In the world of metal fabrication, the 2-roller steel plate rolling machine is a versatile and essential tool. This machine is designed to bend metal sheets and plates into various shapes with precision and efficiency. Understanding the working principle and characteristics of the 2-roller plate bending machine is crucial for manufacturers seeking to create accurate and consistent bends in their metalwork.
Working principle
The elastic roller is made of polyurethane rubber with a hardness of 85-95HS Shore hardness.
The two-roller plate bending machine is composed of a rigid roller and an elastic roller. When the rigid roller is pressed into the elastic roller with a certain hardness and elasticity, the elastic roller deforms in a radial depression, and the sheet material fed between the two rollers is bent by the reverse force of the elastic material deformation to drive the elasticity. Roller, so as to achieve continuous bending of the sheet.
When the reduction amount reaches a certain critical value, and then increase the reduction amount, the diameter of the workpiece is not stable enough, so it is generally not used.
In order to change the diameter of the part, the rigid roller can be covered with an appropriate guide wheel for rolling processing
Working Principle of the 2-Roller Bending Machine
The 2-roller bending machine operates on a straightforward yet effective principle. It uses two rollers, the upper roller (also called the bending roller) and the lower roller (known as the pinch roller or the idler roller), to gradually bend the metal sheet or plate between them. The upper roller exerts downward pressure on the sheet while the lower roller provides support and controls the curvature of the bend.
Actual operation
- For good plasticity (>30%) or thin plates (thickness less than 1.5-4mm), it can be done at one time.
- For plates with poor plasticity or thick, the pressing force of the steel roll should be increased, the inlet and outlet ends of the plate should be bent in advance, and then the parts can be completed once or several times (intermediate annealing can be carried out).
Features of 2-Roller Bending Machine
- Its rubber rollers have of 3-year warranty
- The digital display is adopted for the bending machine
- Heavy-duty steel welded frame with no stress
- All of the operations are controlled by an independent control console
- Hydraulic drop end is employed for the convenience of removing the cylinder
- Automatic leveling rubber roll system
- Automatic discharging device
Optional equipment
- Automatic production line
- Acid-proof rubber rolls are utilized
- Automatic material feeding table
- Portable keyboard
- Oil cooling system
4 steps for plate rolling process
The plate rolling process in the 2-roller machine involves the following steps:
- Positioning: The metal sheet or plate is accurately positioned between the upper and lower rollers, ensuring that the desired bend line aligns with the contact point of the rollers.
- Initial Bending: The upper roller applies downward force, pressing the sheet against the lower roller. As the sheet comes into contact with the lower roller, the initial bending action begins.
- Incremental Bending: The sheet is gradually fed through the machine, and the rollers continue to apply pressure along the length of the bend. The material follows the curvature controlled by the lower roller.
- Final Shape: By adjusting the position of the lower roller and the feeding speed, the machine achieves the desired bend angle and shape.
The working principle of the 2-roller bending machine ensures precise bending while minimizing deformation or damage to the material.
Features of two-roller plate
Advantage
- High production efficiency, generally up to 100-350 pieces/h, up to 1000 pieces/h.
- The parts have high precision and good surface quality.
- Greatly reduce the straight section at the entry and exit ends of the roll bending: the straight section of the thin plate will not exceed the thickness of the material, and the straight section of the thick plate will not exceed four times the thickness of the material; therefore, it is generally not necessary to adjust before the bending The ends are pre-bent.
- Even if the slab is processed by punching, cutting, undulating forming, etc., it will not produce cracks and irregular warping.
Disadvantage
- Since each change in the diameter of the workpiece requires the production of guide rollers, it is not suitable for small batch production of multiple varieties.
- The size of the parts is subject to certain restrictions. Processing range: Thick plates are within 6.3 (soft steel), and the bending diameter is φ76-φ460mm.
Photos of 2-roller plate bending machine
Characteristics of the 2-Roller Bending Machine
The 2-roller bending machine possesses several key characteristics that make it a valuable asset in metal fabrication:
- Flexibility: The machine can handle a wide range of metal sheet thicknesses and lengths, making it suitable for various applications.
- Accuracy: The 2-roller machine offers high precision in bending, ensuring that the final bent shape closely matches the design specifications.
- Uniform Bending: The use of two rollers distributes the bending force evenly across the material, resulting in uniform bending along the entire length of the sheet.
- Ease of Use: The machine’s simple design and intuitive controls make it relatively easy to operate, even for less experienced operators.
- Quick Setup: The machine allows for quick tooling changes and setup, reducing downtime and increasing efficiency in production.
- Cost-Efficiency: The 2-roller bending machine is a cost-effective solution for bending tasks, making it a popular choice for small to medium-scale operations.
Applications of the 2-Roller Bending Machine
The 2-roller bending machine finds extensive use in various industries, including:
- Sheet Metal Fabrication: Creating curved panels, cylindrical shapes, and other components for industries such as HVAC, automotive, and electronics.
- Shipbuilding: Forming metal sheets for hulls, decks, and other ship components.
- Construction: Bending metal plates for architectural and structural applications.
- Manufacturing: Producing parts with curved or bent features, such as brackets, enclosures, and frames.
- Aerospace: Forming metal components used in aircraft structures.
Characteristics Comparison
| Characteristic | 2-Roller Bending Machine | 3-Roller Bending Machine |
|---|---|---|
| Flexibility | ✔️ | ✔️ |
| Accuracy | ✔️ | ✔️ |
| Uniform Bending | ✔️ | ✔️ |
| Ease of Use | ✔️ | ❌ (More complex) |
| Quick Setup | ✔️ | ❌ (Usually requires more setup time) |
| Cost-Efficiency | ✔️ | ❌ (Tends to be more expensive) |
Conclusion
The 2-roller bending machine’s working principle, characteristics, and versatility make it an indispensable tool in metal fabrication. Its ability to produce accurate and uniform bends in various applications, combined with its ease of use and cost-efficiency, positions it as a preferred choice for many manufacturers. Understanding the capabilities of the 2-roller bending machine empowers engineers and fabricators to achieve precise and consistent results in their metal bending projects.
