Manual Decoiler Machine

Decoiler meaning:

A material handling machine located at the beginning of a production line. decoiler used to hold and safely pay off or uncoil the steel strip. Coiler controls the speed and direction of the strip of metal and is sent to the line for processing, such as slitting or tube mill entry also roll forming entry. Decoiling is the action of unwinding a parent coil, making it flat and cutting it into sheets.

decoiler for sale

Decoiler machine design

actually, there is a sensor between decoiler and roll forming machine. If the coil is tight, the sensor will let the uncoiler go forward. If the coil is loose, the sensor will let the uncoiler stop. in fact, LOTOS is specialized in providing custom-built Manual Decoiler to our customers. De-Coiler offered by us finds application as an accessory machine that is used as support for expanded metal mesh machine.

de_coiler or uncoiler use in all roll forming machine such as:

manual sheet metal decoiler

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Roll Forming Operation Manual

 

How to adjust a roll former ??

LOTOSFORMING guides and explains many of the common issues encountered in the roll forming process and roll forming operation manual, all factors that contribute to possible problems such as material, design, and manufacture.

roll forming operation manual is a process that developed by gradually bending the metal through a series of roll stands, or passes. Each stand must produce the appropriate amount of deformation for which it was designed. when roll-forming problems occur, it is important to examine each stage of the process and not merely the stand at which the problem initially appears. The goal of a roll forming operation is achieved when there is uniform metal deformation throughout the line. Roll forming operation manual are designed to be reasonably during the operation. If run “popping” throughout the operation, the operation needs to be investigated.

Kind types of roll forming systems :

Two basic types of roll forming systems are utilized: a pre-cut line and a post cut line. A pre-cut line snips the incoming material to a specific length prior to roll forming operation manual. During post cut line operation, the roll formed panel runs continuously and is sheared to the required length after roll forming.

roll former

Roll forming operation :

MATERIAL

One of the main parameters that define the success of a roll forming operation is the character of the material. for design the optimal process, the designer should be provided material information to be used prior to the tooling designing such as material mechanical property ranges, gauge tolerances and shape tolerances, different metallic coatings.

ALIGNMENT

Mill alignment is critical. forming rolls and their components must be aligned to each other both horizontally and vertically. The rolls must be aligned both side-to-side and pass-to-pass. Forming material with the gauge either lighter or heavier than that for which the tooling is designed can result in problems. Using material thinner than the designed gauge can lead to finish radii greater than the intended design. This is usually offset by over-tightening the rolls, which causes a decline in tool life.

 Processing heavier gauge material than intended can also lead to larger radii than designed. When running thicker material, the tooling will make contact on the side of the tool radii leaving no center contact with the tooling. Since the material is not in proper contact with the tooling, gap differences from side to side become more critical. Small side-to-side roll gap differences can result in a twist, bow or sweep problems.

SETUP

setup by the roll tooling manufacturer, feeler or wire gauges are most often used to set the gaps on roll-forming stands. This should ideally be done each time the metal being utilized changes significantly in gauge. Operators must be sure to periodically check for tooling wear or machine wear.

Each stand consists of top and bottom rolls designed to provide the necessary part dimensions. The position of the top roll can be adjusted via screws to change the gap between rolls, thereby changing the forming pressure applied to the metal at each stand. The final roll gap adjustment on each stand should always be down to compensate for the gear and bearing tolerances inherent to each stand.

CUT-OFF

Cutoff dies or shears are available in many types and variations. The most common types utilized for roll forming machines are the “slugless crop die” and the “flying shear”, or “cutoff die”.The cutoff operation accurately cuts the part to the desired length in a manner that is essential to the continuous operation of the line. Slugless crop dies generally have a short stroke length, possess contoured blades, and rapidly cut-off the finished part. Since the cut-off action is extremely fast, an accurate cut can normally be performed without interruption to the continuous operation of the line. Proper set-up in this type of operation is critical.

