Rolling machine drawings. Rollers for a profile pipe. Rollers: principle of operation
Rollers are one of the most important devices in the metallurgical industry. They help to bend sheets of metal, pipes, as well as other oval and other parts. In addition, rollers are used in jewelry for accurate bending of products.
What are rollers, how three-roll models differ from four-roll ones, and how to make them with your own hands, we will describe below.
Rollers: principle of operation
The key working mechanism of the device is a rotating cylinder through which hot layers of metal are passed and bent. Rolling machines can be equipped with cylinders from 2 to 5 pieces, but three-roll and four-roll products are most often used.
The parts are bent by the action of the third rear roll, and the clamping radius depends on the distance between the top and rear roll.
Sometimes metal rollers break and need to be replaced. When working with iron, the machine must be constantly heated, and the layers of iron after the rollers go into the furnace, they are heated there, and then pumped again. After that, they go back to the machine.
After roller treatment the cross section of the metal decreases, and it becomes longer under the influence of the high temperature of the metal and the degree of pressure.
To obtain a cylindrical product, the rear shaft must be set parallel to the front, and to make a cone, the rear shaft is set at an angle relative to the front.
There are models of rollers with which you can process metal directly on the table, but they are not very functional. You can work with them simplify with fasteners. The cost of rollers depends on their dimensions. And if you decide to make a machine with your own hands, then you will save a lot.
The functions of modern rolling machines, home-made and factory, three-roll and four-roll, are as follows:
- the ability to bend pipes up to 160 degrees;
- work with metal pipes;
- deformation of pipes, regardless of their diameter.
Machine Applications
Rolling machines are widely used in the production of such things as:
- chimneys;
- air ducts;
- pipes;
- ventilation systems;
- drains.
Thanks to its compact size, rollers can be used anywhere, right at the construction site, and hand-held devices will not spoil the polymer coating of the metal.
For the food industry, crushing-type rollers are used, and for the chemical industry, sheet bending, sheeting and others.
Features of machine tools for metal
Without a rolling machine, it is impossible to give sheet metal a cylindrical shape, and pipe rollers help to equip the drainage system. Machines with forging cylinders are needed for cold bending of their metal blanks; also, thanks to the rollers, you can process:
- plastic;
- ductile metal;
- rubber compounds.
You need to choose one or another machine depending on the thickness of the metal:
- two-roll rollers include two parallel shafts, the upper one has a small section and is made of high-strength steel, and the lower one has a large section diameter and is made of rubber-coated steel. Depending on the pressure force of the pipe, its diameter at the outlet is selected;
- three-roll can be symmetrical and asymmetric, they are often used in the manufacture of ventilation, round drains and radius parts. In addition, three-roll rollers are used in the processing of products made of copper, iron, steel, zinc, etc.;
- four-roll structures equipped with an additional roll at the bottom to simplify the rolling process.
The most common rollers are three-roll and four-roll. So, three-roll have such distinctive properties:
- a sheet whose width is less than 6 mm will slip between the rolls;
- the rolling speed of the sheet should be a maximum of 5 m per minute;
- it is difficult to control the machine due to the lack of exact coordinates of the metal clamping point;
- affordable cost.
But four-roll rollers have the following characteristics:
Machine classification
According to the bending method, the rollers are:
- segmental, where the pipes are bent under the action of one pulling segment;
- mandrel, which deform thin-walled pipes;
- spring. Due to the presence of a spring, the plastic bends without deformation;
- crossbow, which are designed for pipes of one diameter or another.
Machine tools are divided into the following categories according to the method of use:
If you purchase or make a machine with your own hands for home small needs, then it is desirable that it has the following characteristics:
- mobility and low weight;
- compactness;
- economical in terms of energy consumption, since a powerful device can damage home wiring.
Making a machine with your own hands
Naturally, assembling a machine with your own hands will be very costly in terms of time and workload, but if you plan to use it for minor repairs, then a home-made assembly will be a more economical option than a factory model, costing from 20 thousand rubles and more.
