section bending machine

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Operation Manual of W24S-75 Section Bending Machine

Section Bending Machine
Operation Manual of W24S-75 Section Bending Machine

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Purpose and basic parameters of the machine

Purpose of the machine

W24S-75 Section Bending Machine is a three-roller profile bending machine with an arc-down type, which is a general equipment specially used for profile bending. The equipment can be used to roll profiles into circular, curved, spiral and other workpieces, widely used in petroleum, chemical, shipbuilding, hydropower, metal structure and machinery manufacturing industries.


W24S-75 Section Bending Machine Technical Parameters

                     Device model

Technical parameters

Unit

W24S-75

The Max bending section modulus of profile

Cm3

75

Bending speed

m/min

4.5

Material yield limit

MPa

α5=235

Oil pump motor

kW

11

Diameter of shaft

mm

Upper shaft φ140, lower shaft φ130

Standard roller diameter

mm

Φ385

Size

mm

1600*1600*1345

Angle bar bending

(outer bending)

Max section

mm

120*120*12

Min bending diameter

mm

Φ1500

Angle bar bending

(inner bending)

Max section

mm

120*120*12

Min bending diameter

mm

Φ2000

Flat steel vertical-bending

Max section

mm

120*25

Min bending diameter

mm

Φ1000

Flat steel plane-bending

Max section

mm

250*30

Min bending diameter

mm

Φ1000

U-steel

Max section

mm

200

Min bending diameter

mm

Φ1000

Rectangular tube

Max section

mm

100*100*6

Min bending diameter

mm

Φ2000

I-beam

Max section

mm

200

Min bending diameter

mm

Φ1000

Square steel

Max section

mm

70*70

Min bending diameter

mm

Φ800

Circular tube

Max section

mm

140*4

Min bending diameter

mm

Φ1800

Remarks: except for round steel and round tupe moulds.

Overview of the structure and performance of the machine

Overview of the structure

The W24S-75 Profile Bending Machine is an arc-down three-roll profile bending machine. The shape of the machine (see Figure 1), the body is welded with steel plate. 

Profile Bending Machine
W24-75 Profile bending machine

The main roller performs a rotary motion by the power transmitted by the hydraulic motor, the gear, and the sprocket. The two side rollers can move in an arc around the central shaft. The power transmitted by the hydraulic motor and the gears is rotated simultaneously with the main shaft.. The support rollers are mounted on both sides of the side rollers, so that the support rollers can do arc motion with the side rollers. Lifting movements can be made through the respective lifting cylinders. Transmission diagram (see Figure 2).

Performance of the machine

The three rollers of the machine are all driving rollers. The end of the profile can be pre-bent during angle rolling, and the distortion of the profile during angle rolling can be corrected by adjusting the guide roll.

All of the above movements are achieved by button operations on the electrical control cabinet. Note: During the angle rolling process, the rotary motion of the three rollers and the lifting movement of the side rollers cannot be performed at the same time to avoid malfunction. After the three rollers are installed, the side rollers can be lifted and moved. After the mold of three rollers are installed, the side rollers can be raised and lowered.

Pre-bending and bending of the machine

Operation name

Operations can be divided into symmetrical bending and asymmetric bending:



Symmetric bending Asymmetric bending


Universal mold combination

The general mold combination is as follows: the mold bending profile specifications are limited, users should put forward the required bending profile specifications and varieties when ordering, in order to prepare different molds.

No.: 1, small standard roll   2, drive roll   3, large standard roll

    4, bolt for drive roller   5, chuck     6, clamping ring    7. screw


Universal mold combination


Universal mold combination

Section bending method

There are three types of Section bending methods, as shown in the figure.

bending method of section bending machine

Figure 3-5

Section bending method 1, Figure 3-5 is suitable for heavy workpieces, cutting the remaining straight edges after bending into a circle or when section bending to a certain arc.

Section bending method of section bending machine

Section bending method 2, Figure 3-6 is suitable for medium and small profiles, or single-piece angle rolling. The angle must be cut before section bending, end bending adopts asymmetric bending.

Section bending method of section bending machine

Section bending method 3, Figure 3-7 Applicable to all kinds of profiles, the workpiece with a large diameter of a single curved bending diameter.

Pre-bending and section bending process

Section bending method of section bending machine

The right roller is in the lower limit position, the left roller moves to the contact workpiece, and clamps the workpiece with the main roller.

Section bending method of Profile bending machine

The right roller slowly rises and begins to roll, pre-bending between the main roller and the left roller.

Section bending method of Profile bending machine

The left roller is down, while the right roller is up, send the material to the left side, and three rollers began to roll, pre-bend between the main roll and the right roller.