Roll forming machine design

Line speeds, die speeds and die clearances must be closely established and monitored to prevent blade drag. This condition can result in panel buckling. Removal of the buckled panel from the line is time-consuming and may result in damage to the cutoff die, or in extreme cases, to the roll tooling. Even if the part does not buckle to the point that it jams the line, improperly timed cutting can cause problems upstream in the roll former.

Momentary interruptions in the later roll-forming stand, while the initial stands are still driving the material, can result in a wide variety of problems and/or imperfections. Minor buckling in the intermediate stands can result in oil canning type imperfections as well as other twist or dimensional issues in the finished panel. If the line is set-up with extremely loose tooling clearances, the effect of momentary line interruption from the cutoff operation may be seen all the way to the uncoiler. In this instance, the alignment of the entire line becomes integral to the cut-off operation. For example, if the uncoiler is out of alignment, the momentary line interruption could „pull‟ the material in a skewed manner from the uncoiler and potentially cause oil canning, twist or sweep problems.

Roll forming stands

A flying shear, or cut-off die, may be required with an increase in the line speed or panel height configuration. This allows the shear or die to attain the speed of the line prior to the cutoff operation. The timing of the shear is critical in this operation. Momentary interruptions in the latter roll-forming stands, as described above, will generally be larger in magnitude and more serious in nature as the speed of the cut-off operation increases. The blade or die should always be cut to an approved part. Improperly designed/machined tools must be avoided because they result in tight clearances, induce blade drag, tool drag, or lose clearances, which result in burrs on the finished panel.

roll forming machine price

 

Roll forming machine configuration :

With a working knowledge of the roll forming machine configuration and the roll former setup procedures, the root cause of many problems can be determined at the plant level. Generally, the most important factor to keep in mind is that roll-forming issues must be approached from a systematic point of view. That is, everything must be considered from the incoming material properties, lubrication, roll former setup, uncoiler, and cut-off methods to the inspection details of the finished product. All or any of these factors can impact the acceptance of the finished part.

Important questions about adjusting roll forming machine :

What are the Tool Gap Settings?

Gaps should initially be set at the material gauge with final adjustments made to achieve the desired final dimensions.

Does It Hold Dimension?

Ensure that the material is within the ordered width and property tolerances. Check the gaps in the overbend stands for proper gauging.

Where Does the Imperfection Appear?

Inspect and check the tooling and gap settings where the imperfection occurs and in the stands upstream. Adjust to appropriate settings.

Are There Tight or Loose Areas on the Finished Panel Radii?

These imperfections typically denote improper tooling adjustment or worn tooling or bearings. Ensure that the tooling has proper gap settings. Inspect the tooling for worn areas (chrome coating loss or increased radii due to wear). Inspect the line during operation for bearings with excessive movement. Occasionally, a worn bearing will make noise during operation. If bearing wear is isolated and is consistently in one stand, it would be prudent to inspect the tooling in the entire line for alignment, wear and proper gap settings.

Do the Radius Lines Appear to Wander Down the Length of the Panel?

 Dry material, worn tooling, and improper tool alignment can cause this problem.

Does the Tooling Run Eccentrically or Wander with Respect to Other Stands?

This is an indication of bent shafts, worn bearings, worn or misaligned tooling. If the tooling visually wanders from side to side, either the bearings are worn or the shaft locknut has come loose, or a shim has worn or fallen out. When the tooling is running in an elliptical pattern (egg shape, or up and down) the shaft itself may be bent. This will require checking the shaft for run-out with a dial indicator for the amount of movement.

Are There Areas Where Excessive Material Has Been Stripped Off During Forming?

This normally indicates dry material, tight clearances or improper tooling setup. Tooling stands where material slivers and/or debris accumulate should be closely monitored, as this can lead to premature wear and finished panel imperfections. Material run with insufficient lubrication (dry areas) will run with increased friction in these areas during forming. This can cause the material to be scrapped during the roll-forming process, especially on the panel edges. In some cases, running dry material can raise the temperature of the tooling sufficiently to reduce the die clearances from heat expansion.

Tooling that is gapped to less than the material being formed, or tooling that is out of alignment from stand to stand, can also cause this problem. Although it is sometimes not possible to prevent material debris accumulation on some stands, tooling should be gapped and checked for alignment frequently.

