The best way to determine the best plate or sheet rolling machine (see Figure 1) for the job is to find out what various machines can do. By obtaining this information, you can properly size and select a machine to fit your particular bending application.
Of course, for more in-depth information and application engineering expertise, you can contact plate or sheet metal rolling equipment experts directly.
Plate or sheet bending rolls are offered in two distinct categories: single and double-pinch, but they may vary in geometry or style. General machine styles are three-roll initial-pinch, three-roll double-pinch, four-roll double pinch, three-roll variable translating, three-roll pyramid, and two-roll systems. Plate rolls are also built in a vertical format for special applications. Matching the most appropriate machine style to the application is important.
Machine capacity is equally if not more important than style. 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. When choosing a machine, you must refer to your mill certificates and verify the average yield strength of the plate you are buying. It is not uncommon to find that the &#;mild&#; steel you are rolling will have actual yields in the 48,000- to 58,000-PSI range. Remember, machine capacity must match your material, and most plate roll manufacturers can provide detailed capacity-versus-yield tables to assist you.
You often will see capacities for both prebending and rolling for any plate rolling machine. Prebending is performed on the plate roll at the leading and trailing edges of the sheet (see Figure 2)&#;and eventually the seam (see Figure 3).
A sheet cannot physically be bent right to the edge, and thus what remains is referred to as the unbent flat (see Figure 4). The minimum flat you can expect is 1.5 times the material thickness and often 2.5 to 3.5 times the material thickness for heavier plate.
It is the prebending operation, in attempting to minimize the unbent flat, which takes the most power. That&#;s why prebending ratings are lower than rolling capacities for any given machine.
You must be mindful when reviewing machine capacities that the maximum rolling capacity is usually expressed with the basic requirement of multiple rolling passes and very long unbent flats. You also must note the material thickness and width and equipment characteristics such as cylinder diameter, machine type, yield, and diameter of rolls. Operator proficiency also should be taken into consideration.
NCs and CNCs are becoming more common in the workplace. Most NC and CNC machines are four-roll types.
Automated controls are recommended for high-volume cylinder or shell production and to roll complex shapes that are not easily reproduced using standard manual controls. Multiple bends, variable-radius bends, and ovals are common examples of these complex shapes.
Three-roll initial-pinch (see Figure 5) or single initial-pinch plate rolls generally are for light-capacity applications and may be electromechanical or hydraulic. They work by pinching the flat sheet between two vertically opposed rolls while the third, offset roll&#;or bending roll&#;moves upward to contact and then bend the sheet. When rotation of the rollers is activated, the sheet exits at a given radius. With the sheet cut to the developed length and the bending roll properly positioned, the part is rolled into a cylindrical shape that can then be welded at the seam to produce a closed cylinder.
When a cylinder is completely rolled, it is extracted from the top roll. Machines generally are equipped with some type of top roll release mechanism that allows for the cylinder&#;s extraction. This extraction is accomplished with the help of a forward-tilting or forward-releasing top roll or a removable end yoke.
In most applications, these machines require removal and reinsertion of the sheet to prebend both ends. They are cost-effective, but may be more labor-intensive in a production setting than their modern counterparts.
Many large, mechanical initial-pinch machines were built during the s and may occasionally be found on the used market. All have cast frames, as modern alloys and welding techniques had yet to be invented.
Double-pinch plate rolls are available in light to very heavy capacities and can have three (see Figure 6) or four rolls (see Figure 7). The terminology can be confusing as these units also may be referred to as double-pinch pyramid plate rolls or double-initial-pinch plate rolls. Both three- and four-roll styles have fixed-position top rolls and two offset, or lateral, rolls, one on each side.
The four-roll styles have an additional roller underneath the top roll, which constantly pinches the plate during rolling. Double-pinch rolls can prebend both plate ends without removal, as is required with single-pinch rolls.
Three-roll machines generally require prebending the leading end, running the sheet through the machine to prebend the trailing end, and then switching roll rotation direction to roll the cylinder body. Four-roll plate rolls have a slight advantage in cycle time because they permit prebending of the leading edge, rolling the cylinder body, and finishing off the trailing prebend, all while rolling in the same direction.
Smaller machines can be mechanical, but most are hydraulic and include drop end yokes (see Figure 8) for easy extraction of the workpiece.
