How to Maintain a Rolling Machine
A rolling machine transforms metal into usable forms by applying pressure to the workpiece. This pressure is carefully controlled to achieve desired deformation outcomes and meet specific manufacturing requirements.
When selecting a rolling machine, evaluate manufacturers to ensure that they are capable of meeting your unique needs. Consider their manufacturing processes, quality control measures, and track record.
Material Selection
Rolling machines use metals that can withstand high pressure and temperatures, requiring the right materials for long-term reliability. When shopping for a machine, consider the manufacturers’ track record and reputation in the industry, and seek feedback from peers and online reviews. This information can help narrow down your options and find the right machine for your needs.
Generally, the abrasion resistance and hardness of the rolling machine’s metals are more important than their specific chemical composition. These factors determine the durability and longevity of the rollers, and they influence the shape size and surface rolling machine quality of rolled products. For example, hardness ratings of between 50 and 55 Rockwell C are ideal for abrasion resistance. Rolls with lower hardness ratings may not have adequate wear resistance and will experience premature fatigue.
The abrasion resistance and hardness of metals also affect the amount of lubricant that can be drawn into the contact zone. The more lubricant is present, the lower the friction coefficient will be. However, a threshold must be reached as too much lubricant can create deposits that reduce the force of contact.
Plate rolls are one of the most versatile types of rolling machines, capable of creating cylindrical, oval and other non-round shapes. These are widely used in many fabrication workshops to produce components and equipment for a variety of industries. They can be operated with either electric or hydraulic machinery and use three, four or more rollers.
Machine Calibration
Machine calibration is essential to ensure that your equipment follows the exact measurements and standards required for the job. This creates an efficient process that eliminates wasted time and money due to inaccurate parts and products. Even small deviations from controlled information can result in expensive rework and product delays or scrap. Working with a professional machine calibration specialist can help speed up the process and eliminate errors that could impact project schedules.
A gear rolling tester is able to verify a wide range of master worms and wormwheels with large diameters and up to a total length of 10.000 mm. The measurement uncertainty of the gear-rolling test is calculated by dividing it into different contributions that have been experimentally determined. These contributions are related to the initial calibration, displacements to the nominal test position, assembly of the gears and the execution of the test itself.
The majority of the error contribution comes from rotary axis location and component deviations. It is also important to take into account the influence of dynamic errors, such as reversal spikes and other difficult to diagnose post calibration issues that can be caused by a change in axis orientation. The final contribution is the influence of linear encoders on test results, especially those that are not numerically compensated. The pitch EBZ and roll ECZ errors of the vertical carriage movement are not detected by linear encoders and are thus not compensated, but can significantly influence the rolling tests results.
Rolling Operation
The frame of the rolling machine must be sturdy and rigid to withstand the substantial forces generated during the rolling process. The frames are typically made of high-strength steel or cast iron. They must also be well-constructed to ensure accurate alignment of the rolls during the forming process. Improper alignment can lead to faulty product quality and reduced productivity.
Rolls must have good wear resistance and sufficient strength to withstand the bending, shearing, and torsional stresses they are subjected to during rolling. Additionally, they must be able to withstand high temperatures without heat checking or oxidation. The dimensions of the rolls are determined by a number of factors, including the prevailing elongation level, the dimensional accuracy of the workpiece, and the desired degree of reduction per pass.
During the rolling process, metal is forced between two or more rolls to form a thinner and wider strip. The rolling process can be used to produce various products, such as structural steel, railroad tracks, and automotive parts. In addition, it can be used to create pipes and other heavy-duty metal fabrications.
When selecting a rolling machine, it is important to consider your company’s unique needs and specifications. Conducting extensive research can help you identify manufacturers that specialize in the type of equipment you require. Additionally, it is essential to prioritize safety features, such as emergency stop buttons and safety interlocks. Lastly, look for machines that offer a wide range of material-feed options, such as manual, semi-automatic, and fully automatic.
Maintenance
Rolling machines are critical assets in various industries, but they’re also susceptible to a range of problems that can halt production and result in costly downtime. Proactive maintenance minimizes these risks and ensures that your metal rolling machine is working optimally. Routine visual inspections, lubrication, cleaning, and the replacement of worn components are key elements of a comprehensive maintenance plan.
Perform regular visual inspections to check for signs of wear or damage on all parts of the machine, including rolls and material feeding components. Check for debris or obstructions in the work area, and inspect electrical connections and safety features. Regularly calibrate measuring instruments and sensors to maintain precision. Examine the quality and consistency of materials rolled on the machine, and ensure that they meet specified standards.
Keep records of your maintenance efforts and monitor the performance of the machine, adjusting as necessary to maximize efficiency. The use of digitally networked systems can provide status rack upright roll forming machine information on sensitive components, allowing you to detect issues that might cause production delays and save costs by reducing the time required for maintenance. For example, if a roller bearing is not functioning properly, you can use the data to determine whether this will cause downtime and take action accordingly. You can even schedule maintenance tasks in advance to reduce the likelihood of unexpected breakdowns and unforeseen expenses.