When assembling the rollers yourself, do not make the following mistakes:
- do not allow cracks to appear on the metal profile;
- do not allow compression and stretching of the surface at the point of load on the structural part;
- do not compress or deform parts before work.
Before starting work, prepare the project drawing, materials and details. The work steps will be as follows:
Here is the finished product. As you can see, rollers can be purchased ready-made, or made by hand, having the required tools, drawings, and having the necessary skills.
The rolling machine consists of a massive base, feed and take-up shafts, a gearbox connecting them and a clamping device. The kinematic scheme of one of the design options is proposed in the figures.
Circuit specification:
1. Hand drive handle;
2. Pickup shaft;
3. Drive shaft;
4. Gear of the receiving shaft;
5. Drive shaft gear;
6. Foundation;
7. Side stand;
8. Shock absorber;
9. Tension plate;
10.Adjusting screws.
Gear design
The main structural elements are shafts.
Detailing.
Shaft and side stand.
Shafts must be made of steel and hardened. They should be turned on a lathe.
The length of the necks should be equal to the height of the ball bearings you have chosen, and one should be increased by the shank (the height of the handle mounting flange). The shank must have a diameter that allows the ball bearing to freely "pass" to the neck.
The situation is more complicated with the gearbox.
Detailing.
Gear.
If it is not possible to make gears (and this is possible only in the factory using special equipment) or to pick up a ready-made planetary gearbox to drive the shafts, then a chain drive from a bicycle is used. In this case, toothed gears - “asterisks” of the rear wheels of an adult road (the cheapest design, without bells and whistles and calipers) bicycle are installed on the axles of the shafts. In this case, it is necessary to perform milling work on the shaft neck to install the key.
We remind you that the shafts must rotate at exactly the same speed, since otherwise slippage of the processed material is possible (with all the ensuing unfortunate consequences). Therefore, new gears or ones that have not been in operation (without wear) should be installed. A spring-loaded chain tensioner with an "asterisk" from a small (children's) bicycle should be provided.
Pay attention to the compatibility of "asterisks" with a bicycle chain (a different module of gears is possible). To check compatibility, each gear should be “rolled” along the chain laid out on the table. If compatible, the teeth should easily fall into the links.
The chain is also better to use a new one. Along with the purchase of “stars” and a bicycle chain, you should buy a repair kit for it, which contains insert links and axle bushings. The chain, before installation, must be adjusted in size (in length) for our device. Here you will need the parts from this kit (how the replacement is indicated in the “Instructions for Use” of the repair kit).
Sheet metal rolling machine assembly technology
Assembly begins with pressing ball bearings (4 pieces) into sliders (4 pieces).
It is advisable to perform this operation in a bench vise.
Further, the shaft necks are pressed into the inner race of the ball bearings (inserted into the sliders). This is done on an anvil by the method of axial blows with a hammer through pads made of soft copper (another soft metal is possible: aluminum, etc.). Anyone who does not find the right ball bearings can press bronze bushings into the sliders, machined to fit his installation dimensions (taking into account the sliding fit for the shaft neck).
Two words about the foundation. As a base, depending on your needs and capabilities, any massive structure can be used: from a steel plate to a welded frame from a corner (or other profile).
The marking and installation of the side racks will be carried out "in place".
Assemble sliders (assembly with shafts) with side posts (4 pieces) and place on the base. When assembling sliders with racks, it is recommended to lubricate the guides of the latter with thick grease (for details on lubrication, see the end of the article). Check the free rotation of the shafts, and make markings for the installation of all side racks (rack sketch - see above). It is advisable to fasten the racks with the help of M 6 ... 8 bolts with a countersunk head (welding is not recommended - the entire structure will “lead”).
The sequence of mounting the side racks:
- install two racks on one side (any), check the free play of the sliders of this side and check the markings for attaching the racks of the other side. If necessary, adjust the markup;
- install one rack of the other side (similar to above), check the free play of the sliders (all!) and the rotation of the shafts. Check the layout of the installation of the last rack and, if necessary, adjust;
- install the last rack (similar to above). Check the free play of the sliders and the rotation of the shafts.
The resulting jamming is eliminated by alternately loosening the fastening of the side racks and placing wedges under them from scraps of thin tin or other suitable pieces of metal.
