Do-it-yourself rolling mill. Rolling mills - basic types and design. Purpose and main varieties

A rolling machine, which many experts call a roll machine or simply rolls, is a device that allows you to bend workpieces made of sheet metal. Rolling machines are distinguished by high efficiency and versatility, which makes it possible to successfully use such equipment in a wide variety of areas, including construction and repair.

Rolling machine W12-4 × 2500 rolls mild steel up to 4 mm thick

Purpose and main varieties

Rolling devices, the versatility of which was mentioned above, can be found today in almost any manufacturing enterprise. It is with the help of such a machine (which, if desired, can be made with your own hands), products of a conical, cylindrical and even oval shape are obtained from sheet metal. A technological operation that allows you to solve such problems is called rolling. In this case, it should not be confused with flaring, through which changes in the configuration and dimensions of tubular products are achieved.

Roller mills of the simplest design are actively used by home craftsmen. With the help of such equipment, various gutters, air ducts, elements of roofing structures, as well as many other products are produced. Rolling mills produced by modern industry can efficiently process sheets made of various metals.

So, devices of this type, represented by a wide variety of models, can successfully cope with sheet blanks from carbon and alloy steels, aluminum, copper and cast iron. Certain models of these machines, the rollers of which have a special design, can bend polycarbonate sheets.

Among the rolling equipment, the following categories are distinguished:

manual machine;
electromechanical machine;
sheet metal machine equipped with a hydraulic drive.

The manually operated roller mill is the simplest type of equipment, which can be produced in a floor (mounted on a rack) or tabletop (mounted on a workbench) version. This manual rolling machine is easy to use, but requires considerable physical effort. Meanwhile, the simplicity of the machine design ensures the maintenance of its reliability for a long time.

The classic manual 3-roll bending machine is suitable for rounding metal workpieces up to 3.5 mm thick

Three-roll manual rollers (namely, with such a number of working bodies, they are mainly manufactured) allow processing pipe and sheet metal with a wall thickness of up to 1.5–2 mm. Such a manual bending machine is the easiest to make with your own hands. It has such advantages as:

compact dimensions;
insignificant weight;
high mobility, which makes it easy to move such machines to those places where their use is most in demand;
savings on electricity bills (manual rolling machine does not require its use);
low cost (when compared with the price of electromechanical type machines).

FormRoller electromechanical three-roll bending machine is used for batch production of workpieces of various geometries

An electrically driven device (electromechanical rolling machine) has a special gearbox in its design, which significantly increases the efficiency of such equipment. The electromechanical bending machine can be used both for processing sheet metal and for changing the configuration of profile tubes. When it comes to sheet metal processing, the electromechanically driven 3-roll machine can be used to process sheet metal that is less than 4 mm thick.

The most powerful type of equipment is a hydraulic rolling machine, which is actively used in power, shipbuilding and machine-building enterprises. A hydraulic three-roll machine or a device with a large number of working elements differs by several times more power when compared with devices of the manual or electromechanical category. On hydraulic rolling equipment, which is often equipped with CNC systems, it is possible to successfully bend metal sheets, the thickness of which reaches 8 mm.

The hydraulic drive of this machine easily moves the shafts of impressive dimensions, and the CNC controls their location and the degree of sheet deformation

Design and principle of operation

The supporting element of the rolling machine, including one made by hand, is the base frame. It is on this bed, which can be made of cast iron or sheet steel of considerable thickness, that the deforming body of the machine is mounted, which can include two, three or even four rolls. The vast majority of such devices, including those made by hand, are equipped with three working bodies, since the two-roll rollers are not highly efficient.

The rotational movement during the operation of the three-roll machine is communicated only to the two lower working bodies, which, meanwhile, can move linearly only in the horizontal plane, which is necessary to change the distance between them. The upper roll of such a device, which is called thrust, rotates due to the friction forces created between its surface and the surface of the workpiece being processed.

The upper roll, which is equipped with the rolling machine, has the ability not only to move in the vertical direction, which allows it to be pressed against the surface of the workpiece being processed with the required force, but also to swing to the side. The latter is necessary in order to quickly replace it with a roll designed for processing workpieces with other geometric parameters.

The machine, the working rollers of which are equipped with special grooves, can be used for bending pipes, rods and even large wire. It should be borne in mind that an additional fourth roll, the use of which significantly increases the load on the equipment drive mechanism, can only be installed on an electromechanical or hydraulic rolling machine.

The bending machine, the main working bodies of which are rollers, works according to the following principle.

A sheet of metal, from which it is necessary to form a cylindrical or conical product, is laid on two lower rolls separated by a certain distance.
Lowering the top roll using a special mechanism, the metal sheet is securely clamped between the three working bodies.
When the two lower rolls rotate, which provides a manual or electromechanical drive, the metal sheet being processed is set in motion and begins to bend around the working bodies of the rolling machine clamping it, gradually assuming the required configuration.

Moving at a certain speed between the rolls, a flat sheet of metal gradually turns into a product of a cylindrical, conical or oval shape. Obviously, this type of machine does not work like a flaring machine, the working body of which rolls out the end of the tubular product, expanding it to the required geometric parameters.

A rolling machine, on which you can effectively bend not only sheet metal, but also tubular products, is not at all necessary to buy. A rolling machine, if high performance is not required from it, is easy to make with your own hands. Of course, the easiest way is to make such a machine with a manual drive, but the power and functionality of this equipment will be quite enough to perform construction and repair work on it.

Diy rolling machine: drawings and video

To manufacture a manual rolling machine, you must first find its drawings or develop them yourself, taking as a basis the design of any serial model.

As an example, consider a set of drawings of the USG rolling machine, which are presented below.

