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What is so strong about roll levelers?

  • JIUZH 

In sheet metal processing companies, the traditional method of leveling is no longer a cost-effective process. Whether hammers and flames, rollers or leveling presses, they are only superficial and cannot reduce the residual stresses in the material. These residual stresses in the material can have serious adverse effects in the subsequent processing of sheet metal parts. They can be released through stamping or laser cutting, leading to bending and deformation of the sheet metal part, resulting in time-consuming rework or even scrap, jeopardizing the entire subsequent process chain, slowing down the processing process and increasing production costs. The high degree of automation in sheet metal parts processing cannot be separated from the precision leveling process. Currently, there are hardly any sheet metal processing companies that can guarantee precision and efficiency in processing without the use of roll levelers.

Stress relief in the material using a roll levelerThe principle of roll leveling is simple and ingenious: the arrangement of the leveling rolls makes it possible to obtain a number of successive alternating bends in the sheet metal part. The degree of bending is greater at the beginning and the whole process is very similar to a decaying sinusoidal curve. After leveling, the sheet metal part is flat and almost all stresses are eliminated. As a result, there are no annoying surprises during subsequent processing. The number of leveling rolls depends on the thickness of the material, and one of the basic rules is that the more alternating bends are made in the roll leveler, and the smaller the diameter of the leveling rolls, the fewer residual stresses there will be in the processed sheet metal, and the better the leveling result will be. When selecting a roll leveler, it should be ensured that the leveling rolls are sufficiently supported to prevent them from buckling. In addition, the machine must be designed to be protected against inadvertent operation and be easy to clean and maintain, avoiding long downtimes that can interfere with daily production and thus increasing machine availability. Bending and leveling roll levelers are suitable for almost all common metal materials, such as plain steel, stainless steel, aluminum or copper. If you do not know the properties of the material you are using, you can determine whether your material is suitable for a roll leveler by means of a trial run. In principle, any metal that can be bent can be leveled, and this also applies to the processing of high hardness and high strength sheet metal. However, the processing of these materials requires the use of small-diameter leveling rolls and the application of high forces in order to shape them.

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