Section bending method of Profile bending machine

Section pre-bending and section bending end.

Section bending of flat steel and square steel

Flat steel and square steel are symmetrical profiles, which are easy to roll, and the pre-bending adopts asymmetric bending. A certain degree of distortion is unavoidable, if one or less times of roll, the distortion can be reduced. If the workpiece is rolled in multiple passes, it is necessary to increase the gap of the molds.

When section bending, please follow the basic parameters on the first page.

The friction clutch should be adjusted to a loose state.


Section bending of flat steel and square steel



Figure 3-8 mold combination: use the form of Figure 3-1. It is suitable for profiles with large section modulus and high height. When section bending, the mold retains at least 0.5mm gap.

Figure 3-9 Mold combination: The upper roller is in the form of Figure 3-2 or Figure 3-3, and the two lower rollers are in the form of Figure 3-1. It is suitable for the angle bending of profiles with large section modulus and small height, small square steel also adopts this combination for bending.

As shown in FIG. 3-8 and 3-9, the third spiral section bending method is not allowed.

Section bending of flat steel and square steel
Figure 3-12

Figure 3-12 applies to the combination of profile molds with small section height, as shown in the figure, and the rest are the same as shown in figure 3-11.

angle roller of flat steel and square steel
Figure 3-13

The flat bend of flat steel, and square steel bending can be combined with optional molds.

Adopts asymmetric bending, the side rollers rise slowly, otherwise the material will be distorted. Adjusting the guide rollers to the same distance, one side profile has the correct angle relative to the roller axis, it is suitable for small workpieces with small bending stress. There will be a slippage during the bending process, mainly due to the small friction during feeding, increasing the roller clamping force eliminates slippage.

The profile can be bent into a circular workpiece of a diameter slightly larger than the diameter of the mold, and the friction clutch should be adjusted tightly.

Profile bending of angle steel

Outer bending of angle bar

Profile bending of angle steel

No.: 1, large guide roller 2, small guide roller 3, main roller 4, left roller 5, right roller

Profile bending of angle steel

Figure 3-15 Figure 3-16

Overview of the outer bending of angle steel


Overview of the outer bending of angle steel

Figure 3-17

The angle steel is an asymmetrical profile. When bending, the distortion often occurs. Therefore, the support roller needs to give the angle steel an anti-deformation external force when it is rolled, so that it can be corrected and the deformation can be reduced.

The support roller must be adjusted slowly to prevent the angled steel from twisting outward. The mold combination is shown in the figure. Pre-bending adopts asymmetric, bending adopts symmetric, friction clutch should be adjusted loose.

Inner bending of angle bar


 Inner bending of angle bar for section bending machine


Figure 3-18

No.: 1, large guide roller 2, small guide roller 3, main roller 4, left roller 5, right roller

angle roller of Inner bending of angle bar

    Figure 3-19               Figure 3-20


Overview of the inner bending of angle steel

The inner bending process of the angle steel is similar to the outer bending of the angle steel flange workpiece. As shown in Figure 3-19, two directions of distortion will occur during the bending process, so the large guide roller (1) and the small guide roller (2) are used to provide the force, the small guide roller (2) is a torsion roller for adjustment.

The inner bends of angle steel is easy to produce distortion. Therefore, when the angle steel is inner bent, the diameter of the bent workpiece is larger than that of other profiles.

Bending

Symmetric adjustment

Start bending the workpiece at one end of the large guide roller, adjust the side roller and feed the workpiece to the tail of the small guide roller, adjust the guide roller so that the workpiece can be rolled back regularly, the large guide roller will be close to the flange end of the workpiece , guiding the workpiece out of the machine.

If the adjustment of the small guide roller is too large, the workpiece will twist to the inside.When the workpiece is rolled, the other end is stopped immediately to the middle of the large guide roller, and the other side is repeatedly rolled, and the winding direction is reversed. Be sure to adjust the guide to the correct position and then bend it as above method until it is bent into the circle of the desired diameter.

Symmetric adjustment of section bending machine

Figure 3-21

Rolling of T-shaped steel

Rolling of T-shaped steel for section bending machine

Figure 3-22 Figure 3-23

Outer bending of T-shaped steel

The mold combination is shown in Figure (3-22), adopts asymmetric bending, the side roller close to the main roller should not be too stressed, as this may cause twisting of the inner side during the beding and the friction clutch is tightly adjusted.

Inner bending of T-shaped steel

The mold combination is shown in Figure (3-23). The bending method is the same as above, and the friction clutch device is tightened, which is especially important for bending small diameter workpieces.. The friction clutch is tightened as above, which is especially important for bending small diameter workpieces.