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Bending Machine Manual: Square Pipe, Bar, Angle Iron, H-Beam, I-Beam, Aluminum, Channel, Tube

Angle Iron Roller Dies
Profile Bending Machine Dies
Section Bending Machine Bending Mold
Universal Roll

PBH Series Profile Bending Machine Operation Manual (2)

Content

angle roll machine
single-pinch of angle roll
Angle Iron Roller Dies
Angle Iron Roller Dies
Angle Iron Roller Dies
Angle Iron Roller Dies

Universal rolls/Angle Iron Roller Dies of PBH Profile Bending Machine

PBH profile bending machine’s universal rolls are designed to bend the most common commercial profiles (like flat bars, square bars, H&I beams, channels, tees, angle irons, etc..) but for some profiles (tubes and profiles with particular geometry) special rolls are required.
Notes: Should put forward the required bending profile specifications and varieties when ordering, in order to prepare special rolls.

Die method for section rolling
Figure 3-1

The composition of the universal roll

  1. small standard roll   
  2. drive roll   
  3. large standard roll
  4. bolt for the drive roller   
  5. chuck     
  6. clamping ring    
  7. screw

Installation of Angle Iron Roller Dies/Mold

Bending process and Profile Bending Machine Dies(universal mold)

Section bending method

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

Section bending methods
Figure 3-5 Section bending methods one

method one

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

method two

Section bending methods
Figure 3-6 Section bending methods two

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.

method three

Section bending methods
Figure 3-7 Section bending methods three

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

Pre-bending

Step one

Section bending method of section bending machine
Step one

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

Step Two

Section bending method of Profile bending machine
Step Two

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

Step Three

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.

Step four

Section bending method of Profile bending machine

Section pre-bending and section bending end.

SECTION BENDING METHOD OF STEEL BAR

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 fewer times 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. Click here.

The friction clutch should be adjusted to a loose state.

Die method for section rolling
Figure 3-1
Section bending method of flat bar and square bar
Figure 3-8

FIGURE 3-8 MOLD COMBINATION

Use the form of Figure 3-1. It is suitable for profiles with large section roll and high height. When section bending, the roll retains at least a 0.5mm gap.

FIGURE 3-9 MOLD COMBINATION

Die method for section rolling of steel bar
Figure 3-9
Die method for angle rolls
Figure 3-2
Die method for angle rolls
Figure 3-3

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 rolling of profiles with large section modulus and small height, small square steel also adopts this combination for bending.

Warning

Section bending methods
Figure 3-7 third spiral rolling method

As shown in FIG. 3-8 and 3-9, the third spiral rolling method (Figure 3-7) is not allowed.

What is the third spiral rolling method for bending steel bars?

FIGURE 3-10 MOLD COMBINATION

Die method for angle rolls
Figure 3-10

Figure 3-10 is suitable for small profile mold combinations. Rolling is performed as shown in the first or second method as shown.

Figure 3-11 Mold combination

Die method for angle rolls
Figure 3-11

Figure 3-11 is suitable for a combination of the roll with a large section. As shown in the figure, three rolling methods can be adopted, especially the third method.

Figure 3-12 & 3-13 Mold combination

Die method for angle rolls
Figure 3-12
Die method for section bending machine
Figure 3-13

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.

How to section rolling of steel bar

3D transverse guide rollers
3D guide rolls

The flat bending of the flat steel bar and the bending of the square steel bar can choose any combination of angle roll.

The steel bar’s section rolling process uses an asymmetrical bending, put the 3D guide rolls are raised slowly in the roll bending process, otherwise the material would be distorted.

Before the roll bending procces, must be adjust the guide roller to the same distance, and the steel bar has the correct angle relative to the roller axis, which is suitable for bending small workpieces with small bending stress, which will cause slippage during the bending process. Mainly due to the low friction during feeding, increasing the roller clamping force can eliminate slippage.

The steel bar can be bent into a circular workpiece with a diameter slightly larger than the die diameter, and the friction clutch should be adjusted tighter.

Bending angle iron method of angle iron roller

bending angle iron
bending angle iron (leg-out) method of angle roller

Bending angle iron – leg out

  1. 3D guide roller
  2. Small guide roller
  3. Main roller
  4. Left roller
  5. Right roller

BENDING ANGLE IRON OUT ROLLING (LEG-OUT) METHOD

Bending angle iron outer rolling process for section rolling machine

The angle iron is an asymmetric profile, and it is often twisted during rolling, so the guide roller needs to give the angle steel an external force against deformation during rolling, so that it can be corrected and reduce deformation.

The 3D guide rollers must be adjusted slowly to prevent the angle from twisting outwards. The mold combination is shown in the picture above. The pre-bending is asymmetrical, the rolling is symmetrical, and the friction clutch should be loosened.

bending angle iron
bending angle iron (leg-in) method of angle iron roller

Bending angle iron Inner rolling(leg-in)

  1. 3D guide roller
  2. Small guide roller
  3. Main roller
  4. Left roller
  5. Right roller

Bending angle iron inner rolling (leg-in) method of angle rolls

The inward bending process of the angle iron is similar to the outward bending of the angle steel flange workpiece. As shown in Figure 3-19, there will be two directions of distortion during the bending process. Therefore, 3D guide rollers (1) (Figure 3-18) and small guide rollers (2) are used. To provide the force, the small guide roller (2) is adjusted by twisting the idler.
Since the angle steel is easily deformed when it is bent inward, the diameter of the bent workpiece is larger than that of other profiles when the angle steel is bent inward.

Bending angle iron method
  1. Symmetrical adjustment
  2. Start bending the workpiece with one end of the 3D guide roller, adjust the side roller and feed the workpiece to the end of the small guide roller, adjust the guide roller so that the workpiece can be rolled back normally, the 3D guide roller will touch the flange end of the workpiece , which guides the workpiece to be rolled out from the machine.
  3. If the adjustment of the small guide roller is too large, the workpiece will be twisted inward.
  4. When rolling the workpiece, stop immediately when the other end reaches the middle of the 3D guide roller, and repeat the rolling of the other side in the opposite direction. Be sure to adjust the guide to the correct position, then bend as above until it forms a circle of the desired diameter.

T sections bending process of angle rolls

section bending method for profile bending machine
Figure 3-22

Outer roll bending of T-section 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.

T-section bending method for profile bending machine
Figure 3-23

Inner roll bending of T-section 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.

H-beam roll bending process and U-channel roll bending process

U-channel roll bending of section bending machine
Figure 3-25
H-beam roll bending of section bending machine
Figure 3-24
Round bar roll bending of section bending machine
Figure 3-26

Round bar roll bending process

  • Special molds adopts one or more v-shaped grooves.
  • Adopts symmetrical bending.
  • Adjust the friction clutch slightly.
Round tube roll bending of section bending machine
Figure 3-27

TUBE ROLL BENDING PROCESS

Adjustment of Friction Clutch of Section Bending Machine
Figure 3-28 No.: 1, Upper roller shaft 2, Friction block 3, Sprocket 4. Adjustment screw 5, Butterfly spring

Adjustment of Friction Clutch of Section Bending Machine

  • Adjustment of friction clutch
  • After opening the cover, adjust the friction clutch.
  • The power transmission is adjusted by tightening and loosening the adjustment screw.
  • The friction clutch is set to a low power transmission state at the factory.
  • Note: The friction clutch cannot be tightened too tightly.

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