Troubleshooting 3-Roll Plate Rolling Machine Issues

Every single day, your 3-roll plate rolling machine is called upon to fight one of the toughest battles against one of the toughest opponents: tough metal sheets. 

So, if you have noticed one of these things with your 3-roll bender: 

• Metal sheets with wrinkles instead of smooth curves.

• Unusual banging or grinding noises.

• Excessive shaking and vibrations.

You are absolutely right to think, “Something is not right!”

So, if you are here because you want to find out whether your 3-roll plate rolling machine is facing some of the most common issues, you’ve come to the perfect place!

In this blog, I will outline 5 issues with 3-roll plate-rolling machines and show you how to spot & fix them. 

Let us get started!

Troubleshoot 3-Roll Plate Rolling Machine Issues: Table of Contents

• Quick Table for Recap: How to Troubleshoot 3-Roll Plate Rolling Machine Issues

• Common 3-Roll Plate Rolling Machine Issues + How to Troubleshoot Them

• Himalay Machinery: Your Trusted Partner for Fixing Plate Rolling Machine Issues

• Troubleshoot 3-Roll Plate Rolling Machine Issues: FAQs

Quick Table for Recap: How to Troubleshoot 3-Roll Plate Rolling Machine Issues

Short on time?

No problem: here is a quick table to help you solve the 5 most common 3-roll plate rolling machine issues!

Problem	My Suggestion
Inaccurate Bending	Recalibrate the machine with the correct material settings.
Excessive Noise/Vibration	Tighten bolts & lubricate parts; replace bearings if needed.
Hydraulic System Failure	Replace fluid/seals; service the pump if whining persists.
Uneven Rolling & End Flare	Realign rolls to be parallel and ensure a consistent gap.
Slip, Skidding & Wrinkling	Clean rolls/plates and increase tension settings.

Common 3-Roll Plate Rolling Machine Issues + How to Troubleshoot Them

1. Inaccurate Bending

The most common issue with 3-roll plate rollers is that they don’t shape or bend metal plates according to the dimensions you have specified. 

So, you get: 

• Poorly bent shapes that are just nowhere near what you need.

• Asymmetrical shapes: one side might be correct, but the other half is not.

• Wrinkles or dents on your bent metal sheets. 

Diagnosing Inaccurate Bending

• Run a quick check to see if you have entered the correct material thickness and type. 

• Look for visible signs: can you spot wear, dents, or grooves on the sheets?

• Is the bend radius consistently wrong or just for a one-off sheet?

How to Troubleshoot Inaccurate Bending

If you spot any of the three problems I have outlined above: 

• Re-enter the correct settings: this is basically like resetting the machine. 

• Use a piece of scrap metal to perform a simple recalibration.

• Check if the rolls are just worn out: they might need to be repaired or replaced (we can help with this!).

If these fixes don’t work, reach out to us! We’ll take a quick look and tell you what needs to be done.

2. Excessive Noise or Vibration

Another very common problem that you will be able to spot very easily is excessive vibration. 

Do not worry: this does not automatically mean that there is a major problem with your roller. 

Check the following: 

Diagnosing Excessive Noise or Vibration

• Listen closely to the noise: is the origin a specific place, like the gearbox or a specific bearing?

• Check the bolts and mounts: are they fixed as tightly as possible?

• See if all 3 rolls are parallel to each other.
  

How to Troubleshoot Excessive Noise or Vibration

• Re-tighten all the bolts and mounts.

• Realign the rolls (use the instructions in the machine’s manual as the guide to the default settings). 

• Lubricate all of the roller’s moving parts. This will reduce the friction and keep the machine humming along. 

If you still hear, see, or feel noise/vibrations, you are probably dealing with a faulty bearing. All you’ll need to do is fix or replace it!

3. Hydraulic System Failures

Next up, we have one of the more difficult issues that you might face with your 3-roll plate roller - hydraulic failure. 

The good news is that you will spot this issue very easily. Let me show you the three obvious signs.

Diagnosing Hydraulic System Failure

• The most obvious sign is fluid leakage under the machine. 

• Do you hear whining in the pumps? If so, your 3-roll plate roller is most likely undergoing hydraulic strain.

  
  

How to Troubleshoot Hydraulic System Failure

• Remove the existing hydraulic fluid and replace it with a new, clean batch.

• Should you spot any broken hoses, cylinders, or seals, contact technicians to replace them ASAP. 

If these do not fix the problem, you are likely dealing with a faulty pump. To fix that, you will need to contact a professional!

4. Uneven Rolling & End Flare

Next, let us consider a more mechanical issue: uneven or asymmetrical rolls. 

This is a very common and also a very fixable issue.

Diagnosing Rolling & End Flare

• Are the rolls parallel to each other? If not, that’s the problem!

• Measure the gap between the top one and the bottom two rolls. It should be the same across the entire length of all three 3 rolls.
  

How to Troubleshoot Rolling & End Flare

• Start with a simple recalibration. Your goal should be to set a consistent roll gap between the 3 rolls. 

• Adjust the alignment of the rolls such that they are parallel to each other. 

These two tricks should solve the problem in most cases.

If not, reach out to us! We will take a comprehensive look and tell you what’s wrong.

5. Slip & Skidding or Wearing

One of the most annoying problems you can face with your 3-roll plate roller?

The metal plate slips while rolling!

That means you will have to deal with products with scratches, scuffs, or wrinkles.

Thankfully, you can (usually) fix the underlying issue without any technical help!

Diagnosing Slip & Skidding or Wearing

• The most common reason is that your machine is overloaded. So check if the metal plate is beyond the machine’s capacity. 

• We’ve also encountered oil, grease, or dirt build-up on the rolls, indicating slips and skids.

• Check the pinch/pressure settings: they might not be at the correct levels for the plates you’re feeding in. 
  

How to Troubleshoot Slip & Skidding or Wearing

• Start by reducing the machine’s load: does it work fine for a less dense sheet?

• Restore grip: thoroughly clean both the rolls and the plate.

• Re-set the tension + pressure settings such that they align with the plate’s requirements.

This should take care of the problem!

Himalay Machinery: Your Trusted Partner for Fixing Plate Rolling Machine Issues

3-roll plate benders go through the same grind every single day.

So, if your plate roller shows signs of wear, tear, or stoppage, do not be surprised or worried!

But I do suggest caution: spotting and addressing a problem before it stops production is much better than finding a fix!

And if you want to be entirely sure your 3-roll plate roller is in the best possible condition, contact us!

At Himalaya Machinery, we have been fixing common problems like repairing and replacing pumps or bearings for decades… 

But if you are unable to spot the problem, that’s where we can be your eyes and ears!

We will run a thorough audit of your bending machine and recommend the best fix that balances both the short- and long-term health of your roller…

Troubleshoot 3-Roll Plate Rolling Machine Issues: FAQs

1. My 3-roll plate rolling machine is shaking loudly. What's the first thing I should check?

My recommendation: start with the bolts and mounts. See if they are loose, and tighten them as fast as possible. Then, focus on the moving parts and lubricate them. If your machine is facing any common vibration issue, this will take care of the problem.

2. Why is my rolled metal cylinder cone-shaped instead of straight?

This is what we call an "End Flare." It’s a sign your rolls are misaligned. 

The fix: check their alignment to make sure they are perfectly parallel and that the gap between them is even throughout the rollers’ length.

3. Hydraulic fluid is leaking. Can I still operate the machine?

NO! Operating a 3-roll plate rolling machine with a leak will most definitely damage the hydraulic pump. Instead, I suggest identifying and fixing the leak. Then, refill the hydraulic fluid.