Four-roll plate rolls generally are the only equipment with NCs or CNCs because the fourth roll provides constant pinching action, minimizing the chance for slippage. Automatic controls use an encoder to track movement of the plate through the machine. If the plate slips, the bending roll movements will be out of synch with the rolling movement.
Variable-geometry three-roll plate rolls are not new, but are gaining in popularity around the world (see Figure 9). They are built to handle medium to extremely heavy plate rolling applications.
The top roll moves up and down while the lower two rolls each move horizontally. This lower roll movement increases the offset distance from the top roll and in so doing delivers a distinct mechanical advantage in bending. A machine of this type works well over a wide range of material thicknesses.
With varying geometry, these rolls can be used like a single-pinch, double-pinch, or pyramid-style machine that requires minimal sheet movement during prebending. In the past these machines commonly were found in shipyards, but are now being placed in general job shop and manufacturing applications.
True pyramid machines are rarely used in cutting-edge facilities. They usually can be found on the used market.
They have three rolls (see Figure 10), with both lower rolls fixed in position and the top, or bending, roll moving up and down. In general, they leave a very long unbent flat and are not as user-friendly as other types of rolling machines.
Two-roll machines (see Figure 11) are designed for thin-gauge material rolled to reasonably small diameters. They use a large-diameter, urethane-coated pinch roller that moves up with extreme pressure against a small-diameter steel top roll. A mandrel or drum, very close in OD to the desired ID of the finished part, is fitted over the top roll.
Two-roll sheet rolls are extremely fast and will roll round parts even if the blank has cutouts or holes. Because they require a mandrel for each part diameter and material thickness, they are not as versatile as some other machines, but for dedicated high-speed production, they are often the absolute best choice.
In terms of optional equipment for rolling machines, the most important items to consider are hardened roll surfaces and cone rolling devices.
Today&#;s harder materials and laser/plasma cutting techniques require hard outer roll surfaces on rolling equipment. Look for a hardness rating from 50 to 55 Rockwell C scale. Hardness in this range will have a reasonable penetration depth and provide long-lasting protection against roll surface wear. Hardness exceeding 60 will have a shallow penetration and result in cracking or crazing of the roll surface.
Cone rolling devices, which permit you to roll a conical shape, are standard on some machines. Lateral material supports and overhead supports are also optional, but less frequently requested. Overhead supports prevent light materials from collapsing when rolled to large diameters. A side support can also assist in preventing light materials from recurving toward the floor if the radius is very large.
Some machines have extended roll shafts that protrude through the machine frame. Section or pipe dies can be fitted on these stub shafts, but it is not practical to roll angle iron on a plate roll. Angle tends to twist when rolled, and plate rolls do not have outboard, adjustable, lateral material guides to prevent this twist. You should consider using a section rolling machine or angle roll for that type of bending. In general, section dies on plate rolls are good for bending flat bar the hard way, rods, or small pipe.
Additionally, most new roll bending machines are equipped with modern safety devices such as emergency-stop buttons; safety trip wires; 24-VAC, low-voltage control circuitry; and detached operator control consoles. However, it remains the responsibility of the owner to ensure the installation and proper use of operation safety guards or devices.
Steel is a vital component of modern infrastructure. Rolled steel, in particular, is a crucial material in various fields such as construction, transportation, and manufacturing. Creating rolled steel involves subjecting raw materials to intense heat and pressure to shape them into flat or long products that can be used for various purposes.
The steel rolling process begins with raw materials such as iron ore, coal, and limestone being processed into usable forms for steel production. The first step in the rolling process is reheating these raw materials to their melting points in large industrial furnaces. Once they reach their desired temperature, they are passed through rollers that are pressed and shaped into their final forms.
Rolling mills come in many different types depending on the metal being processed and the product being produced. Some mills have long products like bars or wire rods, while others focus on creating flat products like sheets or plates.
Importance of Rolled Steel in Various Industries
Rolled steel is one of the most versatile materials today due to its incredible strength and durability. It is used for everything from high-rise buildings to bridges because it can withstand enormous amounts of weight without bending or breaking.
In transportation applications such as automobiles or airplanes, rolled steel provides structural support while remaining lightweight enough not to weigh down these vehicles&#; overall weight. Additionally, it&#;s often used for manufacturing tools and equipment because it can be machined easily into complex shapes while maintaining its strength under stress.
Rolled steel is essential across various industries due to its strength and versatility. Modern life without this critical material is hard, and understanding the complex process behind its creation can give us a better appreciation for its importance.
