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What is the strength of roller leveler?

  • JIUZH 

In sheet metal processing enterprises, the traditional leveling method is no longer an economical and cost-effective processing technology. Whether it is a hammer and flame, a plate rolling machine or a leveling press, they are all superficial and cannot reduce the residual stress in the material. These residual stresses in the material will cause serious adverse effects in the subsequent processing of sheet metal parts. They will be released through stamping or laser cutting, causing sheet metal parts to bend and deform, resulting in time-consuming rework and even scrap, endangering the entire subsequent process chain, delaying the processing process, and increasing production costs. The high degree of automation in sheet metal processing is inseparable from the precise leveling process. Currently, there are almost no sheet metal processing companies that can ensure precision and efficiency in processing without using roller levelers.

Using a roller leveler to eliminate stress in materials The principle of roller leveling is simple and ingenious: the arrangement of the leveling rollers allows the sheet metal parts to achieve multiple consecutive alternating bends. The degree of bending is relatively large at the beginning, and the whole process is very similar to an attenuated sinusoidal curve. After leveling, the sheet metal is flat and almost all stress is eliminated. As a result, there are no annoying surprises during subsequent processing. The number of leveling rollers depends on the thickness of the material. One basic rule is that the more alternating bends performed in the roller leveler and the smaller the diameter of the leveling rollers, the less residual stress will remain after processing of the sheet. , the leveling effect will be better. When selecting a roller leveler, make sure the leveling rollers have adequate support to prevent them from buckling. In addition, the equipment must be equipped with a protective design to prevent misoperation and be easy to clean and maintain to avoid long downtime that affects daily production, thereby increasing the utilization rate of the machine. Roller levelers that can both bend and level are suitable for almost all common metal materials, such as ordinary steel, stainless steel, aluminum or copper. If you do not understand the characteristics of the material you are using, you can determine whether your material is suitable for use with a roller leveler through trial processing. In principle, any metal that can be bent can be straightened, and it is also suitable for processing high-hardness and high-strength sheet metal. But processing these materials requires the use of small-diameter leveling rollers and high forces to shape them.

Roller leveling improves productivity and reduces production costs. The sheet metal processing market requires high quality. If the material contains defects from the beginning, it will hinder the operation of highly automated production processes. This results in an increase in production costs and limits the competitiveness of sheet metal processing enterprises. The application of roller levelers can effectively reduce rework and scrap rates. For example, sheet metal parts produced in laser processing plants may be deformed after stamping, which is not conducive to subsequent processing of process safety. After roller leveling, the sheet metal parts can be welded quickly and accurately, with minimal need for costly rework. Reduce working hours by 90% per year Data shows that by using a roller leveler, you can produce more sheet metal parts with consistent quality. The improvement of processing efficiency means the reduction of production costs, as shown in the case of a large supplier of a construction equipment manufacturing company: using traditional leveling methods, such as leveling presses, it takes an average of 20 minutes for a worker to process each workpiece. Leveling using hammering and flame heating can take up to an hour even for experienced craftsmen. In contrast, a roller leveler can level a large workpiece in less than a minute. Overall, using a roller leveler can reduce the total man-hours required to process 60,000 workpieces per year to about 1,000 hours, which is only one-tenth of the time required by traditional leveling methods. With the reduction of labor costs and the significant increase in production capacity, coupled with the most critical improvement of subsequent processes, the company’s annual cost savings potential can reach millions of yuan.

Currently, maintaining consistently high quality in a highly competitive environment is the primary issue that every company needs to solve. Therefore, sheet metal processing companies must move to a new level in leveling technology. The use of roller levelers is becoming more and more common in the industry, and in addition to lower process costs, it can also significantly save man-hours and production resources, creating room for winning new customers and new orders.

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