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 is important in many industries. Most of the customers use a Bending/Rolling machine to make Circular bending jobs, Vertical bending, and various other jobs. Compared to other machine tools, it exhibits quite an extended working life.
How do Rolling/Bending Machines Work?
Permanently changing the workpiece into a certain shape is called bending. Steel is elastic under normal circumstances. It means that it is subjected to deformity under load, but upon removal of load, it regains the original shape. However, this is true only up to a certain extent of deformation. Beyond a certain level, the material cannot regain its original shape. However, after the load is removed, it does spring back a little.
The plate is deformed (bent) due to the roll's force (see below figures) –
The deformation should be sufficient to develop stress in the plate material higher than the plate's yield point. In simple words, it can be said that yield point is the stress at which a material bends or elongates, while Ultimate Tensile Strength is the stress at which the material breaks into two pieces.
Suppose the rolls are now given a rotary motion. In that case, a continuous bending process results, which is called Rolling (refer to below figure) –
It can be seen that a certain end portion of the plate has not passed under the top roll and remains almost straight, and to reduce that pre-pinching feature is provided.
With the rotation movement and position change of work rolls with different shapes, the plate bending machine is capable of processing oval, arc, and cylindrical parts. Upon the proper adjustment of the relative distance between the lower and upper rollers, users can bend the plate to any value. However, it must be remembered that the lower roller’s radius must not be less than the radius of the upper roller.
The bending roll process is a deformation operation, which can make the plate have a certain curvature. It has the function of rolling O-shaped, U-shaped, and multi-stage R-shaped plates. With a Plate rolling, you can manufacture a wide range of different products. Typically, all steel or metal forming for cylindrical lines use bending rollers for rolling.
How to Use a Bending Machine?
Step-1: From the wall-mounted isolator switch, you have to switch on the main supply to the machine. After this, you will see a 'power on’ indicator light up. If the phase sequence is not 'OK,' or in case of any fault with the incoming power supply, such as phase failure, under voltage and overvoltage, or unbalanced voltage, the single phasing preventer will not allow the 'control on' indication on the operating console. However, the 'control on' indication will automatically light up when the incoming power supply is okay.
Step-2: Switch on the Hydraulic Pump Motor and allow it to run idle for a minute or so.
Step-3: Amidst the idle run of the Hydraulic Pump Motor run, monitor the direction of rotation of the main pump motor and run the cooling fan motor of the oil cooler. They must be in the direction of the arrow indicated on it.
Step-4: You can now try other operations like UP, DOWN, REVERSE & FORWARD etc., at no load.
This idle run spreads the lubricants on the working gear trains and bearing journals. Then, if everything appears fine, you can begin the bending work.
Now that you have a better understanding of the functioning of bending machines, it is recommended that you take a closer look at which options your needs are met. Always look into factors like bending force, length, table height and breadth. Considering these factors will help you determine the efficiency of the machine. To solve your woes, Himalaya Machinery is here with its powerful range of machines. Let us see some of the basic features of the machines.
Features of Himalaya Bending Machine
Sturdy Steel Structure
Himalaya machines exhibit a strong steel structure made up of heavy metal plates. A strong box design chassis connects the frames. The frames have interlocks and strengthening ribs. The roll guideways are machined together utilizing a fixed single reference point which allows for parallelism of all axes and precise surfaces, as well as longevity and precision of the critical characteristics of the machine.
Rolls
Himalaya designs the rolls with the optimal diameter and uses forged carbon steel rolls machined by high-precision CNC lathes. Our rolls have a spline-based design that is extremely efficient in connecting the rolls with planetary gear systems. This diminishes points of roll failure compared to welded connections.
Crowning
All the rolls manufactured by our company are crowned to compensate for roll deflection during the bending process. While ordering, users can select custom crown-machined rolls for different materials or thicknesses.
Hydraulic System
In all our machines, we ensure additional energy saving with the help of a hydraulic system that can work at less than full capacity when jobs with less than maximum thickness are rolled. The twin-speed operation also reduces energy consumption by up to 50% when a slower operating speed is selected. The Himalaya Planetary driving system ™ used in the machines is efficient and eliminates energy wastage associated with heavy transmission systems and yet achieves the goal of speed reduction by increasing the stages in gears and pinions.
Why Choose Himalaya Plate Bending Machines?
Himalaya Machinery is a 40-year-old company that has supplied over 2500+ plate bending machines to customers across India and abroad. Let us see why:
Better Accuracy: All our machines are designed and manufactured with proven superior Linear Guideway (bottom rolls positively guided without any linkages) Design (like HAEUSLER) for Plate Bending machines. As a result, the machine does an accurate bending/rolling job.
3-Year Warranty: We offer a 3-year warranty that demonstrates the performance and; thus, the reliability of our machines at a nominal cost.
400+ Clients Across the Globe: More than 400 customers have already placed repeat orders on Himalaya Machinery. Some names are market leaders like Thermax, Tatas, Godrej, Reliance, etc.
Operator-Friendly & Minimum Maintenance: Himalaya's Machines are robust and convenient to maintain. Also, there are quite operator-friendly machines and therefore a preferred choice among many.
Top-Notch Customer Support: Himalaya is known for its exceptional customer service support – the USP of purchasing the company's wide range of plate bending machines. Our technicians reside in major cities of India. So they are readily available in case of any issues with the machine.
Trusted Brand: The machines by Himalaya come with a high resale value, are quite high in demand, and get resold almost immediately. Some of our valued clients in India are government organizations such as Railways, Defence, Steel Plants, Refineries, Fertilizer Plants, Atomic Energy plants, Shipyards, BARC, BHEL, HAL, BEML, NTPC, etc.
Four decades of excellence: The company supplied its first machine 4 decades ago, which is still functional, speaking volumes about the brand's credibility. We’ve never accepted anything below excellence and never will.
More than 2500+ operational machines: Himalaya Machinery has manufactured over 2500 bending machines, all in operation today. We believe in quality, and the numbers are a testament to it.
Are you looking for a reliable manufacturer of bending machines? Then, Himalaya Machinery is your answer! Schedule a free consultation with our experienced team to walk you through the process of buying a plate bending machine.
Learn more about our 3 Roll Plate Bending Machines and 4 Roll Plate Bending Machines.