Steel rolling is the process of shaping raw materials such as ingots, billets, and slabs into final products such as bars, sheets, and plates. It involves reducing the thickness or changing the shape of the material by subjecting it to compressive force through a series of shaped rollers. The steel rolling process can be classified into two categories: hot rolling and cold rolling. Hot rolling involves heating the material above its recrystallization temperature, while cold rolling processes materials at room temperature.
1. Two-High Rolling Mills: These mills have two rolls that rotate in opposite directions to compress and reduce the thickness of raw materials.
2. Three-High Rolling Mills: These mills have three rolls that combine pressure and friction to reduce thickness.
3. Four-High Rolling Mills: These mills have four rolls arranged in a square pattern that apply pressure from different directions to shape materials.
4. Cluster Rolling Mills: These mills have multiple sets of rolls arranged in clusters that can perform several operations simultaneously on one piece of material.
5. Tandem Rolling Mills: These mills consist of multiple stands arranged together, allowing for continuous processing without stopping between stands.
The Importance of Raw Materials
The steel rolling process uses various raw materials to create the final product. Iron ore, coal, and limestone are the three main components used in steelmaking. Iron ore is mined and processed into pellets or sinter before being fed into the blast furnace.
Coal is a fuel source to heat the furnace, while limestone is added to help remove impurities from the iron. Scrap metal can also be used as a raw material in steel production.
Before being fed into the blast furnace, these raw materials must be processed in specific ways. Iron ore must be crushed and ground into small pieces before forming pellets or sintered. Coal must go through a coking process to remove impurities such as sulfur and produce coke, which is then sent to the blast furnace along with iron ore.
Limestone must be crushed into small pieces before being added to the blast furnace. Once inside the furnace, these raw materials undergo chemical reactions, producing molten pig iron and slag.
The pig iron is then further processed through elemental oxygen or electric arc furnaces to create various steel grades depending on its intended use. Understanding how each raw material is processed and utilized within the steel rolling process is essential for producing high-quality steel products that meet industry standards.
The hot rolling process begins with reheating steel billets or slabs in a furnace to temperatures exceeding °C. This critical temperature softens the steel, making it malleable and easier to shape. The steel is then transported to the roughing stage, passing through a series of rollers, often called a &#;breakdown mill.&#; Here, the steel is shaped into its initial form, usually a square cross-section.
During the roughing stage, the billet or slab endures repeated passes through several pairs of rollers that progressively reduce its size and thickness. These rollers are positioned at increasing heights above each other to apply pressure from different angles and directions to ensure an even reduction in thickness across the entire surface area of the material.
The finishing stage follows after roughing in hot rolling. The now thinner slab or billet enters another set of rollers called finishing mills, where it undergoes further reduction. At this point, temperature control becomes critical as temperature fluctuations can cause warping or cracks on the surface of the steel.
Temperature control is achieved using water sprays and air coolers to regulate thermal conditions during rolling. Water sprays are used at various points along the production line to cool down areas that may be too hot, while air coolers are used for slower cooling over extended periods.
Hot-rolled steel has many benefits compared to cold-rolled steel, including lower costs due to less processing required, increased ductility allowing easier shaping and forming, and generally better mechanical properties such as higher strength-to-weight ratios. Every step during hot rolling must be executed accurately since small mistakes can significantly affect final product quality and consistency.
Cold rolling is a process that takes place at room temperature, unlike hot rolling. During the cold rolling process, steel is passed through a series of rollers at lower temperatures to decrease its thickness and improve its surface quality.
Cold rolling requires less energy than hot rolling because the steel does not need to be reheated before being rolled.
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One key difference between cold and hot rolling is the pressure level applied during each process. Cold-rolled steel undergoes more pressure than hot-rolled steel, increasing hardness and strength.
The surface of cold-rolled steel is also smoother and more uniform due to this increased pressure. As a result, cold-rolled steel is often used in applications where high strength and precision are necessary, such as in the automotive industry for parts like engine cranks or gears.
The primary advantage of using cold-rolled steel is its superior strength and hardness. Because it undergoes more significant pressure during manufacturing, it can withstand higher stress levels without deforming or breaking.
Its smooth surface makes it easier to paint or coat with other materials. Cold-rolled steel has disadvantages compared to hot-rolled steel.
A drawback is that this is expensive due to the additional processing involved in its manufacture. Another issue is its increased hardness. Working with it during subsequent processing steps, such as bending or welding, is challenging.
