When searching for a plate rolling machine it is most important to first know the capacity you're looking for. Second is then to determine the style of machine best suited to your rolling needs and lastly making sure you select a quality machine builder such as Bendmak. Before we delve into the intricacies of selecting a plate roller however we should cover the basics and review machines styles and the process.
There are 3 main “styles” of plate rolling machines and several variations of each. Below we have listed the miinan types of plate rolling systems available and their common uses.
The rolling process starts with a selected piece of material being squared up in the plate roll. In the Initial pinch and other 3-Roll machine designs this is a bit more tedious as it is a visual process. In the 4-Roll Plate roll one of the side rolls can be used as a squaring arm of sorts, to butt the material against squaring it physically before securing it between the two pinched rolls. Once the material is “pinched” securely it is adjusted until the very edge of the material is just barely past the midway or “pinch point” of the clamping rolls. Then the side roll is brought into position bending the plate to begin the angle in what is known as the pre-bend.
On 3 roll machines the material is removed, rotated and the process of pre-bending is repeated. In the 4-Roll design the material can be rolled directly from the first pre-bend until the trailing edge itself is on the opposite side roll where it then too can be pre-bent into the desired angle all whilst being firmly clamped between the 2 centered pinched rolls. Often an operator will make several “passes” to achieve the desired diameter. In some cases the operator will weld the plate ends together and attempt to “roll out” the flat ends that were created during the pre-bend process.
In order to determine plate rolling capacity you must first determine the hardest yielding material you will be rolling, the thickness and width of that material and the smallest diameter in which you will be rolling it to. Understand that as a certain capacity plate roll grows in plate width capability the plate rolls, by design, grow in diameter. The larger the diameter top Roll the less the diametrical capacity of the roll itself. As a rule the smallest diameter you can easily roll material down to is 1.5X the upper roll diameter (with smaller diameters achievable in multiple passes).
Capacity in a plate roll has been well engineered into the design of the machine and careful considerations must be taken most importantly with material yield strength and thickness. Consulting with your BendmakUSA representative is a quick and easy way to determine the right plate roll for your needs.
Often operators or fabrication shop owners will push their machines over capacity. Although all machines are designed for a range of safety above their designated range, eventually you can damage the machine, and in some cases severely. One of the first and most common issues with used plate rolling systems is bent rolls. When rolls are pushed beyond their limit over a shorter range of their surface they can be easily deformed. Another common issue when rolls are overstressed along their full capacity, is breaking of the top roll at the tapered end that fits into the drop end. This area of the top roll is weakest and can succumb easily to highly overstressed scenarios.
Selecting the right plate roll for your needs and budget is a simple process with your BendmakUSA representative. Our team has the know-how to help you select the right plate roll for your application. Call us today at 833-BENDMAK or visit us on the web at WWW.BENDMAKUSA.COM