Profile bending is a common metal fabrication method used to bend metal profiles into desired shapes. However, in traditional profile bending processes, the control of roller positions is often based on the operator’s experience, resulting in reduced bending accuracy and production efficiency. To address this issue and improve the precision of profile bending, it is necessary to analyze the complete bending process and achieve precise control of roller positions. This article provides an in-depth analysis of the profile bending process, including the alignment, pre-bending, continuous bending, and unloading steps.
To prevent twisting and ensure the parallel alignment of the profile’s end face with the side roller axis, alignment is performed before the bending process. In a four-roll bending machine, alignment can be achieved directly without the need for additional alignment tools. The alignment process involves clamping the profile with the lower roller, raising the left and right rollers to the calculated positions, and rotating the upper roller to feed the profile until the left end face aligns with the left side roller axis.
During the profile or plate bending process, there is a portion of the profile’s end that does not come into contact with the side rollers due to the horizontal distance between the top roller and the side rollers. This results in a straight residual edge, which not only wastes material but also generates significant welding seam stress, leading to quality issues. In a four-roll bending machine, the asymmetrical distribution of the rollers can be utilized to perform pre-bending on the profile’s end without the need for additional equipment or tooling.
Continuous Bending Process
The continuous bending process is the main step in aluminum profile bending and requires strict control of the speed, position, and feed rate of the top roller and the side rollers. Depending on the thickness of the profile’s web, single-pass or multi-pass bending methods can be chosen. The continuous bending process involves the following steps:
- Based on the pre-bending operation, lower the right roller to the corresponding position and raise the left roller to the calculated position.
- Rotate the upper roller in the forward direction to feed the profile and complete the bending operation.
After completing the continuous bending process, all rollers should be returned to their initial positions in the unloading step.
Precise Control of Roller Positions
To achieve precise and coordinated control of the roller positions, it is necessary to calculate the displacement feed rate of each roller from one process position to the next. This serves as the foundation and basis for the automation and control of the four-roll bending machine’s processing. Based on the bending characteristics of the profile, the appropriate feed rate and position of each roller can be determined through calculation.
The analysis of the profile bending process is crucial for improving the bending accuracy and production efficiency. By understanding the alignment, pre-bending, continuous bending, and unloading steps, and implementing precise control of roller positions, the profile bending process can be optimized. This not only enhances the quality of bent profiles but also increases productivity. With advancements in automation and control systems, profile bending machines can achieve higher precision and consistency in bending operations.