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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.

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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.

Roll leveling increases productivity and reduces production costs The sheet metal processing market demands high quality, and if the material is defective from the outset, this can hinder the operation of highly automated production processes. This results in increased production costs and limits the competitiveness of sheet metal processing companies. The application of roll levelers, on the other hand, can effectively reduce rework and scrap rates. For example, the sheet metal parts produced by the laser processing plant after stamping appear deformed condition, which is not conducive to the subsequent processing of process safety. After roll leveling, the sheet metal parts can be welded quickly and accurately, with minimal need for costly rework. Reduction in man-hours by 90% per year Data shows that you can produce more sheet metal parts of consistent quality by using a roll leveler. Increased processing efficiency means lower production costs, as shown in the case of a large supplier to a construction equipment manufacturer: With traditional leveling methods, such as a leveling press, it takes an average of 20 minutes for one worker to process each part. Leveling by hammering and flame heating can take up to an hour for even experienced tradesmen. In contrast, a roll leveler can level a large part in less than a minute. Overall, the use of a roll leveler can reduce the total number of hours required to process 60,000 parts per year to about 1,000 hours, which is only one-tenth of the time used by conventional leveling methods. With the reduction in labor costs and the significant increase in production capacity, coupled with the most critical improvements to the subsequent process, the company’s annual cost savings potential could be in the millions of RMB.
Currently, maintaining consistently high quality in a competitive environment is the number one issue that every company needs to address. Therefore, sheet metal processing companies must step up to the next level in leveling technology. The use of roll leveling machines is becoming more and more common in the industry, which, in addition to lower process costs, can result in significant savings in man-hours and production resources, creating room to win new customers and new orders.

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