Assembly drawing of the serial rolling machine USG (click to enlarge)

So, in order to make a manual rolling machine with your own hands, you must follow the algorithm presented below.

The frame of the device is made from metal sheets, cutting them according to a previously prepared drawing, in special grooves of which its lower shafts will be fixed. The structural elements of the bed are interconnected by means of stiffeners, which can be metal pipes or corners.
To accommodate the upper roll, support legs are welded to the device frame. For their manufacture, it is best to use a powerful U-shaped profile. The bearing units are mounted in the support frame, into which the upper roll of the machine is installed.
A drive mechanism is mounted on the side of the bed, which includes three sprockets, a chain and a device for its tension.
The final stage in the manufacture of a homemade rolling machine is to install the handle of the drive mechanism, tension the chain and adjust all structural elements.

Naturally, after the final assembly, the home-made machine must be tested (and the operation of all its mechanisms must be adjusted, if necessary).

Popular models of manual rolling equipment

Manual rolling machines, presented in the modern domestic market, allow you to effectively solve technological problems of any complexity. So, for a reasonable price, you can buy a small-sized table-type rolling device or stationary equipment, the power and productivity of which is quite enough to solve the problems facing a small production or repair enterprise.

Among specialists and home craftsmen who prefer to perform, manual rolling equipment of the following brands is very popular.

Stalex

This company manufactures reliable and efficient equipment designed for processing sheet blanks of various widths and thicknesses.

Metalmaster

Reliable, functional and easy-to-use equipment for rolling is produced under this brand. On many models from Metalmaster, thanks to the special grooves on the rolls, it is possible to bend pipes and rods.

Enkor-Corvette

This is a domestic brand under which inexpensive but rather reliable plate bending equipment is produced in China. Using such machines, it is possible to bend sheet metal, the thickness of which does not exceed 1.5 mm.

Electromechanical type plate bending machines

Rolling electromechanical machines are presented on the domestic market in an equally wide range. So, of the most popular brands of devices of this type, the following are worth noting.

VEM

This is a functional rolling equipment that, due to its high reliability, rarely needs repair and expensive maintenance. By equipping with additional structural elements, the technical capabilities of the machines of this brand can be significantly expanded.

Stalex

Roller electromechanical machines of a professional level are produced under this trademark. The design feature of such machines is the asymmetric arrangement of the work rolls, as well as the ability to quickly retrace the upper working body, which allows for prompt removal of the workpiece from the processing zone.

Electromechanical rolling machine Stalex ESR-1300 × 2.5 (width and thickness of the processed metal are reflected in the designation of the machine)

Metalmaster

It is powerful and reliable equipment with comfortable foot control, which can be used not only for bending sheet metal, but also for processing tubular products and rebar.

Consider a good example of how you can make a rolling machine with your own hands: methods and technologies for its manufacture. But first of all, it is necessary to understand for what purpose we need this machine.

It's hard enough to imagine modern everyday life without metal. It is used universally and requires appropriate equipment to process it. The metallurgical industry mainly uses modern rolling mills, which in turn have a high price tag. For independent use and manufacture of professional pipes, you can design a rolling and punching machine on your own.

What is this equipment used for?

Rolling and punching machines and other metalworking equipment are most often used to create a specific shape for a metal part. As this material is widely used, it is handled with due responsibility and care.

Rolling machines for metal profiles are ubiquitous, but many do not even realize that such complex equipment can be made independently. Due to the fact that the price of such equipment is extremely high, we will clearly consider an example of how to make a rolling and punching machine with our own hands.

A striking example of metal parts, where a rolling machine for shaped pipes is used in the manufacture, are pipes or radiators of batteries present in every house or apartment. All these products are made on metalworking equipment, which can be manufactured independently without any skills and deep knowledge.

Important: if you decide to independently make a rolling-die-cutting machine type, then for the reliability of the subsequent parts produced on it, its assembly should be treated with due attention and responsibility.

Varieties of rolling machine

As it became clear from the above, rolling equipment is necessary for processing a metal blank into a finished geometrically formed part. In this case, the following types of equipment are used for sheet metal:

Continuous extension, which allow the manufacture of metal pipes with a cross section of 110 mm.
Pilgrim machines that are used in the manufacture of massive pipes with a diameter of 400 to 700 mm.
Short-cut models of equipment that are used in the production of seamless pipes with a diameter of up to 450 mm.
Three-shaft machines, which, in turn, are used to make thick-walled pipes, the diameter of which can reach 200 mm. This type of equipment is often referred to as a jewelry rolling machine.

Important: in modern metalworking plants, wide-profile models of the bending system of installations are also often used, which makes it possible to produce shaped pipes with a total length of up to 3 meters.

Component parts of equipment

Typically, any rolling mill has three main components, namely:

working cells;
transmission devices;
electric motors.

The shafts where the metal components of the future part are placed are part of the working cage. Also, this component includes the following elements: installation mechanisms, beds, plates, as well as wiring. Powerful electric motors are responsible for the movement of all components of the rolling mill. They are connected to the working elements using couplings, transmission elements and spindles.

Important: the main component of rolling equipment of the crimping and billet type is the diameter of the shaft, namely the size of its working surface.

Modern metal-working machines can have several working stands at once, this is necessary for the manufacture of parts of complex geometric shapes. It is often called a crow's feet machine, which allows you to perform work in several projections at once.

As a rule, such devices have impressive dimensions and can provide a working surface up to 3 meters. A distinctive feature of modern rolling mills is the work in three directions at once for:

Making holes in sheet metal.
Exhausting the workpiece into the pipe.
Product calibration, which allows you to set the diameter of the future part.

Important: work on the rolling machine can only be carried out by a qualified specialist who has been instructed in safety precautions.

DIY rolling installation

For a profile pipe with your own hands, you will need to make a small machine that differs significantly from industrial installations in size. This can be done in everyday conditions if there is free space for the machine.

