metal rolling machine

Types of Metal Rolling Machines

A metal rolling machine can roll metal into a variety of shapes and sizes using different types of machines, such as bars, pipes, and profiles. The rolling machines come in three broad categories based on their design features:

• Three-roller Rolling Machines: Metal rolling machines with three parallel rollers are commonly used to roll metals into curves and circles. The top roller is moved down to exert pressure on the metal workpiece, which results in a bend in the metal. Then, the bottom two rollers are rotated to move the metal piece forward. The pressure of the top roller can be adjusted to make multiple bends in the workpiece. In some machines, the top roller may be shaped like a smile to make a gentle curve in the metal. The machine can curve all types of metals, including brass, steel, iron, and aluminum alloy.
• Four-roller Rolling Machines: An additional roller in four-roller metal rolling machines helps to obtain better control and precision while rolling metals into different shapes, such as circles and arcs. The additional roller in the middle also levels the metal workpiece before it is rolled, which helps to obtain uniform thickness throughout the entire length of the workpiece. Furthermore, the side rollers called side-shifting and upending rollers help to move the workpiece sideways and upwards. Another advantage of four-roller metal rolling machines is that it is easier to make elliptical and oval shapes, as well as cones with varying thicknesses.
• Universal Rolling Machines: Universal rolling machines are used to roll metals of different profiles. The grooves on the rolling disk help to transform flat metal pieces into U-channels, I-beams, V-channels, Z-channels, and other pieces with varying thicknesses. Additionally, universal rolling machines can make curved and eccentric circles, along with spiral shapes.

Apart from these machines, other types of machines can roll metal workpieces in combination with other processes. For example, a plate rolling machine can roll flat plates into circular and conical shapes. Similarly, a section rolling machine can roll sections and profiles like angles and channels. An orbital rolling machine can roll cylindrical sections with a large radius, such as tubes and pipes. Finally, a straightening and rolling machine is specifically used for the straightening of metal workpieces into flat sections.

Specification and maintenance of metal rolling machines

The specifications of a metal rolling machine depend on the type as well as the models that are available.

• Capacity: The amounts of metal that a machine can handle or rolls per unit monthly are measured in terms of weight, length, and thickness. The capacity is generally higher for industrial-scale machines as compared to smaller ones that are used at homes or workshops.
• Power: The rolling machine power is measured in kilowatts for hydraulic and electronic machines. The higher the power of the motor, the thicker the metal it can handle.
• Dimensions: The length, breadth, and height will determine the space taken by the machine. It will also affect the size of the metal that can be rolled.
• Weight: The heavier the machine, the sturdier it is. It can handle difficult jobs, and the rolling plate will not vibrate.

Maintenance of the machines is a critical factor in the smooth rolling of metals, especially when creating round metal sheets. All parts need to be regularly oiled and cleaned to ensure no dust settles on any component, which can cause friction with other parts and result in damage. The instructions manual provided by the manufacturer will help identify the components that need lubrication. Some areas may need grease while others may need oil.

Both the simple and complex machines require their rolling cylinders to be periodically calibrated so that accurate angles and measurements can be ensured when rolling sheets. The adjustments made during the calibration process may also need to be memorized or noted down. This is important when the same measurements are required in the future for rolling sheets on the machine.

It is important to check for any loose or damaged parts on the rolling machine. The bolts and screws are usually checked to make sure that they are tightly fitted. Any worn-out parts must be replaced immediately to ensure that no further damage is caused to the machine.

Operating instructions must be followed carefully to avoid any accidents or damage to the sheet metal rolling machine. The operator should know about the limits of the rolling machine and take care not to exceed its limits. Before rolling a metal sheet, it should be ascertained that all the edges are squared and deburred to avoid any snagging in the rollers.

Scenarios of metal rolling machines

Rolling machines are highly versatile equipment that finds applications in various industries and sectors that shaped the metal into different forms. Here are some typical scenarios in which a metal rolling machine is used.

• Construction Industry

Metal rolling machines are used to produce many construction materials, such as curved beams, frames, and architectural components. Such components are essential for creating canopies, walkways, and Roofs.

