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Cone Rolling with a 3-Roll Plate Bending Machine: What the Experts Do

Updated: Dec 8, 2023

Is cone rolling becoming a nightmare for you? It’s time to stop scratching your head. This blog contains the methods that expert plate-bending operators use to roll metal plate cones. Let’s become a cone-rolling expert.

To shape cylindrical and conical parts with precision, you need to have knowledge of the type of machine to be used. A 3-roll plate bending machine is an ideal choice for cone rolling. It forms circular, arc, and tapered workpieces off metal plates.

You get enhanced geometric control when you use a 3-roll plate bending machine for cone rolling. It becomes easier to manipulate the position of a metal plate in the presence of enhanced geometric control. The position and movement of rolls can be adjusted to achieve desired cone shape with precision. We will discuss more on that further in the article.

A 3-roll plate bending machine can be either mechanical or hydraulic. They can be symmetrical or asymmetrical. First, let’s understand the working principle of this plate-bending machine, and then we will explore the techniques that experts use to roll cones.

3-Roll Plate Bending Machine: Working Principle Explained!

Of the three rolls in this machine, there is one on the top and two on the bottom. The top roll is an idler. It is not driven through power just like the other two rolls.

The main function of a top roll is to be a support for the metal plate being rolled currently. It rotates as the metal plate moves forward due to the pressure from both the bottom rollers.

Bottom rolls are mechanically or hydraulically driven. All the machines that we, Himalaya Machinery provide are hydraulic plate bending machines. The outdated mechanical plate bending machines have higher maintenance costs and we believe in value for money.

Cone Rolling Machine

As the above image shows, a 3-roll plate bending machine has one top and two bottom rolls.

All three rolls are in their default position in the image on the left.

On the right, the bottom rolls have been pushed up, and the force makes the metal plate bend which is plastic deformation.

The working of a 3-roll plate rolling machine is easier to understand. And once you understand it, rolling cones with it becomes easier.

Rolling Cones With 3-Roll Plate Bending Machines: The Expert Way!

Expert operators use thrust rollers when they have to work on conical or tapered workpieces. Controlling movement and rotation of the workpiece during the rolling process becomes easier with a thrust roller.

It applies pressure and force against the metal plate to guide and stabilize it as it moves through the rolling machine. A thrust roller ensures the metal plate doesn’t slip or slide out of the machine or the rollers.

Thrust Roller Cone Rolling Methods

Bending jobs are not always similar in the manufacturing industry. Thus, there is always a need for different rolling methods. It ensures that the desired shape is achieved at the end of the process.

There are six types of thrust roller cone rolling methods.

Method 1: Thrust Roller on the Overturning Side of the Upper Roll

The thrust roller sits between the upper roll body and the overturning side bearing. This setup prevents unwanted rotation. It comes into contact with the small end plate edge of the workpiece.

The thrust roller uses friction to create the rotational movement of the steel plate. Ideal for thinner plates, larger tapers, and smaller head thrust rollers, it ensures a smooth and controlled rolling process.

Method 2: Thrust Roller on the Overturning Side of the Lower Roll

The thrust roller is attached to the lower roller-bearing blocks and connected to the upper part of the lower roll-bearing seat on the 3-roll bending machine.

The working method is similar to the first method, it is ideally used for workpieces with a larger taper and smaller head thrust roller. It can handle thicker plates compared to the first method.

Method 3: Thrust Roller On the Frame of the Overturned Side

This method is used in a 4-roll metal plate bending machine. The thrust roller is mounted on the frame on the overturned side using bolts. The upper surface of the thrust roller is positioned slightly higher than the lower edge of the upper roll.

This configuration allows for proper contact and friction between the thrust roller and the workpiece during the rolling process.

Method 4: Thrust Rollers on Both Sides of the Upper Roller and on the Overturned Side

Short sliding keys are set between the overturning frame and the machine’s main frame. Thrust rollers are set up on the overturning frame and both sides of the upper roller.

With this setup, there is enhanced stability and reduced workpiece slippage due to multiple thrust rollers. More rollers also provide better precision.

Method 5: Thrust Roller on a Machine Bed

The machine frame provides the facility for dynamic movement and adjusting rollers and the metal plate fed.

The thrust roller frame is designed to rotate around the pin shaft. It enables flexible positioning and alignment of the metal plate. Enhanced rotation capability ensures proper contact and pressure between the workpiece and the roller, facilitating smooth and accurate rolling.

Additionally, the thrust roller can be lifted and lowered within the thrust roller frame. This allows for easy adjustment according to the specific requirements of the workpiece.

Method 6: Thrust Roller at the Transmission Side on the Frame

In this method, the operator gets the benefit of working well with a larger taper. It ensures minimal interference with the workpiece and accommodates a smaller head thrust roller which can be used according to the requirements.

Optional features such as internal threads, trapezoidal grooves, pin shafts, and keys allow for secure fastening.

To Conclude

Rolling cones is a very complex task. But as they say, it is never easy to gain expertise in something right away. Practice makes you perfect. Thrust rollers are one of the most effective ways of rolling cones with precision.

We hope this article has helped you with all your questions. Contact Himalaya Machinery, and we would love to help you with your plate-bending machine requirements.

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