When it comes to workshop machines, one of the versatile machines is a Plate Bending/Rolling machine. It can do various jobs over and above circular shells when used suitably. Its ability to bend any workpiece makes it important in sheet metal and other industries. You can produce Circular shells and other shapes like Conical l, radius, and Elliptical with a good quality Plate Bending (Rolling) machine. Compared to other machine tools, it exhibits quite an extended working life.
Primarily, there are three different types of bending machines:
2-roll plate bending (rolling) machine
3-roll plate bending (rolling) machine
4-roll plate bending (rolling) machine
Choosing the right bending machine for your machine shop or metal fabrication company demands understanding the differences between each and their unique features, applications, advantages, and disadvantages. It is crucial to understand which machine gives what type of output and which machine will be best for one’s rolling jobs/application.. However, this article will discuss 3-roll plate bending (rolling) machines and 4-roll bending machines.
3 Roll Plate Bending/Rolling Machines (Linear Guideway Type)
The bottom rolls in linear guideway geometry machines are positively guided in the machine frames. The axis of the bottom rolls is closer to the top roll. The close spacing between the top and bottom rolls enhances the circularity of the rolled shell. Therefore, the precision/circularity of the final resultant rolling workpiece is better when compared to swing guide or variable geometry machines.
The design is such that the bending forces are directly transferred from cylinders to rolls, as no linkages are involved. Due to this, no wear and tear are caused and the guideways and roll parallelism are maintained. An ideal machine's front and back frames are cut and machined to achieve an extremely precise alignment of the guideways in which the bottom rolls move. Thus, the users can get excellent accuracy in terms of roll movement and superlative Bending / Rolling quality.
Here's a video showing the bending/rolling capabilities of Himalaya's 3 Roll Plate Bending/Rolling machines:
Himalaya’s Plate Bending (Rolling) machines are designed for hassle-free usage and energy-saving features; to ensure peace of mind and operational convenience for plate bending work. The general components of the machine go something like this:
Rolls - three or four - depending upon the model
Two frames ( Head and Tail Side frame)
Swing Arm for the removal of the rolled shell
Coaxial planetary gearboxes
Hydraulic system with an energy-saving feature
Comprehensive overload protection
Easy centralized controls, PLC & CNC version
Roll parallelism mechanism
The 3-roll machines have linear guideways for the two bottom rolls. There is a minimum distance between the bending points to achieve higher precision of rolling jobs.
Advantages of Three Roll Plate Bending (Rolling) Machine
Compact construction: Demands less floor space and is thus useful for site conditions.
Offers easy Re-rolling of a welded shell: Since no rolls are pressed against each other, the welded seam can jump over the rolls.
Cost-effective: You can buy a larger and better machine for a given investment compared to the same rolling capacity of a four-roll or variable geometry plate bending machine.
Operator-friendly machine: Ease of operation for bending/rolling of Cylinders, Cone bending attachment is also provided to make this operation easy. The main three basic operations can be easily learned: Rolling, Pre-Bending and Removal of the shell.
All the functions performed by a 3-roll bending machine are the same as a 4-roll bending machine. However, the key difference is that with a 3-roll bending machine, you have greater control over the desired output.
Four Roll Plate Bending (Rolling) machine
As the name suggests, the four-roll plate bending (rolling) machine has four rollers. In this machine, the top roll remains stationary, the bottom roll moves vertically, and the two side rolls move in a linear guide way to form the shell.
In this arrangement, the workpiece is held between the top and bottom roll while the side rolls create the bend by moving vertically. For holding the plate surface, the bottom moves up securely against the top roll while the side roll rises to create a precise bend.
Here's how it looks:
The planetary gearboxes and hydraulic motor power drive the top and bottom rolls.
The location of the bottom roll directly below the top will ensure a good grip while bending plates/sheets.
Thin plates demand closely spaced rolls to eliminate driving slippage.
Due to the high productivity of low-thickness shells, the four-roll machines are a good investment for the mass production of pipes and shells.
Over and above the cones, other non-circular shapes like oil tankers & elliptical shells can be made.
The 4-roll configuration also allows CNC operation.
Out of the four rollers, the upper roller is a drive roller, and the lower inside is an enslaved person-driven ruler; the former is fixed while the letter can be lifted and moved. With the help of a hydraulic motor, you can drive the upper roller; however, with the lower and side roller rotation, you have to use only the friction in the steel plate and the roller to drive it.
One of the biggest benefits of using this machine is that it is simple and convenient. These machines also perform the same function as three-roll machines.
Advantages of 4 Roll Bending Machine:-
Large material- Like the 3-roll version, these bending machines can handle plate thicknesses from about half an inch to four inches or even more, based on the model.
Higher productivity - With CNC features, one can achieve higher productivity than 3 roll plate bending/rolling machines.
Suitable for mass production: Due to the high productivity of low-thickness shells, the four-roll machines are an attractive investment for producing pipes and shells.
Parameter | 3 Roll Plate Bending/Rolling Machine | 4 Roll Plate Bending/Rolling Machine |
Structure | The bottom rolls in our linear guideway machines, are positively guided in the machine frames. The axis of bottom rolls is closer to the top roll. The close spacing between top roll and bottom rolls improves circularity of the rolled shell. Hence accuracy of resultant job is better than swing guide or variable geometry machines. | The four-roll plate bending (rolling) machine has four rollers. In this machine, the top roll remains stationary, the bottom roll moves vertically, and the two side rolls move in a linear guide way to form the shell. |
Application | Based on models, these bending machines are capable of bending plate thicknesses from about half an inch to four inches. | Based on models, these bending machines are capable of bending plate thicknesses from about half an inch to four inches. |
Unloading Process | Usually, the unloading process of four rollers is controlled by push buttons, thus making the process easier. | Usually, the unloading process of four rollers is controlled by push buttons, thus making the process easier. |
Before investing in any metal-forming technology, it is important to explore the priorities. Once you are sorted with your requirements, you can choose the right bending machines. An ideal piece of the bending machine should be capable enough to handle common materials, special materials, and different shapes.
So, are you looking for a good quality plate roll bending machine for your business? We have got your back. Feel free to contact Himalaya Machinery to get the best bending machine and get your work done in a jiffy.