What Is an Angle Roll Machine or Angle Roller?
Angle Roll (aka, Angle Roller, Angle Iron Roller, Angle Roll Machine, Section Bending Machine, Aluminum Bending Machine) are roll-bending machines used to roll out shapes of materials to a specific radius or diameter. Their working principle is similar to the plate rolling machine, but the structure is more complicated than the plate rolling machine．
Read More: Angle Roll Machine, Angle Roller – CNC Complex Shape Bending
3 Different Bending Process Types of Angle Roll Machine(Angle Roller)
Angle rolls are divided into three forms according to the different roll bending processes: pyramid, single pinch, and double-pinch profile bending machines.
Read More: Profile Bending Machine: 5 Things Before Buy, 6 Steps to Bend
The number of rolls an angle roll has is an important difference, the rolls are the round, spinning parts of the angle roll that allow it to do its job.
Every angle iron roller comes with at least one pinching roll, which is the roll that holds the metal in place and allows it to be fed through the angle bender machine.
Angle rolls come in two varieties: single-pinch and double-pinch, referring to how many pinching rolls it has.
Pyramid-type angle roller: It is a symmetrical bending roll bending machine.
Single-pinch and double-pinch angle roll: both of its forms are machines for asymmetrical roll bending machines. The double-pinch angle roll can perform asymmetrical and symmetrical bending processes, and the special structure makes it a better pre-bending ability.
Type 1#: Single pinch angle roll
In the single pinch angle rollers, only one of the bottom rolls can move. With this, kind of angle roller, it is possible to work only in an asymmetrical way. We can’t even find its pictures on the Internet.
Type 2#: Double pinch angle roll machine
In the double pinch angle roll machine, the top roll has a fixed position, while the bottom two can move and can be moved independently one from the other. This kind of machine is the most flexible, and consequently is the one that allows for obtaining better performances The possibility to move independently the bottom rolls allow us to manage in the best way the pinching and bending operations, permitting them to work symmetrically and asymmetrically.
Type 3#: Pyramidal of angle iron roller
In the pyramidal section bending machines the bottom rolls have fixed positions, while the top one can be moved down. With this kind of angle iron roller, it is possible to work only in a symmetrical way.
Difference between three types of angle roller
Production costs: The double pinch angle roller style is the most expensive one to be constructed because there are more movable parts and consequently more components. The pyramidal angle iron roller and single pinch profile bending machine have more or less the same production cost.
Flexibility: Double-pinch angle rollers are the most flexible. During operations, it is possible to maintain A stable position of the profile at the loading side of the Angle Roller and use only the roll at the opposite side to bend the steel or aluminum profile. It is possible to operate in this way also in the single pinch style section bending machines, but not on the pyramidal section benders.
3-roll angle roller & 4-roll angle iron roller
Pressing rolls are part of the angle roll bender that does the actual bending. Here there are even more varieties than with pinching roll.
Examples of different types of angle rollers based on the number of pressing rolls include three-roll double-pinch, four-roll double-pinch, three-roll initial pinch, and more.
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Six tips for choosing the best angle iron roller
Choosing an Angle Roll Machine may seem difficult but it really breaks down into a few simple steps. First, determine the metal material you will be rolling and the maximum size and type of material you will be rolling. Next determine the types of profiles (angles, flats, tubes, etc.) that you will be forming. Lastly determine if you will be rolling material into one simple radius or if you will have or need the ability to have, the capability of forming variable radii.
Tips 1#: Pressing rolls for angle roller
Pressing rolls are responsible for the bending process and come in far more varieties than angle iron rollers. Common examples include four-roll double-pinch and three-roll initial pinch.
Tips 2#: Yield strength
The yield value of Q235: refers to the yield value of this material, around 235MPa.
Regarding the yield strength of the angle iron roller, BIT machines are uniformly calculated based on the yield value of Q245 and have a yield strength of between 36,000 and 38,000 pounds per square inch (PSI). If you have special requirements, please indicate the yield strength of the metal material in the inquiry.
Tips 3#: Correctly sized
Whether operators are bending angle iron, tool choice is critical. The tools need to fit the profile yet not be so tight as to negatively affect workpiece shrinkage and growth. A tool that’s too tight can cause localized distortion and, at worst, actually gouge the material surface.
When operators need to bend an open profile like an angle, they have fewer distortion-mitigating tools at their disposal. Beyond tool choice and fit-up, angle iron roller must choose a correctly sized machine, one with sufficient forming tonnage and adequate grip lengths—enough to provide the needed leverage to reduce distortion, but not so long that they will require an excessively long sacrificial straight section, the long sacrificial flat section becomes expensive scrap, reducing the roll shop’s competitiveness.
Tips 4#: Pre Bending
How do minimize the unbent flat of the bending process?
