Can Roller Leveling Improve Your Part Quality?
Sheet metal must be precise for downstream processes, making roller leveling vital. It ensures quality and consistency, enhancing parts and plates.
Sheet metal components come in various shapes and thicknesses for different applications. Each piece of sheet metal requires precise and consistent form to ensure it can reliably pass through various downstream production processes, necessitating manufacturing processes that are fault-tolerant, repeatable, and efficient. In this context, the role of roller leveling in sheet metal processing is particularly important. In this article, we will share with you why and how roller leveling can enhance the quality of plates and parts.
Finding the Right Internal Stress
Every sheet of metal has its internal stresses, which affect the quality and reliability of subsequent manufacturing processes. However, they are often challenging to quantify, typically manifesting as surface irregularities or deformations in the sheet metal. Sometimes not visible to the naked eye, these issues may only become apparent during welding, milling, or bending, making it difficult to determine how much residual stress remains in the sheet metal after leveling.
Therefore, for some decision-makers, evaluating the actual benefits of leveling sheet metal is not easy. Generally, the smaller the internal stress of the sheet metal, the smoother the manufacturing process and the higher the efficiency. For example, welders often marvel at how post-leveled sheet metal is not only flat and easy to handle but also significantly reduces assembly time. Additionally, dimensions during assembly are more precise and require no rework. These outcomes contribute to improved production quality, production planning, and ultimately cost savings for decision-makers.
In addition to the internal stresses inherent in the sheet metal itself, stresses and irregularities may also occur during the manufacturing process. For instance, during thermal cutting such as laser or plasma cutting, the high heat generated at the cutting edge creates temperature gradients, leading to stress formation and hardening of the edges. The result is deformed parts that hinder effective downstream processing. The only solution to this problem at that moment is leveling.
Sheet metal deformation and irregularities can lead to a significant increase in rework later on, a surge in non-conforming products, and negative impacts on manufacturing efficiency. This is neither economical nor conducive to enhancing customer satisfaction and competitiveness. Roller leveling, on the other hand, can prevent these issues from arising and has been proven to be the most efficient method. It not only applies to quick and easy leveling of sheet metal and plates but, most importantly, it scientifically reduces irregularities and internal stresses in the material through alternating bending processes.
Roller leveling machines used in production must possess the following characteristics to achieve the best leveling results: modular design of leveling work units, correct layout of leveling rolls and support rolls, a certain number of rolls and roll diameters. The principle is: the smaller the roll diameter, the more rolls the equipment should be equipped with. Small roll diameters and roll gaps are crucial for meeting high-precision flatness requirements. Additionally, the leveling rolls themselves need excellent support to ensure continuous rolling of the sheet metal without sliding between the working rolls, resulting in waves. To produce the highest quality sheet metal parts, the number of leveling rolls in the leveling machine is a critical factor you must pay attention to.
Leveling Ensures Consistent High-Quality Standards
In the sheet metal manufacturing industry, the quality of products determines the success of a company and its future prospects. This requires that every sheet metal piece processed meets high standards and strict requirements, which is why the leveling process must be an integral part of your high-quality production.
By using automatic leveling, you can also reap tremendous benefits. Through standardized and automated processes, roller leveling ensures consistently high-quality results. Compared to manual leveling, production efficiency is greatly improved.
Abandoning the Leveling Process is a Risky Decision
The decisive advantage of leveling parts with roller leveling machines is well understood by your customers. They typically adopt standardized production processes that heavily rely on smooth downstream processing.
Unleveled sheets may cause angular errors in subsequent processes such as edging and bending, leading to increased rework and non-conforming product counts. Additionally, welding becomes very time-consuming. When using welding robots, such materials also affect process reliability and welding duration negatively, resulting in higher process costs and increased heat in the material, leading to deformation. Correcting this phenomenon requires rework and longer production cycles, which is highly detrimental to process efficiency.
Perfect Sheet Metal Brings Satisfied Customers
Customers vary, and so do their needs. Ensuring quality while ensuring optimal processing is particularly important. Leveling sheet metal not only eliminates stress and repairs flatness defects but also reduces potential problems during downstream processing. High-quality leveling machines can help you quickly and reliably achieve high-quality leveling results. They can automatically calculate the correct settings, with operators needing to make only minor adjustments at most. Additionally, some leveling machines also have the capability to automatically detect flatness, coupled with the right automation devices, autonomous leveling processing can be achieved in many application areas. Using a plate leveling machine to level your sheet metal parts will immediately yield perfect flatness, improving the quality of your sheet metal parts and your market competitiveness.