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The principle of forming process design of cold roll forming machine.



The working efficiency of cold bending equipment mainly depends on the shape of the roll and the structure of the production tool. The most widely used production tool is the forming roll. The most complicated problem in the forming of cold bending equipment is the determination of the shape of the forming roll. With the improvement of strip stability and profile quality, as well as the increase of forming speed, higher and higher requirements are put forward on forming rolls.

The basic principles for determining the number of forming passes and the shape of the roller are as follows:
     1. In the case of using the least number of passes, the shape of the roll should make the material have uniform and most reasonable deformation.
     2. Determine and calculate the vertical and horizontal dimensions of the roll shape according to the selected central axis. The central axis remains unchanged every time it passes. For symmetrical shapes, this axis is the axis of symmetry.
     3. Divide the profile into several parts and calculate the length of each part. The total degree of each line segment to the left and right of the selected centerline remains unchanged in all paths.
     4. The bending angle of the forming wall of each pair of rollers cannot exceed the following values: thickness ≤lmm l~2.5mm  >2.5mm, the bending angle is 30 ~ 45, 25 ~ 35, 20 ~ 30 (degrees). The large value is used for the first few pairs of rolls, and the small value is used for the next few pairs of rolls, considering that the metal hardens after the material passes through the first few pairs of rolls.
     5. In a pair of rollers, the corner of the arc at the bottom of the contour must not exceed 45.
     6. The vertical bending cannot be performed at the same time as the arc bending at the bottom.
     7. It is recommended that the inclination angle of the upper shaft roller is 1.5 ~ 2 degrees larger than that of the lower roller.
     8. When the bending inner diameter is very small, in order to make the bending of the material easier and to calibrate the position of the bending line, you can cold-roll a concave contour groove on the strip in advance. Therefore, it is necessary to make protrusions with a height of (0.3-0.4) seconds on the corresponding rollers.
     9. The rollers of the last forming platen should properly take into account the elastic recovery value of the pressing.
     In order to avoid the profile produced by the equipment, a discharge guide is installed to straighten the profile after it is separated from the last roll. When cold bending equipment is designed for the forming process of a specific product, the factors that should be considered include forming passes, strip width, roll design, forming roll parameters and forming roll material.

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