At the same time, it can be noted that a home-made machine can allow you to make parts of any complexity. With its help, you can easily make wire of any diameter, cut sheet metal, which provides for the roofing of any roof, as well as many other details that are often in demand in everyday life.

First, you will need to select the appropriate drawings so that you get a homemade rolling machine. After that, you have to prepare its components, namely:

a pair of powerful struts made of strong metal;
a rod of steel, whose diameter will be at least 5 cm;
top plate with M10 nuts;
two gears of the appropriate size;
gear;
springs and stops;
as well as bronze bearings and bushings.

After you have all the components in stock, you can start making a work machine, which will be mobile enough to move:

With the help of bolts from the racks and a metal plate, a kind of working cage is assembled.
Two working shafts are mounted to the same racks. They should first be carved from a previously prepared steel bar. They also need to be hardened to obtain improved metal strength.
The lower shaft is mounted between the struts using prepared bushings and bearings. In this case, the upper shaft is mounted on special sliders and is a movable element of the machine. The upward movement of the sliders is limited by stops.
The two separate shafts are continuously compressed by means of a spring, which keeps them in constant tension. It is attached simultaneously to the plate, the bases and directly to the movable upper shaft.

Important: to ensure the operation of such a machine, synchronous rotation of the working shafts is necessary. You can solve this problem with the help of a gear transmission, which transfers torque to a gear, which is installed on the lower shaft. Thus, using the handle, you can start the device.

The installation made in this way has a manual drive. It requires continuous rotation to work. If the manual mechanism stops, then, accordingly, the shafts will stop rotating. Thus, a universal device is obtained on which it is possible to change components and thereby change the profile suitability of the machine.

Pros of a homemade device

Ultimately, everything you need to make such a universal device can be bought at a low cost in any hardware store, or you can pick up the necessary components from old long-forgotten things, as well as pick up drawings. In any case, the price of such a machine will pay for itself very quickly, since parts of any complexity can be made on it with minimal expenditure on consumables.

Important: Renting a rolling machine will cost a lot, which is why you can post ads and make good money on your device.

The work done pays off quickly enough, since you can make any parts. Here is just a small list of them:

professional pipes;
metal guides for gypsum plasterboard profiles;
seam roofing;
elements for metal siding;
square and rectangular metal sheets;
additional siding mounts;
wire for electrical wiring.

All these homemade products will come in handy when building a new house or renovating it. As practice shows, self-made sheet bending machines are extremely in demand, since their scheme does not require complex manufacturing, but at the same time it allows you to make a lot of useful and necessary parts.

Video: DIY rolling machine.

Outcome

Thus, by hand, you can make an excellent machine for folding roofing sheets and other structures with minimal investment and labor costs, and you will never need to rent sheet bending machines or any other metalworking equipment again.

Real master jewelers have long been working part-time, thus, having a stable, profitable part-time job, or using their homemade equipment as their main source of income.

A rolling machine is a special equipment that is used in the metallurgical industry and is designed to process a metal workpiece by pulling it through special rolls.

With the help of a rolling mill, products such as rolled metal sheets, square or round beams, wire are obtained. In the future, complex mechanisms and machines are created from these materials.

Rolling machines for sheet metal

Rolling machines, with the help of which sheet metal is obtained, belong to the so-called section mills.

Such machines can be:

large-sized;

medium-grade;

rail rolling.

Fox rolling mills can be hot or cold formed, and can be used to produce metal plates from 50 to 350 mm thick, sheet metal from 3 to 50 mm, and metal strips from 1.2 to 20 mm. After the product is ready, the product is wound in standard 50 ton rolls.

Rolling machines for shaped tubes

Rolling machines, with the help of which it is possible to obtain profile pipes, are divided by experts into three types.

Roller bending machine - a machine that is used to deform sheet metal. Most often, this unit is used for the manufacture of thin-walled parts. For example ebbs or gutters.

Three-roll machines - these devices make it possible to deform not only the sheet, but also the pipes. With the help of equipment, profiled rolled products are also processed. The power of this equipment is determined by the downforce generator. If the machine is hydraulically driven, then it can deform even the T-rails.

Four-roller machines - the most powerful unit of this type. Such equipment allows you to make even an annular profile. It is these machines that are used in industrial enterprises with mass production.

Manual rolling machines

A manual rolling machine allows you to make specific metal workpieces, wire or, for example, flatten metal plates at home.

The design of a manual rolling machine includes:

two gears;

two racks;

gear;

springs;

bushings;

bearings.

A manual rolling machine can be versatile due to the fact that the machine can use shafts of different designs. So, if you put shafts with special grooves, you can make wire, and the installation of circular knives allows you to cut metal.

Production of rolling machines

Many companies in different countries of the world are engaged in the production of rolling machines.

The rolling line includes equipment such as:

the main line of the rolling mill;

heating furnaces;

descaling systems;

equipment for cutting, transportation, coiling, marking, packaging.

Modern rolling equipment must have characteristics that allow to obtain products of the required quality, while it must be sufficiently compact, versatile, economical and energy-intensive.

An important factor in classy equipment is its production flexibility, the ability to quickly change to another product, durability and the possibility of easy maintenance.

Rolling machine manufacturers and suppliers

The rolling equipment for the metallurgical complex is a complex system, in the production of which the most modern technologies are used. Among the world brands that produce rolling machines, the following enterprises stand out.

JSC “Elektrostal Heavy Machine Building Plant” is the only Russian company that manufactures fluid-friction bearings for rolling mills.

BORA Group of Companies is a major manufacturer of lines and other automated equipment for processing thin sheet metal in Russia.

NPP Mechatronica is a Russian company that designs rolling mills and manufactures rolling mills for individual orders.