A shock absorber (made of hard rubber) is placed on top of the sliders and a clamping bar is placed on it. With four screws, this bar presses the shock absorber to the sliders of the receiving shaft and the last one to the drive shaft. During operation, these screws regulate the pressure of one shaft on the other.
A manual drive handle is installed on the shank of the neck of the drive shaft - you can use the handle from a manual meat grinder.
In this case, on the shank under its connecting size, “remove the flat” with emery.
You have assembled homemade sheet metal rollers, but it is too early to start using them.
Final operations
After assembly, be sure to remove the burrs (with a file or any other tool at hand) and “fill up” (blunt) the sharp edges. To make the tool pleasant to use, it should be painted. This way, in addition to aesthetic properties, you will increase its anti-corrosion protection. Paint can be used pentaphthalic type "PF". Before painting, do not forget to clean (including degrease) metal surfaces.
And the final operation is lubrication. Check for grease on the slider guides (you greased them during assembly). Lubricate adjusting screws and bearings.
You can use any grease (grease, lithol, grease, etc.).
What can be improved in this design
The design offered to your attention has an independent adjustment of forces on the side racks. From above, if desired, you can install a gearbox that will equalize these efforts, and your device will look something like this.
note
Please note that the dimensions on our drawings and sketches are indicative and cannot be taken as executive. The proposed design documentation is a hint for DIY enthusiasts. It is intended only to show you the "direction of movement." Therefore, some (non-responsible) nodes have not been fully developed structurally and are “farmed away” to you, those who like to experiment. Moving in this direction, you will be able, based on your needs and capabilities, to develop an acceptable for you executive design documentation (a set of sketches) with executive dimensions and think over your device manufacturing technology.
We wish you success!
Where can I buy
If you still decide not to do it, but to buy a finished machine, select the contacts of the sellers on the page "".
One of the most used machine tools in metallurgical production is a rolling machine (rollers). Using a rolling machine, you can carefully bend a metal sheet or pipe, give an oval shape to other metal products. In addition, such machines are widely used in the jewelry industry, as well as the food and chemical industries. Crushing rolling mechanisms are used to produce flour, and in the chemical industry, refining and sheet-bending mechanisms are used. Do-it-yourself rollers for a profile pipe can be made at home according to pre-drawn drawings. Moreover, such a machine will practically not be inferior in its technical characteristics to products manufactured at the factory.
The working parts of the rolling machine are cylinders. Giving the necessary shape to the metal is carried out by rotating cylinders and passing the metal between them. As a rule, rolling machines have from 2 to 5 shafts, but models with 3 or 4 shafts are the most popular and practical.
Shaft 3 is responsible for giving the necessary shape to the metal, and the distance between the rear and upper shafts provides the radius of rounding of the workpiece. The product is stretched and reduced in cross section due to the passage between the shafts. This is ensured by a sufficiently high heating temperature, as well as pressure, which is created using shafts. To obtain from a workpiece in the form of a cylinder, the rear and front shafts are adjusted in parallel, in the event that a product in the form of a cone is required, then the rear shaft is placed at a certain angle to the front.
According to the methods of bending, the following types are distinguished:
- Crossbow. They specialize in the processing of pipes of a certain diameter;
- Spring. They are characterized by the presence of a spring that allows you to bend the plastic without its deformation and additional damage;
- Segment. Pipe deformation occurs under the action of a certain segment;
- Dornovye. They are mainly used for processing thin-walled pipes.
There are also stationary rolling mechanisms. Processing can be done at home. The main disadvantage of such mechanisms is extreme discomfort during operation, since such machines do not have fasteners and must be held with a free hand during operation.
Before creating a homemade rolling machine, it is necessary to understand that the dimensions of the mechanism significantly determine its final cost. Therefore, it is necessary to take into account in advance the dimensions of the parts that will most often have to be processed. Machines that are used on an industrial scale have shafts that can bend pipes of various diameters at an angle of 180 degrees.