Portable roll forming machine

Does the Material Track Properly into and from the Line?

Material that has differential lubrication edge-to-edge, the material with significantly different thickness edge-to-edge or tooling that is out of adjustment can cause tracking issues.

Does the Imperfection Appear at One Stand?

If this is the case, ensure the tooling is gapped properly at both the imperfection stand and also at the stands prior to where the imperfection occurs.

Does the Cut-Off Operation Run Transparent to the Line?

Drag or an out-of-time cut-off operation can induce a variety of imperfections or problems. In a post-forming cut-off process, the cut-off should not alter the continuous forming of the panel. Dull cut-off dies or knives can impart sufficient drag in the cut-off operation so that the formed panel actually begins to buckle in the cut-off operation. A similar condition is possible if a flying shear is out-of-time with the speed of the forming operation. Both of these conditions should be addressed when they first appear, as permitting them to continue will eventually cause the panel to buckle in the line prior to the cut-off.

Does the Material Pop, Crackle, or Wrinkle at One Stand?

This is often the result of either tooling misalignment or the material entering the rolls in a skewed fashion. Roll-forming should be approached from a systematic point of view; each stand is designed to perform a specific amount of forming.

Roll forming machine for sale

Successful roll-forming relies on a combination of factors, including material properties, tooling set-up, and roll former operation. As problems arise, it may be difficult to ascertain which factor is negatively impacting the finished panel to the point of rejection. This is why it is imperative to view the roll-forming process from a systematic point of view. With this approach, it is possible to determine the root cause of the problem and take the appropriate corrective course of action.

roll forming machine for sale

You can find all information about the following :

  1. Shaft and roller design

  2. installation for roll forming machine
  3. How to design shaft and roller for roll forming machine
  4. Complete video for roll forming down roller adjustment
  5. Complete video for roll forming base setting
  6. How to fix roller position on the roll forming machine
  7. How to adjust roller on roll forming machine
  8. How to adjust the roll forming machine
  9. Advanced roll forming
  10. Custom Roll Forming Process
  11. Roller Die
  12. roll forming roller material
  13. roll forming roller design
  14. roll forming basics
  15. roll forming process
  16. small roll forming machine
  17. roll forming dies
  18. sheet metal roll forming machines
  19. roller materials
  20. how to adjust a roll former
  21. roll forming operation manual

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Roll Forming Machine Basics parts and how Roll Forming Machines Work:

How do Roll Forming Machines work? All Roll forming machine in the industry has the same basic design, a roll forming machine includes:

DE COILER: to load raw material coil on that and open coil to a sheet, based on forming speed

Feeding roller and leveling: after recoiler material should be straightening and leveling before forming to has a better result from forming steps, so we add leveling station in the first part of a machine, but mostly is used for more than 1 mm thickness,

Pre-punching and marking: some of the wholes should punch before forming based on design, also upon requirement, we will add marking roller before forming stations,

Forming stations: the number of stations come from our experienced design DPT, based on thickness and shape each drawing need different forming stations number,

Torque head or final guide: in any roll forming machine last station before cutting should be torque head, to modify length twisting and turning to have final 6-meter length in standard accuracy and shape.

Cutting or saw machine: in end of forming machine we install the cutting system that’s hydraulic or mechanic saw, and it can be flying to make non-stop cutting, it’s up to forming machine speed and budget requirement,

Electronic cabinet: in developed manufacture such as LOTOS use PLC CONTROL to program and set machine, this is the machine brain for control and manage punching, cutting, speed, feeding.

In LOTOSFORMING we select match HDMI, DRIVE, PLC, ENCODER with machine electronic motor to reduce PLC error as much as it can.

Rollforming Systems Machine Development:

In 2019 any roll forming manufacturer doesn’t use CAD/CAM design software cannot produce long term performance roll forming machines. roll forming design is one of difficult machinery in the industry that definitely need CAD/CAM software to analyses and simulation steel with each station before producing. running roll forming machine nowadays most of the manufacture use PLC control to have less tolerance in final products.

