750mm Feed Width, 0.18mm Thickness Curved Single-Skin Panel Roll Forming Machine
Equipment Overview
This is a highly specialized cold roll forming system designed to continuously and efficiently process ultra-thin (0.18mm thick), wide-format (750mm width) metal coils (such as stainless steel, aluminum alloy, galvanized steel, etc.) into **curved single-skin metal panels with specific radii through a series of precision-engineered forming rolls.
Core Functions & Features
1. Precision Forming of Ultra-Thin Material:
Key Challenge:Forming 0.18mm material (ultra-thin gauge) is highly susceptible to wrinkling, scratching, surface indentation, and unstable deformation (e.g., difficult-to-control springback).
Solutions:
High-Precision Roll Stands: Utilize multiple sets (typically 16-24 passes or more) of precision-ground, dynamically/statistically balanced forming roll sets. Rolls are made from high-hardness alloy steel (e.g., Cr12MoV, SKD11) with hardened surfaces (e.g., hard chrome plating, TD treatment) to minimize friction, wear, and scratching.
Progressive Incremental Forming: Bend angles and curvature are gradually and minimally increased over multiple passes to prevent excessive localized stress causing wrinkles or fractures.
Precision Guidance System: Incorporate precision guides (e.g., side rolls, edge rollers) before, after, and between critical passes to ensure exact material centering and prevent wandering.
Tension Control: Precise control of material tension between the decoiler, recoiler, and forming mill is critical for stable forming and preventing wrinkles in ultra-thin material.
2. Wide Feed Width (750mm):
High Rigidity Requirement: The 750mm processing width demands exceptional rigidity and stability in the machine frame, drive shafts, bearing housings, etc., to withstand significant radial forming forces and prevent deflection-induced loss of precision (e.g., center sag).
Large Roll Shaft Aspect Ratio: Long roll shafts (typically >800mm) impose stringent requirements on shaft material, heat treatment, and bearing selection/layout to ensure minimal deflection and vibration at high speeds.
Uniform Load Distribution: Roll design and arrangement must ensure forming forces are as uniform as possible across the 750mm width to prevent local overloading or under-forming.
3. Curved Single-Skin Panel Forming:
Forming Objective: Produces panels with a single, continuous radius of curvature (or approximation thereof), not complex cross-section profiles. The arc can be upward (crowned), downward (concave), or custom-designed.
Roll Tooling Design: Roll contours (profiles) are specifically engineered for the target curvature. The profiles of the final passes determine the ultimate arc shape and surface quality.
Springback Control: Springback is significant in thin-gauge forming. The equipment (via precise overbending design) and tooling (via compensation design) must effectively predict and compensate for springback to achieve the required curvature accuracy. This demands extensive experience and precise simulation.
4. Continuous High-Efficiency Production:
Production Line: Typically integrates a decoiler → leveler → entry guides → roll forming mill → cut-to-length unit (e.g., servo flying cut-off, pneumatic punch) → outfeed table/recoiler or stacking system → forming a continuous production line.
High Productivity: Once set up, enables high-speed (line speeds typically 15-40 m/min or higher, depending on material, curve complexity, cutting method), continuous, high-volume production, significantly boosting efficiency and reducing per-piece cost.
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