Areas of use
Most of the parts processed on rolling machines are cylindrical in shape. Therefore, their application is very diverse: downpipes, chimneys and ventilation systems. Therefore, home-made stationary rollers of small sizes are very convenient to use directly at the construction site. In addition, do-it-yourself rollers do not damage the polymer coating of sheet metal.
Rolling mechanisms
The most common orders for the rolling mechanism operator are the manufacture of gutters and ventilation systems. For such orders, as a rule, a thick layer is not required. Therefore, in this case, it is recommended to use rotary mechanisms that have a wide range of processed thickness of metal products: from 0.1 to 120 millimeters. Plastics, plastic types of metals and rubber compounds are also processed on such devices.
Differences between common models
Machines that have 3 and 4 shafts differ from each other in the following parameters:
- For three-roll models sheet feed speed should not be higher than 5 meters per minute. They are also unable to process metal sheets thinner than 6 millimeters. Three-roll models do not have the exact coordinates of the clamping point of the machined surface, which makes it much more difficult to control the workpiece. But the advantages of such models include low cost.
- Four-roll machines they are highly reliable, due to good adhesion between the shafts, such machines provide increased safety during work (due to the impossibility of slipping the metal surface). The metal feed rate is more than 6 meters per minute. Four-roll machines are distinguished by the automation of the workplace. Due to the complexity of the machines and ensuring safety in the workplace, such devices have a fairly high price.
Variety of rolling machines
Manual machines. The stationarity and practicality of using this type of machine cannot but bribe. Simplicity in operation and independence from power sources make such devices truly indispensable. A clamp and several shafts, which are driven by a chain drive, are fixed on the machine bed. Of course, it must be understood that such rollers are not intended for large-scale or industrial use, otherwise the service life of such devices will be quite short. With the correct use of manual rolling machines, a number of advantages can be distinguished:
- Low cost;
- Possibility of dismantling the upper shaft;
- Available adjustment of the lower and rear shafts;
- Small dimensions;
- The reliability of the device due to the simplicity of the design.
Such mechanisms are widely used by jewelry workshops. The rotating cylinders are made from carbon alloy steel for added strength.
Hydraulic Models. They have a hydraulic drive, which is characterized by high power. It has high performance and high weight.
Electrical units. They are distinguished by high performance due to the use of high power electric drives. The principle of operation is identical to manual rolling machines, the difference lies only in the presence of an electric motor.
Requirements for homemade rollers
Rolling machines at home must meet the following requirements:
- Mobility. The machine should not be bulky and have a lot of weight to ensure its mobility;
- Profitability. You should not use a high power machine unless absolutely necessary, because powers of 20-25 kW can damage the wiring. 1.5 kW is the best option, with good throughput and low energy consumption.
Assembling the machine on your own
When assembling the machine with your own hands, it is necessary to prepare all the necessary tools, pre-prepared drawings of the machine and materials. It is desirable to have experience in the mechanization of devices and apparatuses, as well as to take into account a certain sequence of actions:
- Manufacturing starts from the ground up. That is, from the bed. As a bed, you can use a small frame assembled from pipes;
- In the upper part of the profile, as a rule, deformation elements are installed. For its reliable fixation, a threaded clamp is used. The support is made in the form of the letter P, followed by fixing the lower part in the bed;
- For the rotation of the device, the use of a transmission chain is necessary;
- After mounting the chain on the sprockets, it must be tensioned and work on the assembly of the feed handle must be carried out;
- For the production of rollers, steel is the best material;
- A prerequisite for such a mechanism is the ability to adjust the gap between the shafts;
- To fix the rollers to the frame, experts recommend the use of rolling bearings.
It is worth it or not to make a rolling machine with your own hands - it's up to you! It should be noted that the cost of finished units ranges from 500 to 1000 USD. Then, in calculating the profitability of the application, take the cost of the planned design, which may be several times cheaper than the new unit.
Rollers are one of the most important devices in the metallurgical industry. They help to bend sheets of metal, pipes, as well as other oval and other parts. In addition, rollers are used in jewelry for accurate bending of products.
What are rollers, how three-roll models differ from four-roll ones, and how to make them with your own hands, we will describe below.