Despite these drawbacks, many industries continue to use cold-rolled steel for applications where high strength and precision are necessary.
After the steel has been rolled and cooled, it is ready for finishing processes that enhance its appearance, durability, and suitability for specific applications. The most common finishing processes include pickling, galvanizing, and painting.
Pickling:
Pickling is a chemical process in which the surface of the steel is cleaned by removing impurities such as rust and mill scale. Acidic solutions like hydrochloric or sulfuric acid are applied to the steel surface to clean it thoroughly. The pickling process serves two purposes; it removes surface impurities that can weaken the steel and prepares the steel surface for subsequent finishing processes. Other treatments, such as plating or painting, adhere better to the steel with a clean surface.
Galvanizing:
Galvanizing is a popular method of protecting steel from corrosion by coating it with zinc. Zinc serves as a sacrificial anode in this process; when exposed to moisture or other corrosive elements, zinc corrodes before iron does, preventing damage to the underlying structure. In galvanization, molten zinc is usually applied via hot-dip galvanizing or electroplating methods onto clean steel surfaces. Hot-dip galvanization involves immersing pre-cleaned metal structures into a bath of molten zinc. At the same time, electroplating uses electric current to deposit a layer of zinc on top of the metal structure for protection.
Painting:
Painting is another popular method of protecting rolled steel by forming an additional barrier between environmental factors and structural components. It involves applying different types of paint coatings, such as acrylics, epoxies, urethanes, or polyurethanes, depending on specific application needs (e.g., weather resistance).
Stainless Steel Rolling: Unique Properties That Make It Ideal for Certain Applications
Stainless steel is a unique steel type with 10.5% chromium content by mass, which gives it its characteristic corrosion resistance. The properties of stainless steel make it ideal where resistance to corrosion and staining is required.
One of the advantages is rust and oxidation resistance, making it widely used in the construction and automotive industries. Stainless steel can be rolled using hot and cold rolling processes, but the cold rolling process is more commonly used due to its smoother finish. Stainless steel has excellent formability, enabling it to be shaped into various products with ease. Additionally, stainless steel&#;s aesthetic qualities make it popular in producing items such as jewelry and kitchen appliances.
High-strength low-alloy steel is an alloy with low carbon content with small additions of other elements such as vanadium, niobium, titanium, or zirconium. These elements increase the strength-to-weight ratio while maintaining good formability and toughness. Structural applications, such as bridges, buildings, ships, and offshore platforms, widely utilize HSLA steels due to their exceptional strength.
The rolling process is vital in producing HSLA steels with enhanced mechanical properties such as high yield strength and improved impact resistance. Manufacturers typically produce them using the hot-rolling method, followed by controlled cooling to enhance microstructure characteristics that directly influence mechanical behavior.
Specialized types of rolled steels, like stainless steels, have characteristics making them suitable for applications. On the other hand, structural applications commonly use HSLA steels due to their high strength, good formability, and versatility. The steel rolling process plays a vital role in producing these specialized steels with desirable properties, so optimizing the rolling process is crucial to meet customers&#; specific requirements for their respective applications.
The Importance of Roll Wear Profiles
One often overlooked steel rolling factor is the importance of roll wear profiles. Roll wear profiles are the patterns that form on the rolls over time due to repeated use. Determining the quality and consistency of rolled steel products relies on these patterns, as they impact the shaping and maintenance of the product&#;s form.
Several factors influence roll wear profiles. To achieve optimal roll wear profiles, engineers must carefully balance all these variables to create a reliable and consistent product.
Another small detail that has a significant impact on steel rolling is laser measurement technology. This technology allows engineers to precisely measure critical parameters like thickness, flatness, and profile shape during every stage of the rolling process. Using laser measurement systems in real time, engineers can adjust on the fly to ensure that every batch of rolled steel meets strict quality standards.
Laser measurement technology also allows engineers to develop highly detailed digital models of their products before rolling them. This will enable them to identify potential issues early in the process and make necessary adjustments before wasting valuable materials or resources.
The world&#;s reliance on high-quality rolled steel continues growing each year. Steel is essential in modern society, from automotive parts to building materials. As we have seen throughout this journey through the steel rolling process, there are countless details to produce high-quality finished products.
The details ensure that we meet strict quality standards for every batch of rolled steel, making it reliable for various applications. With the development of new technologies and techniques, we can be confident that the future of steel rolling is bright and that this essential industry will continue to thrive for generations.
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