If we talk about global manufacturers, then we can note the following companies:

MS COSTRUZIONI SRL, Italy. This enterprise is engaged in the production of complex equipment and machine tools for the metallurgical industry. Among other things, the company is engaged in the production of rolling mills of various capacities.

ELEKTROMASHSTAN, Spain. The plant produces rolling machines that allow the production of metal sheets, pipes, profiles. The company has a developed network for the sale of its equipment and is well known in many countries around the world.

Luoyang Sennuo Precision Bearing Co., Ltd China. This company develops and manufactures machines for a wide variety of purposes, including a rolling mill. It should be noted that despite the good quality, the company sells its equipment at quite reasonable prices.

Where can you buy a rolling machine

You can get acquainted with manufacturers of rolling equipment for further cooperation at specialized events (exhibitions, fairs). You can buy rolling machines from supplier companies and on the Internet.

Among the most famous sites offering such equipment, experts note the following trading platforms:

prostanki.com. On the site you can find offers for the sale of rolling machines of various capacities, from manual to powerful industrial equipment;

kovkapro.com. On this resource you can order rental equipment for small businesses and private use;

pulscen.ru. This site offers a wide range of rolling machines. On the site, you can choose equipment to equip a large factory or a small factory.

Rolling machines at the exhibition

Industrial companies have the opportunity to get acquainted with the most modern models of rolling equipment at specialized exhibitions.

Usually, well-known foreign and domestic manufacturers demonstrate their products at such events.

In addition, here you can get acquainted with the most advanced technologies in the field of metalworking. For example, not only Russian companies are participating in the competition, but also representatives of other countries.

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Rolling machines are the most important equipment in obtaining metal in the form in which it is needed. They will be discussed in the article.

General information

Today, metal is the most common material from which a huge variety of things are made, from small household parts to large industrial facilities. However, there is a very important point that not everyone knows about. It is not enough to simply smelt the metal, and then turn it into an ingot. After the ingot is formed, any metal is transferred to the rolling mill. The only equipment available in such workshops is rolling machines. It is these devices that give the desired shape, which is suitable for the subsequent use of metal. It should be noted that this equipment is one of the oldest to date. However, over the years of its use, the machine has proven itself from such a good side, has such good characteristics and an indicator of productivity that it is used to this day.

Machine device

In fact, the structure of the rolling mill is not difficult or difficult to maintain, assemble or repair. The sole purpose of this device is to shape the ingots of metal. In other words, large ingots enter the rolling mill, and as they pass through the rolling mill, it shapes them into a more familiar sheet metal. In order to achieve this effect, the design of the rolling mill has two rollers that constantly rotate towards each other. From the point of view of the technological process, this work is considered quite simple. In addition, the constant improvement of technology has allowed for many improvements and modifications to the operation of this device. Thanks to these changes, all equipment of this type is now capable of operating in fully automatic mode.

Rolling

The metal rolling machine has another very important function. It doesn't just shape the leaf. As the ingot passes through this machine, the metal becomes more homogeneous and more dense in structure. This is due to the fact that the rollers completely overwrite or close all cracks or empty spaces that could well have formed on the ingot.

Another important point is that the process of converting or rolling metal into sheet form takes place in several stages and with the participation of several types of machines. Blooming and slabbing devices are engaged in primary rolling. It should be noted that before sending the ingot for rolling to these machines, it must be slightly warmed up. Increasing the temperature of the metal will increase the ductility of the material during rolling. If we talk about the performance of such machines, then it is enormous. One machine is capable of producing about 6 million tons of metal per year. This is taking into account the fact that the weight of ingots supplied to rolled products can range from 1 to 18 tons.

Blooming or slabbing

Before being rolled out, the ingots are heated in special wells. The temperature that is maintained in such devices can reach 1800 degrees Celsius. After passing the well, an electric car is used, which, in fact, gives out the heated ingot to the rolling of blooming or slabbing. The difference between these machines is that blooming has only two rollers, while slabbing has four. It is important to understand that the passage of this stage and the processing process itself are only primary, since at the exit from blooming or slabbing, the ingot still does not have a full-fledged form of sheet material. These aggregates are designed to form bars. Depending on its shape and size, the resulting material is divided into blooms or slabs. An important note - the use of blooming or slabbing rolling machines is carried out only at those industrial facilities where the metal will later be poured into molds.

General characteristics of the machine

Rolling mills are devices with smooth rollers through which metal is passed in order to give it a sheet shape. Currently, there is a huge range of these devices. The biggest difference between the machines is the shape of the rolls. For example, there is a unit that was originally made for the production of rails. Even during the production of the machine, the shape of its rollers was prepared specifically for this task. It is also important to understand that the machine has several pairs of rollers through which the metal passes. Constant progress has led to the fact that all types of devices are capable of operating in constant automatic mode. The speed at which the stands are pulling the ingot through the machine can reach a record 290 km / h. The productivity of such a rolling mill reaches several million tons per year. Today, such units as casting and rolling are gaining popularity. The advantage is that they can act as a separate complete production line, in contrast to conventional rolling mills.

Currently, there are such as billet, sheet, strip, bar, and some types are capable of producing wire or beams.

Pipe rental

Another large category of rolling machines is intended for the production not of sheet metal, but of metal pipes. There are only three main types of pipe rolling machine currently in use. These include stitching, rolling and finishing machines.

If we talk about piercing mills, then they can have three different types of rollers used for rolling. There are barrel rolls, mushroom rolls and disc rolls. A device of the first type, that is, barrel-shaped, is characterized in that these machine elements have a double-taper shape with a diameter of 450 to 1000 mm. Both parts are located in the horizontal plane, but along the vertical axis, the feed angle can be adjusted from 5 to 18 degrees or more.

