RS Machinery Group

Plate rolling tips for operators; Upskilling your people

Even though powered by new and evolving technologies, roll forming is an intricate, human operation that undoubtedly needs experienced hands and minds. Advanced CNC and software are bringing forward the art of roll forming, yet this process gives totally different results if managed wisely. A lot of processes have indeed been reshaped by automation, but pressing a button and hoping for the best is never an option.


In this article, we are going to talk about the importance of having a great team to operate your new plate rolling machine.

 

As we have mentioned in our previous articles, a lot of factors can compromise the quality you are aiming for. Material characteristics mainly, accompanied by other variables, may change the result. Not having the required knowledge about these factors, not only can hinder your work but can also make workplaces less safe.

The biggest challenge plants are facing nowadays, is good human capital in certain operations. Unfortunately, finding experienced operators for roll forming is easier said than done. That’s why plants nowadays are turning to their own teams, shaping them into the experts needed in roll forming. If you are soon looking to give more attention to your roll forming department then you should give a thought to operator training.


Why upskilling?

Before we get to the technical details of what it means to take up the challenging task of upskilling your team, let’s not forget to mention one big benefit of this practice. Training your team into experts in a particular field is a costly endeavour, that makes a lot of sense in the long term.

As a company, you know your operators for quite some time. They have been with you for months, years, and if you still want them, that means they are a good hire. Upskilling some of your actual team is a great way to make them grow in the workplace. Besides being good for them, another plus is that you already are familiar with them and know what it means to be working with them. This eliminates the need to experiment with new people, removing surprises.

Metal Fabrication Knowledge

During the bending process, the material reacts. The sheet metal is changing its shape in the outer part of the material, but the inside layer doesn’t deform. Every shop floor professional should gain the basic information that is crucial to understanding the process they’re performing. Knowing the material allows the operators to understand the pressure: thickness ratio, the tolerance of the workpiece, and how to better manage the material in general.

The material follows a stress-strain curve while forming. 

This pattern guides the operator into settling the pressure on the material and the location where the pressure is applied. This is one of the first lessons in roll forming. The process is not flat-lined. Instead, it is very changeable. The material and the rolls are continuously moving. That’s why being aware of the changes the metal experiences during bending is something a plate rolling machine operator must know.

Another misconception is that when talking about different materials, operators assume steel, aluminium, brass, etc. This is not entirely true. Even different types of aluminium are different working materials. Material features are not only the size and thickness, but also the softness, consistency, or age of the workpiece. All these features make the particles and the grain structure of the metal act differently, thus performing differently on the machinery.

An operator with press brake knowledge may be a close call to become a roll forming expert. Make sure to conduct continuous training as a plant for your assigned roll forming operators. Teaching and learning is a delicate process that puts a lot of your future performance at stake.

Upstream Processes

In the manufacturing and the production world, there is upstream and downstream processing. Upstream refers to the material inputs needed for production. Those are the elements needed for downstream processing. In a metal fabrication shop, the upstream process is done by laser cutters that create the blanks. Then the blanks are produced, for example, into tubes and pipes by roll forming. Upstream processing can greatly help the quality of the final product. How?

Rolling with the grain structure makes working easier. But operators cannot find the grain direction with their available technology. Laser cutting machine operators can. By placing their material in an orderly manner, the roll forming operators can start working with the given material knowing the grain structure’s direction and not feeding the workpiece randomly to the machine.

If your plant and your operators are just starting with plate rolling, consider investing in a machine that fits your needs but is easy to operate at the same time. A four-plate roller machine is one of the best picks for these situations. Furthermore, find a trusted machinery supplier that will help you as much as possible in the training process.

Our team at RS Machinery has built the ultimate purchasing journey and aftersales process that will lead towards the best prospects for success. Reach out to us here to learn more.

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