Many companies tend to fall into such a dilemma: orders continue to decrease, while workers’ costs continue to rise, leaving the company’s profit margins squeezed continuously.
Not only that, but the business owner must also add new production equipment to replace the old equipment, but also pay attention to the production capacity of the equipment to ensure the competitiveness of its products in the market.
Therefore, before purchasing a new plate rolling machine, companies must make a serious and responsible assessment of their purchases.
Adding new equipment obviously requires cost considerations.
However, if the new equipment is not as productive as the old one, then the investment will be ruined.
According to a study, a considerable part of the procurement is too price-conscious, ignoring the production capacity of the equipment and the impact of equipment maintenance, so that the newly added equipment cannot meet the production needs.
As a professional manufacturer of plate rolling machines, Artizono has summarized its experience in the past 30 years into the following five points for the reference in the procurement of plate rolling equipment.
Let’s dive right in.
Influence of material on plate rolling
One of the most important factors in the design of the plate rolling machine is the material of the metal.
For example, rolling a metal plate of the same thickness, the plate with a high yield strength must have a high pressure on the roll bending machine. If not considered, the processed material will be deformed at corners or some other defects occurs.
Today, the strength of the steel is much higher than before, and the pressure requirements on the rolling press are also increased.
In this regard, the association of mechanical engineers in various countries has also developed standards that classify various types of steel. Different types of steel have different rolling pressures.
The temper brittleness of the metal, the yield strength, and the use of the sheet are important factors that the plate rolling machine manufacturer needs to consider.
This is especially important since the reform of the steel smelting industry over the past few decades.
For example, the former as soft steel has long been a history and is no longer popular.
To cooperate with plate rolling manufacturers who are willing to discuss details
In order to get the answers you want, you must first learn to ask the right questions.
Each company has its own unique needs. By answering the systematic questions, sales can make a set of solutions that best suit the procurement needs.
Companies should also consider whether they need to roll conical or parabolic products in order to open up the market.
The CNC plate roll bending machine with a coarse upper roller and fine lower roller is the ideal model for rolling this shape of products. The advantage of this type of plate rolling machine is that it can effectively eliminate the surface wear of the metal plate, thus eliminating the edging polishing process of the tip of the cone.
Artizono found that the theoretical balance that can be achieved with CNC systems is not perfect, and the precise conical rolling system is actually achieved by the balance of torque. The precise balance allows the material to be perfectly tapered in 5 seconds.
On the one hand, the purchase must let the supplier know all the details, including diameter, material, error, shape…
For example, in the pressure vessel industry, there are often requirements for roundness error of diameter less than 1% or no flaw. Sometimes the power of the plate rolling machine is too high, otherwise, there will be a cylinder phenomenon which will directly lead to product failure. It will seriously affect the efficiency of the enterprise.
On the other hand, the manufacturer of the plate rolling machine must take into account all the special needs of the buyer.
Purchaser must also find a manufacturer who is willing to sit down with a detailed discussion.
There are many details that are important, but they are often overlooked by the buyer. At this point, the responsible manufacturer must confirm these details.
Make choices according to optimal conditions
The enterprises often have to determine what materials and thicknesses can make them achieve the best benefits. Plate rolling machine manufacturers also need to design and manufacture corresponding roll bending machines based on these parameters. This will not only save a lot of time but also greatly reduce rework rate.
According to our experience, high-end plate rolling machine generally achieve the best efficiency at 50% of full load. For example, a plate rolling machine capable of rolling a 10 mm thick material sheet has the highest efficiency when rolled up a 5 mm material plate.
A big problem with the operation of the plate rolling machine is that the size of the sheet is problematic. Apart from this problem, most of the problems are concentrated on the pressure of the lower roll to the upper roll.
If a plate roller capable of rolling a 10mm-level material is rolled into a 6mm material, a certain cylindrical distortion will occur and this often leads to big troubles.
But the biggest trouble is when the plate thickness reaches the limit of the plate roller.
Unless the gasket is used, the entire machine can only be disposed of.
Conversely, when designing a plate roller with a thick plate to roll a thin plate, the middle of the plate is stronger than the surrounding. Thus, the hourglass deformation will not be corrected unless a gasket is used.
Careful consideration of the thickness and diameter of the plate for rolling
The smaller the diameter, the greater the rolling pressure required.
When rolling the thick plate with a very small diameter, the designer should pay attention to the position of the upper roll and the structure of the plate rolling machine, because these two factors are important factors affecting the size of the opening.
Almost all plate rolling machines are designed with a maximum roll diameter of 1.5 times that of the upper roll.
In this case, the maximum inner diameter of the rolling with 50 mm upper roll can be 75 mm.
Now there is a new technology that allows nearly half of the material to be under pressure during the bending process so that the maximum design of the rolling diameter can be 1.1 times that of the old method, and the effective diameter range is increased 30%.
Keep in mind that the best precision rolling range that all plate rolling machine can achieve is half the design standard.
Coordination of horizontal and vertical support forces
For the plate rolling machine designer, the support that needs to be considered is mainly in two directions: horizontal and vertical.
The benefit of this is that the amount of work that would otherwise take two people can be done by one person, which saves valuable labor.
When rolling a cylindrical product, it should be noted that if the diameter is more than 200 times the thickness of the plate, the plate will be bent due to its own weight.
Without support, the ideal diameter cannot be obtained.
If you buy a plate rolling machine with material support, these problems will be solved.
However, some manufacturers often use forklifts and cranes as support to reduce costs, but this practice often does not help and will limit the scope of the equipment.
Many purchasers tend to ignore a number of key factors, which ultimately lead to unsatisfactory equipment purchases, causing many problems in the production. In this regard, I hope that the five key factors summarized above can be helpful for the plate rolling machine purchaser.