Screw rolling

The rolling machine can also perform screw processing of metal. When performing this type of operation, tensile and shear stresses are created in the metal in double-cone rolls. It is important to note that the radial stress of the workpiece can reach quite large values, which creates a cavity of small diameter, which has uneven walls. In order to get a hole with the required diameter and at the same time avoid the presence of irregularities, and make even walls, it is necessary to carry out rolling on a mandrel. The mandrel is understood as a cone-shaped tool that is located at the end of the rod between the rolls along the path of the metal blank. There is a special stop for fastening a rod with such a mandrel. As the metal moves forward, it is stitched with this rim, which goes through the hole, expanding and flattening it.

Rolling machines are the most important equipment in obtaining metal in the form in which it is needed. They will be discussed in the article.

General information

Machine device

Rolling

Blooming or slabbing

General characteristics of the machine

Currently, there are such types of machines as billet, sheet, strip, section, and some types are capable of producing wire or beams.

Pipe rental

Screw rolling

The profile tube rolling machine can also perform screw processing of metal. When performing this type of operation, tensile and shear stresses are created in the metal in double-cone rolls. It is important to note that the radial stress of the workpiece can reach quite large values, which creates a cavity of small diameter, which has uneven walls. In order to get a hole with the required diameter and at the same time avoid the presence of irregularities, and make even walls, it is necessary to carry out rolling on a mandrel. A mandrel is understood as a cone-shaped tool, which is located at the end of the rod between the rolls along the path of the metal blank. There is a special stop for fastening a rod with such a mandrel. As the metal moves forward, it is stitched with this rim, which goes through the hole, expanding and flattening it.

It is rather problematic to collect reviews about a rolling machine for a profile pipe, since such units are used mainly only by large enterprises. However, here the very use of these particular units already suggests that they work stably and well. In other words, conclusions can be drawn from the fact that all metalworking factories use such machines for a huge period of time. And this means that the presence of an automatic mode and great productivity do their job. The disadvantages include the fact that the dimensions of such devices are quite large, and their stopping and starting again is very problematic.

Thin-tube rolling

It is worth noting that thick-walled sleeves are obtained when the rolled metal passes through the piercing machines. After passing through processing on this device, the workpiece is transferred to thin-tube rolling to such a device as:

pilgrim;
auto;
continuous;
three-roll.

The name of each of these units is determined by the type of rolling mill used on that equipment.

Rolling and cutting machine

The most famous manufacturer of this unit is Kadzama. This device is also called a roller press. The device of this thing is very simple, but it is intended for cutting down cardboard, paper or plastic boxes for confectionery.

The advantages of this device include the fact that it pays off rather quickly. The first 10,000 boxes is the approximate cost of one such machine. The cost of finished goods, that is, boxes, is also very low. You have to pay only for the raw material itself - cardboard. It is very easy to work with this type of machine. All that is needed is just two things. First, a sheet of cardboard is placed on the cutting knives, and then the feed handle is turned. The dimensions of such a device are also quite small. You can even install it on a regular table.

How to make a rolling machine?

In order to make a rolling machine for the production of profiles, you will need 3 obligatory things - metal, bearings and a lathe. The design of the machine itself is also quite simple. The constituent parts of a one-piece rolling mill is a table to which a worm gear motor is attached. In addition, it is necessary to fix 7 additional receiving stands on the table. It is important to know here that each stand consists of several components, and all of them are meshed with each other. That is, each stand is connected to the next. One more nuance concerns rollers. In this model of the machine, they are removable, and their fastening is carried out on the shafts. This type of arrangement and the type of rollers itself opens up ample opportunities for the production of various profiles in terms of their dimensions, as well as the type of products. If there is such a desire, then you can put a new type of rollers that will make it possible to manufacture the LSTK profile. In order not to make mistakes in manufacturing, it is best to make a drawing of the rolling machine before proceeding with its assembly.

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Rolling machine - equipment for bending sheet metal

The rolling machine (roller machine, rollers) is a versatile equipment used in the construction and repair industry for bending various metals.

Such machines are used in any modern enterprise for the production of conical, oval and cylindrical products from sheet metal. The procedure for making such structures is called rolling. It makes it possible to receive any pipes, blanks for subsequent stamping, a variety of finished metal products.

Simple rolling equipment is also used in everyday life when you need to make gutters, chimneys, pipes, air ducts, and other products for roofing and construction work with your own hands. Modern roller machines allow you to work with almost any metal. They easily bend sheets of stainless steel, alloyed and carbon alloys, aluminum, cast iron.

There are also models of rolling equipment that work with polycarbonate blanks.

All the units we describe for bending sheet metal are divided into the following groups:

manual;
electromechanical;
hydraulic.

The manual machine can be mounted on a stand (floor) or on a workbench (table). It does not have a mechanical drive, therefore, to perform work on it, muscular strength is required. Hand-held machines are very easy to use. Their elementary design ensures high reliability of equipment operation for a long time.

Hand rollers are designed to produce pipes and other products from sheet metal up to 1.5–2 millimeters thick. They are lightweight and compact, which allows them to be carried and used directly on the object of performing certain works (roofing, repair). Most importantly, they don't need electricity. For the price, a desktop and floor-standing manual unit is always preferable to an electromechanical one.

Machine tools with an electric motor equipped with a gearbox are more efficient in operation. They facilitate and significantly speed up the pipe bending process. The electromechanical unit is installed permanently in the corresponding workshop of the enterprise and is used for processing metal up to 4 millimeters thick.

Hydraulic equipment belongs to the heavy class. It is used for the manufacture of pipes and other structures on an industrial scale at power engineering, shipbuilding and machine-building plants. In terms of its technical potential, a hydraulic machine is several times superior to an electromechanical and manual machine. Hydraulics can produce pipes from metal sheets up to 8 millimeters thick. Often, hydraulic equipment is equipped with software control.