BIT’s angle iron roller has the independent motion of the two side rolls allowing the operator to minimize the sacrificial unbent flat sections on the workpiece. Again, typically a roll shop that bends a small workpiece on a large section bending machine (angle roller) must factor in a long flat section, which increases material costs.
But because the BIT angle rollers (profile bending machines) move the way they do, an operator can move a joystick or push a few buttons on the control to reconfigure them into a smaller-machine orientation. Beyond this, operators can fine-tune the roll position to minimize the unbent flat even further.
Tips 5#: Different bending capacities of angle rollers
The types of metal an angle iron roller can process largely depend on its bending capacity, we use the section modulus to evaluate the capabilities of the angle iron roller. Capacity is one of the most notable differences between these angle iron rollers, each angle roll has a section modulus rating.
Make a list of the materials and the size of the metal profile you work with on a regular basis and consult an expert to figure out what type of angle iron roller is best for you. When determining which angle rolling machine is best suited for the task one has at hand, it is important to research what each section bending machine is designed to do, and to understand the materials that one will be working with.
We provided detailed information about the section bending machines, such as capacity and yield.
Tips 6#: View Bending Capacity Table
Compare the information about how much force an angle iron roller can produce and what kind of metals (sheet, roll, etc.) it is designed to handle, and compare this to your site’s mill certificates or other relevant information to see which angle roll best fits your needs.
4 Reasons Pre-Bending is Crucial When Selecting an Angle Roll Machine
Again, typically a roll shop that bends a small workpiece on a large section bending machine must factor in a long flat section, which increases material costs.
After bending due to the position of the rollers on the angle steel inevitably remains a flat angle at the ends of the angle iron. This flat part is approximately half the length of the gap between the centers of the lower rollers.
Although the appearance of a straight part is considered to be a flaw of symmetrical roller with 3 roll section bending machine, their simple structure, comfortable use, and low price still make them the most wanted model of roll profile metal section bending machines.
Read More: How to bending angle iron
How To Reduce The Flat Part In Bending？
In addition, there are methods which we can use in order to easily eliminate this problem. You can find some of them below:
Pre-bending: this solution involves bending the edges of the workpiece on a press brake before the roll bending process.
:: READ MORE:PRE-BENDING AND BENDING PROCESS
Adding a “base” for the workpiece during the pre-bending: this method involves the installation of a “base” together with a workpiece designed for bending and performing the edge pre-bending process on the circular bending machine itself. The application of this method should take into account the possibilities of the circular bending machine and calculate the strength of the applied force on the “base” and the workpiece.
BIT’s section bending machines have independent motion of the two side rolls allowing the operator to minimize the sacrificial unbent flat sections on the workpiece.
But because the BIT angle rolls (profile bending machines) move the way they do, an operator can move a joystick or push a few buttons on the control to reconfigure them into a smaller-machine orientation. Beyond this, operators can fine-tune the roll position to minimize the unbent flat even further.
What Is Pre-Bending In Angle Bending Process?
Pre-bending refers to holding an angle iron firmly between multiple rolls and pushing it to create the initial bend. With the rotation of the rolls on the angle roll machine(aka angle bending machine, angle roll, angle roller), the material is fed through the rolls and once the 360-degree rolling process is completed, the pre-bent end of the angle iron makes it very easy to connect the 2 ends, thanks to the pre-bending process.
Read More: Angle Bending Process, Angle Bending Machine – 2023 Guide
4 Reasons Pre-Bending is Crucial When Selecting an Angle Roll Machine
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Reasons 1#: Eliminates Waste
The pre-bending process helps minimize waste by creating an optimum geometrical formation so that both ends of the angle iron can get in touch after rolling as perfectly as possible. Practicing the pre-bending process while having an experienced and skilled angle roll machine operator plays a very critical role in eliminating waste.
Reasons 2#: Eliminates the Need for Extra Trimming
The resources used on extra material trimming in angle iron rolling are nothing to be ignored for any efficiently and effectively functioning fabrication shops or operations. The need for extra trimming can easily be avoided through pre-bending by forming an optimum alignment of both ends of an angle iron after rolling the material.
Reasons 3#: Saves Time
Especially for high-volume production shops, wasting a minute out of the production time means wasting money and can add up quickly over time. Since pre-bending helps an operator to form the desired shapes faster, the operating time per angle iron on an angle roll machine(angle roller) diminishes, which means rolling more parts with less time.
Reasons 4#: Smooth Bending Surface and Uniform Curvature / Thickness
The pre-bending process is one of the most important practices in angle iron rolling when it comes to being able to get the results that were initially intended to get, which is simply roll bending the material correctly. The properly rolled angle iron will inevitably result in a smooth material surface and uniformity in material curvature and thickness.
Angle Iron, also known as L-bracket or angle Iron, is a 90° metal bracket that is often used in roof trusses. On support beams and structural platforms, Angle steels can also provide reliable stability and corrosion resistance.
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