Our guide to rolling automation couldn’t be complete without discussing some of the top benefits of having a plate rolling machine in your plant.
Different rolling machines have different benefits, so knowing what are their strongest and weakest links is crucial in choosing the right machinery. Throughout this article, we will talk about the benefits of in-house rolling automation and why you should consider it.
If you plan to purchase a roll forming machine, we strongly advise you to take the opinion of a trusted professional before making a decision. Reach out to us for more information.
Roll forming can do round, conical, or square-shaped workpieces with high precision and effectivity. These machine systems can form any type of metal (Aluminium, Brass, Copper, Galvanized steel, Stainless steel, etc), conducting operations such as braking and extruding.
We are going to mention some of the biggest benefits of roll forming, focusing with:
A plate rolling machine can make parts assembly, clad shaping, punching, pre-painting, etc.
Pre-punching is able to create holes and slots that cannot be formed as a secondary operation. They make possible the production of hollow shapes with thinner walls. Compared to a press brake in the forming department, plate rolling machine systems have quicker turnover. Furthermore, they have more consistency in their results.
Roll forming also affects operations’ structure, cutting off several stages and eliminating secondary tasks by incorporating them in the forming process. It also allows doing welding, punching, notching and other similar operations in line. This shift in the application process affects processing costs by reducing them and production timelines.
Plate rollers, besides being economic by their fast pace in production, are also energy-efficient. Most of the time, they do not need added heat to conduct operations. Plate bending done at room temperature is also known as cold roll forming.
Another help in production is that plate rollers can form any metal, at any length using almost the same tolling. Its ability to combine several manufacturing processes in line with roll forming, affects costs (manufacturing, handling, shipping) greatly.
Performance-wise, roll forming can achieve closer tolerances than most processes, guaranteeing high accuracy. Alongside precision, plate rolling machines are consistent in providing a clean end result, without the need for finishing touches like curating of surface marks, asymmetrical parts, additional contour details, etc
The rolling method of a two-roll bending machine is placing a hard roller on top and a polyurethane roller in the bottom, to balance each other and work in harmony to bend metal sheets. The polyurethane roll gives traction to the motion created and positioning accuracy.
A two-roll plate bending machine is perfect for thin metal sheets. Their main advantage is that they are really fast, so if your line of work requires that you produce numerous products with low thickness materials, then this machine is way better for you than e three or four rolls bending machine.
This machine system is high production and in some situations, it can conduct operations in total autonomy, without human interaction. But, as we said, not every task can be done with a 2 roll. Some operations are better suited and some not.
The two roll plate bending machine, because of its design, is extremely efficient, as it can form certain materials with one pass, whereas normally it would take three or more. However, keep in mind that the two roll technology works best on light metal, so do not expect to see these results in every material type.
Except for one pass bending, another benefit is minimizing the flat surface. Pre-bending in a two-roll plate bending machine gives less residual flat area than the norm. A typical bend leaves a flat area of 2 times the thickness of the material, in two rollers this reduces by almost a half.
The technology and working design of two roll benders open ways for conducting other types of applications like conical shapes, bending very small parts, etc.
Following the same working principle as the two-roll, but powered with the capabilities of a third roller, this type of rolling machine can conduct the entire set of rolling operations. Asymmetrical three-roll machines are known for fast delivery, energy-saving, and fewer production costs. Mostly, these three rollers are used for carbon steel of thickness no more than 4 mm. The biggest challenge in these type of machines is the need for highly skilled operators.
In hydraulic horizontal three-rollers, on the other hand, we have more variety in allowed thickness and plate size, and one of the biggest values is the price compared to other options.
Lastly, the variable geometry machine system is the most technology-driven three-roll type, as it can be connected with a CNC and PLC. It also can bend large-angle conical shapes, has virtually no pre-curving linear segment, and can replace the upper roller with different diameters. Looking at the benefit: price ratio, it is a reasonable cost, considering that it doesn’t need a full team of operators or extra devices.
This machine can complete cylindrical products, arc forming, and crimping. This plate rolling machine type can do pre-bending without additional equipment. Also, the 4 roll bender can do some limited plastic works on a sheeted metal.
Different from the 3-roll plate benders, it can roll the metal without turning it. The procedure becomes more simple in terms of efficiency for production and relieving labour intensity for the operators. In complexity, these benefits make for excellent results.
Overall, the 4-roll plate rolling machine systems are very reliable in conducting fast-paced operations and handling materials. It can have great workpiece positioning, adjustment alignment, etc.
High-quality plate rolling machines can conduct one-time rolling perfectly, achieving the desired shape by rolling once while being very effective to possible damages that can happen on the plate. Regarding their equipment, quality 4-roll plate benders possess a loading device, to roll large diameters, a feeding device for minimizing mistakes, and lifting equipment.
There are many models out there that have their advantages and disadvantages, according to your needs. We at RS Machinery are professionals at roll forming, with vast experience in the manufacturing industry. To make a smart and confident decision for your shop floor, feel free to contact us for a one-on-one conversation.
To learn more, read our latest articles on rolling automation and plate bending machines. For more insights, contact our team and we will further discuss your needs.
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