Introduction to Single-Layer Small Arc Roll Forming Machine
The Single-Layer Small Arc Roll Forming Machine** is a specialized metal processing equipment designed to transform metal strips into small-radius arc-shaped cross-sections (e.g., semicircles, U-shapes, or complex curves) through progressive bending by multiple sets of rollers. It features a compact structure, high precision, and is suitable for small-to-medium batch production or customized applications.
I. Structure and Components**
1. Frame
Constructed from high-rigidity steel to ensure stability during high-speed operation and minimize vibration-induced deformation.
2. Roller System
Roller Sets: Multiple forming rollers gradually bend the metal strip into the desired shape.
Material**: Rollers are typically made of alloy steel or surface-hardened materials (e.g., chrome-plated, carburized) for enhanced wear resistance and precision.
Adjustment Mechanism**: Manual or motorized adjustments for roller spacing to accommodate material thickness or curvature requirements.
3. Drive System
- Powered by servo motors or variable-frequency motors coupled with gear reducers for precise speed control and smooth operation.
4. Control System**
Basic*: PLC-controlled for parameter setting, speed adjustment, and fault alarms.
-Advanced**: Touchscreen interface with programmable multi-process storage for rapid switching between complex shapes.
5. Auxiliary Devices
- Automatic feeders, leveling units (to ensure material flatness), and cutting systems (for synchronized trimming).
II. Working Principle
1. Progressive Forming: The metal strip passes through sequential roller sets, with each pair applying localized pressure to incrementally bend the material into a small arc (e.g., radius <50mm).
2. Springback Control: Optimized roller design (e.g., transitional rollers) and feed speed adjustments minimize material springback, ensuring dimensional accuracy.
3. Continuous Production: Integrates with uncoilers and recoilers for long-length workpiece processing.
III. Core Applications
1. Construction: Light steel keels, decorative trims, door/window frames.
2. Automotive**: Exhaust pipes, body reinforcements, sealing strips.
3. Home Appliances**: Air duct components, refrigerator internal brackets.
4. Renewable Energy**: Solar mounting systems, battery casing arcs.
IV. Advantages and Limitations
Advantages:
High Precision: Tolerances within ±0.1mm for critical components.
High Efficiency: Continuous forming speeds of 10-30 meters/minute, far exceeding traditional stamping.
Cost-Effective: Low tooling costs (reusable/adjustable rollers) for small-batch multi-variety production.
Material Versatility: Processes cold-rolled steel, stainless steel, aluminum, copper, etc.
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