Beam Roll Forming Machine
Beam Roll Forming Machine is a special type of metalworking equipment, which is used to produce structural steel, metal pipes, and other shapes. It has the features of multi-point stretch forming, flexible gripping jaws, Horizontal hydraulic cylinders, and computer-aided tooling design. With these features, the machine is ideal for any kind of business. Moreover, it reduces production cost and increases profit for customers.
Multipoint stretch forming machine
The Multipoint stretch forming machine is an innovative production equipment that allows individual control over clamping. It includes a supporting frame 110, top and bottom punch modules, and control unit 150. The support frame provides space for a moving cylinder 180 that moves up and down on the supporting frame. This type of machine can be used to form various types of panels of different sizes. There are many benefits of using Multipoint stretch forming machines.
Multipoint stretch forming machines can be controlled by a common electromagnetic directional valve. They can be adjusted in several different angles and positions to meet the bending requirements of a variety of different shapes. One of the most notable benefits of Multipoint stretch forming is that the cost of the forming process is 90% lower than traditional methods. The fabrication time of a single panel is reduced from several hours to as little as fifteen minutes.
The main parameters influencing the cross-sectional distortion during the stretching process are studied by the range method and by the use of numerical simulation techniques. The optimal combination of these parameters is obtained when the pre-stretching and poststretching amounts are equal to 1% of the overall profile length. The maximum number of hydraulic cylinders is 12 per die head. The Multipoint stretch forming machine is capable of performing both simple and complex curved sheet metal forming processes.
The multipoint stretch forming machine was developed to make it easier for a manufacturing engineer to understand the process. It was designed to minimize springback by reducing the force and thickness of the plastic sheet. The sheet holder was placed over the forming area to compensate for springback. The result was a reduced springback in the final part. These results are the first proof of concept for Multipoint stretch forming machines. This research was supported by Innovate UK and the Engineering and Physical Sciences Research Council.
Flexible gripping jaws
Unlike conventional beam form machines, which employ multiple jaws to create a single part, CTGs employ flexible and compliant gripping jaws. This allows users to quickly and easily change jaw surfaces. These jaws can also be used to measure the tensile properties of samples, which can be important for certain types of work. There are two types of grips: hydraulic grips and wedge grips. The hydraulic grips can reach capacities of up to 3,000kN.
A bead roll form machine can also stretch material to a yield point and then lay it over the die form. This process helps to maintain uniformity while minimizing excessive spring back. A beam roll form machine may also have a wiper roll that can be hinged at the center of the curve. These machines have several advantages, including their versatility. Ideally, the bend radius should be three to five times greater than the gauge of the material being formed.
In addition to the traditional gripping jaws, a beam roll form machine can use flying cut-off units to form short-length sections. The material type will influence the number of passes necessary, as well as the type of tooling used. Various degrees of spring back must be compensated for, so tooling must be adjusted accordingly. Ductile materials, for example, can be rolled to an inside radius of zero, while non-ductile materials can be rolled to a sharper outside radius.
CTGs also provide more flexibility and controllability than traditional jaws, and can be designed to be asymmetrical. This asymmetry helps in generating twisting motions in the component, and can also make controllability difficult. In addition, asymmetrical CTG may restrict the range of motion of a specific part. Therefore, NBGs with asymmetrical jaws are a better option for certain processes.
Horizontal hydraulic cylinders
Beam roll forming machines require hydraulic cylinders which are mounted on a mandrel. The hydraulic cylinders act on the ends of the top girder 12 and the U-girder 93, exerting pressures and maintaining forming pressures. The top girder is designed to safely resist all upward forming pressures while the bottom girder springs downward.
The forming machine includes a slidable frame 252 with a hydraulic cylinder 254 mounted in a support guide 258, which is positioned adjacent to the machine’s exit end. The rolls are positioned 45 degrees from the vertical center line of the roll forming machine. The forming roll 30 is powered in either direction. The bottom girder is supported by two horizontal plates 262 and 264.
The springback roll is retracted by the cylinder 208 prior to the bending operation. The springback roll is then used to prevent the plate from being sprung away from the mandrel. It also maintains the plate against the mandrel when it reaches the top pressure rolls. Once this process is complete, the forming process is completed. The process will be repeated until the plate is symmetrically formed and the top girder reaches its predetermined stop position.
The upper bale forming means travels around the roll forming machine 10 on a series of idler sprockets. The takeup mechanism 54 has parallel arms 56 that pivot about a bearing 58. In the end, the finished bale is discharged onto the horizontal beam member 28. The horizontal beam member 28 is connected to a stop bracket 85 that limits the upper bale forming means’ counterclockwise rotation.
Computer-aided tooling design
A roll forming machine produces parts with complex cross sections, a high degree of precision, and minimal finishing. It can produce parts of any length with the same tooling. The process is also useful for parts that require a relatively smooth finish with fine details. A roll forming machine is also highly flexible, allowing it to be used in different applications. A roll forming machine also reduces the cost of labor by reducing the need for hand-feeding.
The technology used to design and manufacture tooling for a roll forming machine is similar to that of a CNC machine. The PLC continuously monitors and adjusts the various devices. During the process of roll forming, operators enter cutting commands for a variety of operations. The more complex the operation, the more commands are needed. The white device in the image below is a PLC controller for a rail guide roll forming machine.
Modern roll forming machines feature programmable logic controllers to ensure accuracy. PLCs help tighten tolerance levels and minimize the risk of error. Some models also offer welding capabilities. Although this method results in a reduction in energy efficiency, it does remove an entirely important step from the manufacturing process. And because it is highly accurate, a beam roll forming machine is capable of producing parts that are perfect.
The design of the tooling for a beam roll forming machine has several distinct advantages. The process enables the creation of integral branched profiles. The supporting rolls and obtuse-angled splitting rolls increase the surface of the band edge. The additional branches lead to new properties and geometry. Additionally, the process allows for sheets to be made with less than 2 mm of thickness, which provides excellent perspectives for lightweight structures.
Energy efficiency
The energy efficiency of a beam roll forming machine depends on the speed of the molding process and the material being formed. Cold-roll forming speeds range from 0.50 to 2530 m/min. The speed of molding depends on the hardness, composition, yield strength, and material properties of the strip. The molding speed in the experiment is 25 m/min. The friction between the strip and the roll is sliding friction. The material used for the roll is typically Cr12. Steels are commonly found to have a friction coefficient of 0.05 to 0.1.
The resulting shaped metal strip should have an approximate center line and be in the same horizontal direction during forming. The strip passes through the forming rolls to roll out the required product. During the forming process, the web of Z-steel rotates continuously. When the strip is formed, it must be in a certain direction in both X and Y directions. The resulting product strip should have a consistent X-Y distance between its ends.
The use of coil material to produce the parts results in reduced labor requirements and lower overall cost. The roll forming process can also be improved by introducing additional processes to further improve efficiency. Its ability to produce parts at high speeds and minimal manual involvement makes it an excellent choice for mass production. Moreover, the energy efficiency of beam roll forming machines allows for the production of a variety of parts. They are also highly efficient, as they require low-cost labor and reduce overall costs.
This paper aims to provide a quantitative measure of the energy efficiency of a beam roll forming machine. This indicator is derived by performing a matrix of experiments, with the most important factors being the bending angle concept, line velocity, and inter-station distance. These parameters together determine the energy efficiency of a beam roll forming machine. Further research is needed to determine the precise parameters that are relevant to the design of the beam roll forming machine.