The main unit of the described machines is a cast bed. It is made of steel or cast iron. A special deformation mechanism is mounted on the bed, consisting of several (3-4) rolls. Two rolls are stationary, the third and, if any, the fourth rotate during operation. The movable shafts can also be moved vertically.

The upper roll is fixed on the bed according to a scheme that makes it possible to quickly remove it, if necessary, or quickly adjust it for the production of pipes with different cross-sections. The adjustment of this structural element is carried out with a single wing-type screw. If there are grooves on the work rolls, they can bend not only pipes, but also rods or thick wires. A manual metal bending machine usually has three rolls, an electromechanical one - 3-4. But hydraulic units are always produced with four rolls.

At the same time, the process of making pipes on any unit is really simple:

first, a sheet of metal is clamped between the middle and outer shaft using a special handle on the machine;
then the workpiece is pressed against them by the third roll;
start to manually rotate the rolls or start the electric motor.

Passing through the shafts at a certain speed, the metal is bent at the right angles. To make pipes or gutters of quite decent quality with your own hands, you can purchase a manual machine. By and large, there is even no need to buy it (although they are inexpensive), since you can assemble a homemade unit and use it effectively to perform small jobs. For information on how to do this, see the next section of the article.

Anyone who sets a similar task for themselves can make such a machine with their own hands. We will very briefly describe what materials and how exactly you can make a homemade unit. First, you need to take a frame made of pipes or a curved profile that will serve as a bed.

Then we prepare a U-shaped profile (ideally when hardened steel is the material for it) for the manufacture of the vertical support of our equipment. The deforming unit of the rolling machine is located in the open (upper) part of the profile. You can fix it with a clamp on which the thread is applied. The lower part of the P-profile is fixed under the bed.

After that, we take the transmission chain, without which the roller device will not work, and mount it on sprockets. Here it is important to tighten the chain well and be sure to check the ease of its movement.

Then we install the feed handle and attach the entire mechanism to the bed using rolling bearings. You have made the simplest DIY hand rolling machine! It is desirable to provide in its design a special mechanism that allows you to adjust the gap between the shafts. Then you can process metal of different thickness.

It is not difficult to make with your own hands a more complex rolling mechanism. There are many materials on this issue on the Internet now. Find a website with relevant information, look at the drawings of homemade installations, and DIY the equipment that is perfect for you.

The modern market for metalworking equipment is able to satisfy any request. Everyone can find the machine they need at a reasonable cost. It is not difficult to purchase both an inexpensive compact installation for do-it-yourself pipe bending, and a professional floor-standing unit for a large production workshop or a modest private workshop.

Rollers from the following manufacturers are popular:

You can also buy equipment from other manufacturers - SAHINLER, JET, SCHWARTMANNS, PRINZING. The machines vary in their price, but they all do their job well.

The range of motor-driven bending machines is equally impressive. The demanded electromechanical roller machines are produced by the already mentioned companies, as well as by Russian factories. We will describe several popular models of such equipment:

As you can see, the choice of rolling equipment is currently very good. You can easily purchase both professional machines for use in industries and amateur units for domestic use.

tutmet.ru

Rolling mills - main types and design

It is difficult to name a branch of industry where metal and metal products are not used, for the production of which a rolling mill is actively used. Metallurgical enterprises today make rather high demands on equipment. That is why modern industrial machines, in particular rolling mills, differ significantly from the models that were previously produced.

Rolling mill for the production of corrugated board

What is this equipment for?

The demand for such a strong and reliable material as metal is constantly growing, which leads to the need to open new metallurgical enterprises and modernize those already operating. The list of industries in which the use of metal simply cannot be done is endless. These are mechanical engineering, automobile and shipbuilding, construction industry and many others.

In order for metal ore to turn into rolled metal of a certain grade, it is necessary to perform a lot of basic and auxiliary operations, for each of which special equipment is used. One of the main types of metallurgical equipment on which, as a result of plastic deformation, a sheet of metal is obtained from a red-hot workpiece, is a rolling mill. It is on it that the bulk of the work is carried out, which are carried out by metallurgical enterprises.

Varieties of rolling mills

As we have already found out, a rolling mill is an equipment on which, due to successively performed operations, a metal billet is transformed into long products with the required geometric parameters. Depending on the parameters of the final product, these machines can be of several types. Blanks and crimps (slabs and blooming) are designed to produce a blank from a large ingot of metal, which is fed for further processing to a special rolling device. The equipment of the latter type, on which rolled metal of the required configuration is already obtained, includes section, tube and wire mills.

The category of section mills includes equipment for the production of various types of rolled products. So, it can be mills for the production of sheet steel, angles, channels, rails, etc. Depending on their functionality, such mills can be large and medium-section, rail-rolling and MPS categories, which receive profiles of various sections. Sheet rolling mills capable of processing billets by cold or hot deformation are used to produce metal plates (50–350 mm thick), sheet metal (3–50 mm) and strips (1.2–20 mm). After production, finished products are wound into rolls weighing up to 50 tons.

The classification of rolling mills that produce various types of seamless pipes divides them into the following categories:

continuous extension, on which pipes with a cross section of up to 110 mm are produced;
short straightening mills required for the production of pipes with a diameter of 60–450 mm;
equipment of three-roll type - for the manufacture of thick-walled pipes with a diameter of 35–200 mm (pipes produced with such equipment are distinguished by a reduced degree of wall thickness difference);
pilgrim mills used for the manufacture of seamless pipes of significant diameters (400–700 mm).