• Automotive Industry

The automotive industry uses metal rolling machines to manufacture many vehicle parts, such as chassis, body panels, and structural components. The machines ensure that the panels are accurately shaped and have consistent dimensions when an automotive component is created.

• Metal Fabrication Shops

Metal fabrication shops use rolling machines to bend and shape metals for custom projects. The machines are used to create unique fixtures, brackets, enclosures, and other specialized components as required by different industries.

• Aerospace Industry

The aerospace industry employs metal rolling machines to shape and size metal components for aircraft and spacecraft. Such parts may include fuselage sections, wing structures, and internal frames, among others.

• Marine Industry

Shipbuilding and marine companies use metal rolling machines for parts of marine vessels and boats. The machines are used to create hull sections, frames, and supports, as well as other marine structures.

• Energy Sector

The energy sector, including renewable energy, relies on metal rolling machines to produce energy-related components. The machines are used to make turbine blades, generator housings, and wind farm supports, as well as solar panel mounts, among others.

How to choose metal rolling machines

When choosing the right rolling machine for business needs, consider these factors:

• Nature of the Project

  Businesses should start by determining the nature of their projects. This includes understanding the types of materials that will be rolled, the maximum thickness needed, and the desired dimensions and shapes. Once the project requirements are defined, it will be easier to select a machine that can handle specific materials and thicknesses.

• Production Volume

  Evaluate the production volume to determine whether manual, hydraulic, or CNC is the right choice. If the business rolls a small number of parts occasionally, a manual or handheld rolling machine is the most suitable. On the other hand, if the production volume is high and efficiency is a priority, consider investing more in a hydraulic or CNC machine.

• Floor Space and Portability

  Consider the available floor space. Rolling machines tend to take up considerable space. A portable rolling machine tends to be smaller and more compact. Therefore, it can easily be moved from one location to another.

• Budget Constraints

  Businesses have to consider their budget range when buying a rolling machine. Due to financial limitations, it may be necessary to compromise on certain features and specifications. Manual machines tend to be more affordable options, as hydraulic and CNC machines are more advanced and expensive.

• Availability of Technical Support

  When purchasing a rolling machine, it's essential to consider the availability of technical support during installation and subsequent maintenance. It is critical to ensure the machine is installed and operating correctly so that staff can use it efficiently and safely.

Metal Rolling Machine Q&A

Q1 What industries use rolling machines?

A1 All industries that use metal rolling machines. The main ones are construction that uses curved and rolled beams, frames, pipes, and ducts. The automotive and aerospace industries use rolling machines to make vehicle parts, fuselage elements, and other components. The shipbuilding industry uses rolling machines to make ship hulls and other maritime structures. Other industries that use rolling machines are the furniture industry, the power-generating industry, and the defense industry.

Q2 What are the significant developments in rolling machine technology?

A2 CNC-controlled rolling machines are prevalent now. They allow machine operators to program the speed, angle, and pressure precisely when rolling metal sheets. The interchangeable rolling machine attachments increase a rolling machine's versatility. Standard, spiral, and fan-shaped rolling attachments are just a few examples. Hydraulically-powered rolling machines require less manual effort and offer safer solutions to roll metal sheets with greater precision.

Q3 What safety measures should be considered with rolling machines?

A3 All rolling machines have removable safety shields that cover the rolls. Do not operate the machine without the guards and shields in place. Operators should wear tight-fitting clothing that does not have loose sleeves. Ensure all rollover operators have received proper training. Follow the manufacturer's instructions for specific safety measures.

Q4 What is the maximum sheet thickness that can be rolled with a metal rolling machine?

A4 The maximum sheet thickness that can be rolled with a metal rolling machine varies depending on the machine's specifications. Different types and sizes of rolling machines can roll different thicknesses. Large machines with heavy duty motors and over three feet of roll diameter can perhaps roll up to an 18 mm sheet. Smaller machines can roll sheets that are no more than 3 mm or 6 mm thick.

Q5 What are the limits to the radius and curvature that a metal rolling machine can achieve?

A5 The radius and curvature that a machine can roll are limited by the diameter of the rolls. Generally speaking, the larger the diameter of the roll, the more radius and curvature it will roll without deforming the metal object.