical type: compact structure, light weight, easy to manufacture and maintain. However, this type of plate rolling machine will leave a large straight edge during the rolling process. Its working method is to achieve rolling by vertical lifting of the upper roller and rotation of the lower roller. The hydraulic three-roller plate rolling machine provides torque for rolling by moving the upper roller vertically and rotating the lower roller with the help of the output gear of the reducer.

Asymmetric type: In an asymmetric three-roller plate rolling machine, the upper roller is located above the lower roller, and there is a side roller on the side. The upper and lower rollers are driven by the same motor. The lower roller can be adjusted up and down. The maximum adjustment distance is approximately equal to the maximum thickness of the steel plate that can be rolled. The side roller is a passive roller and can be adjusted obliquely. When bending, first feed the plate between the upper and lower rollers, then adjust the lower roller to press the plate tightly, use friction, and then adjust the position of the side roller to make the plate bend when the upper and lower rollers rotate. The advantage of this type is that it can bend the edge of the plate, greatly reducing the length of the remaining straight edge to less than twice the thickness of the plate. Although the plate between the side roller and the lower roller will not bend, the bending process can be completed by removing the plate from the machine and flipping it.

Four-roller plate rolling machine

The working principle of the four-roller plate rolling machine is to realize the rolling of the plate by rotating and bending deformation. It is also divided into symmetrical and asymmetrical types. It consists of an upper roller, a lower roller, a side roller, and a support roller. It is similar to the asymmetrical three-roller plate rolling machine, but with the addition of a side roller, which solves the problem of the asymmetrical three-roller plate rolling machine needing to flip the plate. The side rollers and support rollers can move in a straight line or arc to adjust the rolling curvature radius. This type of plate rolling machine is widely used in the fields of petroleum, chemical industry, cement, boilers, ships, aerospace, water conservancy, and power transmission tower equipment. In addition, the four-roller plate rolling machine can also be subdivided according to the structural type, transmission mode, etc. According to the structural form, it can be divided into C type and H type, which are suitable for metal plates of different specifications and materials respectively; according to the transmission mode, it can be divided into mechanical type, hydraulic type, and CNC type; according to the equipped CNC system, there are different types. Among them, the CNC four-roller plate rolling machine can realize automated and high-precision operation, can be programmable, and can realize complex rolling modes, which is very suitable for high-precision and large-volume production environments. There is also a high-precision CNC-EVO plate rolling machine, which uses a unique core algorithm to perfectly solve the problems of misalignment, deformation, and large errors that are prone to occur in the rolling process of traditional plate rolling equipment. The quality of the rolled products meets or even exceeds the standards of conventional machines in the industry.

Performance comparison between three-roller plate rolling machine and four-roller plate rolling machine

1. The three-roller plate rolling machine is more economical and practical: the price is lower than that of the four-roller plate rolling machine, it has good rigidity, high stability, high pressure resistance, mature manufacturing process, simple structure and convenient maintenance.

2. The four-roller plate rolling machine is more efficient: the rolling accuracy is higher, the straight edge is smaller, the rolling speed is fast, and it is suitable for mass production. No other equipment is required, and the end of the plate can be directly pre-bent, and the residual straight edge is smaller, which improves the quality of the workpiece and production efficiency.

3. The production cost of the four-roller plate rolling machine is lower: it adopts multiple sets of rollers for continuous rolling, which can efficiently process large quantities of metal plates and reduce production costs. In contrast, although the three-roller plate rolling machine is cheap, the rolling time is longer, the edges of the products produced are straight, and the processing accuracy is average.

4. The four-roller plate rolling machine is more compact: due to the use of a hydraulic system, it is smaller in size and can operate efficiently in a limited space.

5. The four-roller plate rolling machine is more precise: it adopts an electrical centralized control system, which is easy to operate and has a high degree of automation, which improves the production efficiency and precision of the equipment.

6. The four-roller plate rolling machine has a wider adaptability: it can also perform certain leveling and shaping operations on metal plates, broadening the application range of the equipment and making it more widely used.

7. Comparison of maintenance complexity: The symmetrical three-roller plate rolling machine has a simple structure, easy operation and low maintenance cost; the asymmetrical three-roller plate rolling machine has a complex structure due to the asymmetrical arrangement of the rollers, and has a high maintenance cost; the four-roller plate rolling machine has a relatively simple structural design and uses lubrication-free bearings, which reduces maintenance costs and complexity.

Rolling process of plate rolling machine

1. Pre-bending: When rolling the plate, there is a length at each end of the plate that does not bend because it cannot contact the upper roller, which is called the remaining straight edge. Technically, the moment arm at which the flat plate begins to bend is called the theoretical remaining straight edge, and its size is related to the equipment structure and its bending form (symmetrical bending, asymmetrical bending).

2. Centering: The purpose of centering is to make the workpiece busbar parallel to the roller axis to prevent skew.

Rolling: Rolling is the main process of product forming. It is divided into two types: single feeding and multiple feeding. Multiple feeding is commonly used for rolling thick plates. The number of feeds depends on process constraints (such as the allowable upper limit of deformation during cold rolling) and equipment constraints (such as non-slip conditions and power conditions). When the amount of cold roll rebound is significant, a certain amount of over-rolling must be added.

3. Rounding: The purpose of rounding is to make the curvature of the entire circle as uniform as possible to ensure product quality. Generally, the rounding process is divided into three steps:

(1) Loading: Adjust the work roll to the required corrected curvature position based on experience or calculation.

(2) Rounding: Roll the roller 1-2 times under the corrected curvature to make the entire curl rate uniform.

(3) Unloading: Gradually remove the load so that the workpiece rolls multiple times under gradually decreasing corrective loads.

conclusion

Plate rolling machines play an important role in metal plate processing, including three-roller and four-roller types, each with its own characteristics and advantages. Their working principles, structural components, performance comparisons, rolling processes, and the CNC trend of related equipment are introduced in detail.

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предыдущий : A complete analysis of the operation and application of bending machines: a key guide to metal processing

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