Rolling stand of sheet rolling mill

Part-rolling or special type mills are also used in modern enterprises. They are used for the production of shaped and tube blanks, the length of which does not exceed 3 meters. In addition, the capabilities of such equipment make it possible to use it to produce blanks in the form of balls, bent profiles, gear wheels, screws, ribbed pipes, etc. The blanks are finished at the enterprises that use them for the production of their products.

Components of the rolling mill

The design of any rolling mill includes three main elements: the so-called working stands, transmission devices and drive motors. The rolls, along which the sheet or profile metal moves, are part of the working stands. They also include installation mechanisms, beds, plates and wiring. The movement of all working parts of the rolling mill is provided by powerful electric motors, which are connected to them by means of the elements of the transfer device: couplings, spindles and gears.

You should be aware that the main characteristic of billet and crimping rolling mills is the diameter of the work roll. If, in the process of processing the workpiece, several working stands are used at once, then the diameter of the roll on which the finishing operation is performed is used as such a characteristic.

Section rolling mill, where products of complex shape and with sufficiently accurate geometrical parameters are obtained, includes several stands at once, through which the rolling passes sequentially during its processing.

At modern enterprises today, universal rolling mills are used, equipped with 3 or 5 working stands. Some rolls of such mills (2–3) have a diameter of 1350 mm, the rest - 800 mm. Equipment for the production of sheet metal of considerable thickness, as a rule, is equipped with one or two working stands. The working width of such mills, formed by the length of the rolls, is in the range of 3.5–5.5 meters. A sheet metal mill is usually equipped with additional working stands with vertical rolls, which ensure the reduction of the side edges of the formed metal sheet. Sheet metal in the form of strips is produced on a device equipped with 10-15 working stands, equipped with horizontal rolls with a length of 1.5-2.5 meters and vertical rolls for crimping the ends.

A rolling mill, as can be seen from its design, can be of considerable length. The most remarkable in this respect is the pipe-rolling equipment, which includes three mills at the same time. On the first of them, a hole is pierced in a metal workpiece, on the second, the workpiece is drawn into a pipe, on the third, calibration, which is carried out to give the finished product the required diameter. On detail rolling mills, the workpiece is subjected to both helical and transverse processing.

Rolling mill arrangement

Making a rolling mill with your own hands

If you need a low-power rolling mill for use in a home workshop, then it is quite possible to do it yourself. It is possible to use such equipment, despite the simplicity of its design, to perform various types of work. So, with its help, it will be possible to independently produce wire of various diameters, straighten or cut sheet metal, the thickness of which does not exceed 0.5 mm.

In order to manufacture such rolling equipment, the following structural elements will be needed: two powerful struts, a steel bar 5 cm in diameter, an upper plate, bolts with nuts (M10), two gears and a cogwheel, bronze bushings and bearings, springs and stops.

The construction of such a homemade rolling mill is assembled in the following sequence:

from racks and a steel plate by connecting them with bolts and nuts, a kind of cage is created;
on the racks, two working shafts are mounted, which are previously ground from a steel bar and hardened to give them increased hardness;
the lower shaft is installed between the racks using bushings with bearings, and the upper shaft, which is movable, is mounted on special sliders, the upward movement of which is limited by stops;
constant compression of the two working shafts will provide springs, which should be fixed simultaneously on the base plate and the upper shaft.

Hand rolling mill option

In order for such a rolling mill to work, it is necessary to ensure the synchronous rotation of the working shafts. This problem is solved due to the gear transmission, which transmits torque from the gear, fixed on the lower shaft, to the gear, mounted on the same axis with the upper shaft. To set the entire mechanism in motion, it is necessary to rotate the handle, which is rigidly connected to the lower gear. Conveniently, the gap between the working shafts of such a mill can be adjusted.

The versatility of such equipment is ensured by installing shafts of different designs on it. Thus, the use of shafts in the form of circular knives makes it possible to cut sheet metal, and working elements with grooves of the required size allow the production of wire. You can use such simple equipment and in order to form stiffeners on the workpiece. To do this, it is necessary to install the working shafts on it, which will touch their surfaces according to the "groove-comb" principle.

met-all.org

Rolling sheet metal and making rollers with your own hands

Such a technological operation as sheet metal rolling has remained widespread for quite a long time. Of course, the rolls used for processing sheet metal have undergone major changes since their invention, but the principle of their operation has not changed much. The development of modern technologies has led to the fact that today on the market you can easily find equipment that allows you to perform such a complex technological operation as rolling, even at home.

Rolling sheet metal on an electromechanical machine

Technology features

Rolling, which can be applied to products not only from metal, but also from other plastic materials (rubber, plastic, etc.), is a process necessary to give sheet blanks the required configuration. Despite the fact that the most widespread is sheet metal rolling, pipe-rolling products can also undergo such a technological operation.

In this case, special equipment is used, the main working elements of which are the shafts acting on the blank from sheet metal. If it is necessary to give it a cylindrical shape, the technological operation is called rolling (or rolling). When it is required to increase the diameter of the pipe, the procedure is called flaring.

Working principle of 3-roll plate bending machine

At industrial enterprises, equipment with electric or hydraulic drives is used to carry out rolling or expanding operations, and at home, manual machines are used for this, which can be either serial or self-made. Several factors contribute to the high popularity of such technological operations as rolling and flaring, which involve deformation of metal in a cold state.

Steel or other metal from which the processed products are made are not exposed to temperature effects and, accordingly, do not change their original characteristics.
Internal cracks do not form in the structure of the material that has been subjected to this treatment.
The workpiece is deformed evenly over its entire surface.
With the help of cold deformation, the process of which can be controlled, products are made with the most accurate geometric parameters.

Due to the listed advantages, these technological operations are used to process not only large-sized, but also miniature items made of steel and other metals (such as, for example, jewelry parts).

