| Unfortunately, many buyers end up
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| | 500 series and AR 200/300 series, for
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| purchasing equipment that lacks the
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| | example. And these different steels
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| capability and flexibility to meet
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| | require varying pressures to roll.3.
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| production volumes and tolerances, simply
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| | Carefully consider bending diametersAll
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| because they don't understand all
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| | machines achieve precise measurements at
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| available options and
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| | 50 percent of the full-rated value.
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| considerations.Between diminishing
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| | Therefore, given a 1.1 roll geometry, a 3
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| factory orders and increasing labor and
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| | 8-inch machine with a 10-inch top roller
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| energy costs, companies that use plate
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| | can consistently roll 3/16-inch plate to
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| metal in their fabricating processes are
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| | 11-inch ID without any barrel defect.As a
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| finding their profit margins increasingly
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| | rule of thumb, most machines can roll
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| pinched.Yet, manufacturers must still
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| | plate at 1 1/2 times the upper roll
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| invest in new production equipment --
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| | diameter. Hence, given a 10-inch-diameter
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| whether to replace obsolete equipment or
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| | top roll, inside diameters as tight as 15
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| to take advantage of new business
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| | inches can be obtained. However, new
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| opportunities -- in order to remain
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| | machines that incorporate planetary
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| competitive.Manufacturers must make
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| | guides are able to keep approximately 50
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| careful assessments when evaluating the
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| | percent more area of the plate under
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| addition of new plate-rolling equipment.
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| | bend-pressure during the rolling
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| Debt capital is still available to
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| | operation, thereby achieving ratios of
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| purchase new machinery, but paying back
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| | 1.1 times the upper roll diameter. This
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| the loan will not yield a satisfactory
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| | creates a 30 percent advantage on tight
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| return on investment unless the equipment
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| | diameters.The tighter the diameter, the
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| adds value to the production.In an effort
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| | more bend pressure required. For
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| to help manufacturers optimize plate
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| | instances where thick material must be
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| rolling operations, 5 key considerations
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| | rolled into tight inside diameters (ID),
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| are offered in order to choose a proper
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| | the diameter of the top roll and the
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| plate bending machine.1. Work with an
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| | layout of the machine can make the
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| equipment dealer that is willing to
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| | difference between a product whose
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| discuss your specific plate-rolling
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| | cylindrical edges meet and one that won't
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| needsCustomers must know the correct
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| | close.4. Incorporate both side and
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| questions to ask, in order to get the
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| | vertical supports to prevent unwanted
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| correct answers. Each manufacturer faces
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| | bendsWhen rolling a cylinder, once the
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| unique challenges, and through systematic
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| | inside diameter is more than 200 times
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| querying an astute sales representative
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| | greater than the thickness of the
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| can determine exactly what equipment will
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| | material, the weight of the material
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| work best for their process.Customers
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| | becomes sufficient to bend the cylinder
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| need to discuss issues such as inside
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| | as it exits the top roll and gets further
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| diameters, material type, tolerances and
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| | away from the machine. Without proper
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| the desired shape of the finished
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| | support, unwanted radii result.Purchasing
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| product. As an example, some products,
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| | a machine with both side and vertical
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| such as those found in the pressure
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| | roller supports easily solves this
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| vessel industry, demand a maximum of 1
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| | problem.Some manufacturers attempt to
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| percent out-of-round on their diameters
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| | skimp on this ancillary equipment by
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| or they are considered defective. By
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| | resorting to "makeshift" support such as
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| using an underpowered plate roller, too
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| | a forklift or overhead crane. However,
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| much of a barrel effect can render such a
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| | this shortcut ties up the use of
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| product useless and quickly erase any
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| | equipment that can best be utilized
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| potential profit margin.Manufacturers
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| | elsewhere. Because it cannot adequately
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| must also carefully consider whether they
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| | support the material, unforeseen bends
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| wish to roll conical or parabolic shapes
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| | can still appear.Adequate support
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| to take advantage of a broader market.
| |
| | requires both side and vertical
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| Hydraulically operated four-roll machines
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| | roller-supports, as designed by the
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| are ideal for this type of work by
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| | manufacturer of the plate-rolling
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| eliminating surface scarring, thereby
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| | machine. Once employed, plate rolling
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| decreasing the need for grinding the
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| | becomes a one-man job instead of two.
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| lamination (bullnosing) on the minor
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| | This frees up valuable manpower that can
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| diameter edge of a cone.Accurate conical
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| | be re-routed to other jobs.5. Stay within
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| rolling is further achieved through
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| | ideal operating parameters of the
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| features such as torsion bar parallelism,
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| | machineIt is recommended that
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| as opposed to electronic systems or
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| | manufactures identify what material and
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| proportional value systems that merely
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| | what thickness represent their highest
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| maintain a theoretical balance. Finite
| |
| | volume of work. Then (a company) can
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| parallelism allows the machine to be
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| | deliver a machine that will camber to
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| adjusted to its full conical tilt and
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| | that specification, thus conserving
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| back to parallel in only five
| |
| | valuable production hours and eliminating
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| seconds.Matching plate-rolling equipment
| |
| | large amounts of scrap.Quality rolling
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| to the specific needs of a manufacturer
| |
| | machines are usually cambered at 50
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| requires attention to detail. It is
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| | percent of the full-rated value of the
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| imperative that the dealer you work with
| |
| | machine. Hence, a 1-inch machine is
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| is willing to sit down with you and
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| | cambered to roll 1/2-inch plate at a
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| discuss the specific needs of your
| |
| | nearly perfect edge.Disregarding this
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| business. There are many issues that need
| |
| | important fact can result in out-of-spec
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| to be addressed, many of which a
| |
| | product that the customer will not
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| purchasing manager may not initially
| |
| | accept. Problems most commonly arise when
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| foresee.2. Factor in the properties of
| |
| | rollers attempt to push the upper limits
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| the material to be rolledA metal's temper
| |
| | of their plate roll. If 5/8-inch plate is
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| and yield strength must be matched with
| |
| | rolled through a 1-inch-rated machine, a
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| the customer's application to correctly
| |
| | small degree of barrel effect will likely
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| determine the specifications of the plate
| |
| | occur. This may or may not be an
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| roller. This is especially important
| |
| | acceptable margin for error.However, when
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| since steel characteristics have changed
| |
| | plate thickness approaches the upper end
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| drastically over the past couple of
| |
| | of a machine's rating, then severe
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| decades. What was once known as mild
| |
| | defects can occur. Unless corrected with
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| steel no longer exists.Even though
| |
| | a shim, it will not be sellable.
|
| drawings call for a plate to be rolled
| |
| | Conversely, when very thin material is
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| down to the same dimensions, a tougher
| |
| | rolled through a machine rated for very
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| material will require a much higher-rated
| |
| | thick plate, the finished product may
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| rolling machine. In absence of such
| |
| | come out tighter in the center than at
|
| considerations, defects will result and
| |
| | the ends. Again, time consuming shimming
|
| the manufacturer will end up with
| |
| | is necessitated to correct for this
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| excessive scrap.Today's steel is much
| |
| | "hourglass" effect.Robert E. Heller is
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| stronger and requires more strength to
| |
| | the current President of E.G. Heller's
|
| bend. Thanks to detailed classifications
| |
| | Son, Inc. For more information about the
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| by the American Society of Mechanical
| |
| | proper selection of metal fabrication
|
| Engineers, countless varieties of steel
| |
| | equipment contact, E.G. Heller's Son,
|
| abound: A36, A516 grade 70, Hardox 400
| |
| | Inc.
|