So to have developed manufacture for roll forming machine, such as LOTOSFORMING, should have a great design team with enough experience on CAD/CAM software in roller drawing.

Roll Forming Tolerances and accuracy:

To compare roll forming producing tolerance with old way machinery with shearing and break machines, for sure roll forming accuracy is really much higher than any other way. during the forming station also should care about material reaction and spring back to reduce tolerance,

The advantages of Roll forming Lines Machines 

Except for benefits we explained in previous comments and posts:

  1. Roll forming is energy efficient, cause in forming station we won’t use any heating during forming, most of forming machine work in normal room temperature.
  2. Also based on CNC control it also reduces worker in a factory.
  3.  Before we design roller we will calculate input material width to make waste as less as it can.

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Custom Roll Forming Processes

Roll Forming Process

what is mean Roll Forming Process?

Roll Forming Process is a type of rolling involving the continuous bending of a long strip of sheet metal (typically coiled steel) into the desired cross-section. Roll forming involves uncoiling a long strip of metal and sending it through several stacks of rollers set up in a long line. It is performed at room temperature, hence the moniker ‘cold’, which is often dropped. Roll forming at room temperature maintains or even improves the properties of the feedstock material. The strip passes through sets of rolls mounted on consecutive stands, each set performing only an incremental part of the bend until the desired cross-section (profile) is obtained. Roll forming is ideal for producing constant-profile parts with long lengths and in large quantities.

Cold Roll Forming Process :

Cold Roll Forming Process is a bending process where the bending occurs gradually in several forming steps from an undeformed strip to a finished profile in roll forming machine. The process is very interesting for the sheet metal industry due to the high speed in which the profile can be produced by a roll forming machine. High strength steel has, in recent years, become more common in cold roll forming. These materials have advantages but also disadvantages that affect the design of the process. The cold roll forming process is a highly efficient process used to produce profiles for many applications, for example, vehicles, buildings, domestic machines, etc. Therefore, it’s market share is increasing every year. Many of the above products are already today made of high strength steel and the usage of these materials will likely continue to increase.

Metal Cold Forming  :

Cold Roll Forming Process, as an energy-saving and material-saving metal cold forming process, is widely used in construction, automobile, railway, aerospace, and other fields. As a kind of common metal skeleton in construction, the forming quality of C-channel steel is particularly important. However, with the shape of forming products becoming more and more complex, the requirement for forming process is becoming higher and higher. In industrial production, technicians also generally design roll flowers by the trial-and-error method, which causes a large number of human and financiallosses, and also makes cold roll forming process is still generally considered as art, not science.

Cold roll forming is a process of metal slow deformation due to its special forming length. The front part of the sheet is always formed faster than that of the back part. In cold roll forming a profile is formed in several forming steps from an undeformed strip to a finished profile. The forming process is geometrically complicated due to the fact that. the forming does not only occur in the tools but also between each forming stand. When creating the tools the tool designer must decide how many forming steps the profile demands. The number of steps is dependent on the shape of the cross-section, tolerance, thickness and material properties. It is important to minimize the number of steps as this reduces the cost of the cold roll forming machine. Then the process can be a competitive alternative also for smaller production volumes. Therefore the knowledge of how high strength steel affects the number of forming steps is important.

Rolled Steel :

Cold Rolled Steel is steel which has been rolled at room temperature, below its recrystallization temperature. This increases its strength and hardness and decreases its ductility. In addition to the improvement of mechanical properties, cold rolling results in more control over the shape and dimensions of the finished product. Cold Rolled steel has an improved surface finish and tighter tolerances compared to hot rolled steel. It is commonly used for parts requiring cold forming, such as crimping, swaging or bending. It can also be used for Shafts, machinery parts, bolts, pinions, gears, as well as in the creation of furniture, appliances and other consumer goods. Cold Rolled Steel can be purchased online and at any Metal Supermarkets location. It can be cut to your exact specifications.

YOU CAN SEE THIS VIDEO FOR ACCESS MORE INFORMATION :

Roll forming
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