Equipment used

The equipment used for rolling is distinguished not only by its versatility, but also by its simplicity of design, so it is not difficult to make it with your own hands. Of course, home-made rolling machines are optimally suited for home use, and to equip a production workshop where the load on such equipment is large enough, it is best to purchase serial models of rollers that are available on the modern market in a wide variety.

Both serial and home-made models of machines, with the help of which rolling is carried out, work on the principle of rolling sheet material around the main roll located on top. Side rolls are also involved in this process, which can be moved, thereby adjusting the diameter of the shell being formed.

The rolls of this machine are rotated manually, and the approach of the upper roll is made using two handles

Important characteristics of the rolls are the radius of their working elements - rolls, as well as the greatest thickness and width of the workpiece. The radius of the rolls, in particular, influences such a parameter as the minimum bending radius of the workpiece. The larger the rolls are in their diameter, the correspondingly larger the value of the minimum bending radius of the sheet metal blank. The thickness of the sheet itself also affects the value of the minimum bend radius. As a rule, for rollers, the minimum bending radius of the sheet blank should be 5-10 times its thickness.

Taking into account the high loads that the rolls experience during operation, only high-strength steel is used for their manufacture, which significantly improves their performance characteristics. By the number of working elements, two-, three- and four-roll machines are distinguished, the latter two being the most popular.

Key differences between 3 and 4 rolls

3-roll plate bending rolls, the working elements of which can be arranged symmetrically and asymmetrically, although they differ in an acceptable price, have such disadvantages as:

low rolling speed (no more than 5 m / min);
the complexity of processing workpieces with a thickness of less than 6 mm, which can simply slip between the rolls;
lack of exact coordinates at the clamping point of the workpiece.

The rollers, on which an additional - fourth - shaft is installed, are devoid of all such shortcomings. Due to the reliable clamping, the sheet metal blank does not slip between the rolls during processing. This provides a high rolling speed - 6 m / min and more.

The machine with 4 rolls is capable of producing, in addition to cylindrical, oval and polycentric workpieces

Rollers of this type, as a rule, are equipped with automated control systems, which positively affects not only their productivity, but also the accuracy of the processing performed. The big and, perhaps, the only drawback of such a device is its high cost.

Roller classification by drive type

By the type of drive used, equipment for rolling sheet metal blanks is divided into the following categories:

manual;
electric;
hydraulic.

The most simple in design are the manually operated rollers; it is their craftsmen who most often assemble with their own hands for their own needs.

On simple three-roll rollers, the workpiece is clamped, the shafts rotated and the bending radius is formed manually

Significant advantages of such a device, which does not require any additional power supply for its operation, are:

compactness and, accordingly, high mobility;
reliability;
ease of operation and maintenance;
low cost (especially if the rollers are assembled by hand).

Of the minuses of machines of this type, it should be noted:

low productivity;
the impossibility, especially in the case of self-made machines, to roll products from sheet metal of large thickness (more than 2 mm);
the need to apply significant physical effort for bending sheet steel blanks.

Electromechanical programmed double-sided rollers

More productive and efficient in work are machines equipped with an electric drive. Of course, their cost, even if they are made by hand, is higher than the price of manual rollers, but they allow you to process sheet products of considerable thickness.

The most powerful are the hydraulically driven drums. The capabilities of such machines, which are distinguished by their large dimensions, make it possible to successfully perform rolling of sheet metal blanks of even very large thickness. Devices of this type, as a rule, are installed in industrial plants where high demands are placed on power, reliability and functionality of the equipment.

Industrial drums with hydraulic drive

DIY sheet bending rolls

Due to the simplicity of the design of the manual rollers, making them with your own hands is not difficult. Naturally, in order to assemble a workable home-made machine, on which sheet metal processing will be performed, you must have certain skills and have at your disposal all the necessary tools and consumables. In addition to getting acquainted with the recommendations for performing such a procedure, it is advisable to watch a video on this topic.

Drawing of homemade hand rollers for rolling wide billets (click to enlarge)

The first thing you need to make your own rolls are drawings that you can find on the Internet or draw up yourself. Having made the drawings, you can start preparing materials and assembling the structural units that will make up your homemade machine. Such nodes include, in particular:

the frame of the rollers, on which all their other elements are fixed;
side racks, in the bearing units of which the rolls will be installed;
the rolls themselves, made of high-strength steel (the number and diameters of these elements depend on what technical capabilities you want to give your device);
a handle that will rotate the lower rolls;
a drive unit (chain or toothed), providing synchronous rotation of the lower rolls (it should be borne in mind that such rolls must rotate in one direction);
a spring-type pressure unit, due to which the upper roll is pressed against the surface of the sheet metal blank.

Compact DIY rollers for narrow workpieces

Main parts of compact rollers

The assembly of the rollers begins with the manufacture of a frame that can be welded by hand from steel blanks of large thickness. The dimensions of this element, of course, must be checked against the drawing you have. Powerful channels made of low carbon steel can be used as side posts, which are also welded to the frame.

The elements of the drive unit are fixed on one of the racks, for which special holes are provided on it. After the side columns with the drive unit are completely mounted, the rolls themselves are installed in their bearing units, which must be set parallel and only after that the final fixation of all other units should be performed.

DIY bending rolls option

Before starting work on a machine that you assembled with your own hands, you should perform a test bending on it in order to immediately detect all existing shortcomings and eliminate them.

A video can help you figure out how to properly operate the drums, but in essence, the process is not too difficult. Rolling, on whatever equipment it is performed, is carried out in the following sequence.

The sheet of metal to be processed is placed on the two lower rolls.
By means of the upper roll equipped with a pressure unit, the sheet is pressed against the lower working bodies.
Due to the rotation of the handle of the machine, rolling starts.

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