Rollers: principle of operation
The key working mechanism of the device is a rotating cylinder through which hot layers of metal are passed and bent. Rolling machines can be equipped with cylinders from 2 to 5 pieces, but three-roll and four-roll products are most often used.
The parts are bent by the action of the third rear roll, and the clamping radius depends on the distance between the top and rear roll.
Sometimes metal rollers break and need to be replaced. When working with iron, the machine must be constantly heated, and the layers of iron after the rollers go into the furnace, they are heated there, and then pumped again. After that, they go back to the machine.
After roller treatment the cross section of the metal decreases, and it becomes longer under the influence of the high temperature of the metal and the degree of pressure.
To obtain a cylindrical product, the rear shaft must be set parallel to the front, and to make a cone, the rear shaft is set at an angle relative to the front.
There are models of rollers with which you can process metal directly on the table, but they are not very functional. You can work with them simplify with fasteners. The cost of rollers depends on their dimensions. And if you decide to make a machine with your own hands, then you will save a lot.
The functions of modern rolling machines, home-made and factory, three-roll and four-roll, are as follows:
- the ability to bend pipes up to 160 degrees;
- work with metal pipes;
- deformation of pipes, regardless of their diameter.
Machine Applications
Rolling machines are widely used in the production of such things as:
- chimneys;
- air ducts;
- pipes;
- ventilation systems;
- drains.
Thanks to its compact size, rollers can be used anywhere, right at the construction site, and hand-held devices will not spoil the polymer coating of the metal.
For the food industry, crushing-type rollers are used, and for the chemical industry, sheet bending, sheeting and others.
Features of machine tools for metal
Without a rolling machine, it is impossible to give sheet metal a cylindrical shape, and pipe rollers help to equip the drainage system. Machines with forging cylinders are needed for cold bending of their metal blanks; also, thanks to the rollers, you can process:
- plastic;
- ductile metal;
- rubber compounds.
You need to choose one or another machine depending on the thickness of the metal:
- two-roll rollers include two parallel shafts, the upper one has a small section and is made of high-strength steel, and the lower one has a large section diameter and is made of rubber-coated steel. Depending on the pressure force of the pipe, its diameter at the outlet is selected;
- three-roll can be symmetrical and asymmetric, they are often used in the manufacture of ventilation, round drains and radius parts. In addition, three-roll rollers are used in the processing of products made of copper, iron, steel, zinc, etc.;
- four-roll structures equipped with an additional roll at the bottom to simplify the rolling process.
The most common rollers are three-roll and four-roll. So, three-roll have such distinctive properties:
- a sheet whose width is less than 6 mm will slip between the rolls;
- the rolling speed of the sheet should be a maximum of 5 m per minute;
- it is difficult to control the machine due to the lack of exact coordinates of the metal clamping point;
- affordable cost.
But four-roll rollers have the following characteristics:
Machine classification
According to the bending method, the rollers are:
- segmental, where the pipes are bent under the action of one pulling segment;
- mandrel, which deform thin-walled pipes;
- spring. Due to the presence of a spring, the plastic bends without deformation;
- crossbow, which are designed for pipes of one diameter or another.
Machine tools are divided into the following categories according to the method of use:
If you purchase or make a machine with your own hands for home small needs, then it is desirable that it has the following characteristics:
- mobility and low weight;
- compactness;
- economical in terms of energy consumption, since a powerful device can damage home wiring.
Making a machine with your own hands
Naturally, assembling a machine with your own hands will be very costly in terms of time and workload, but if you plan to use it for minor repairs, then a home-made assembly will be a more economical option than a factory model, costing from 20 thousand rubles and more.
When assembling the rollers yourself, do not make the following mistakes:
- do not allow cracks to appear on the metal profile;
- do not allow compression and stretching of the surface at the point of load on the structural part;
- do not compress or deform parts before work.
Before starting work, prepare the project drawing, materials and details. The work steps will be as follows:
Here is the finished product. As you can see, rollers can be purchased ready-made, or made by hand, having the required tools, drawings, and having the necessary skills.
When carrying out repair and construction work in the private sector, it often becomes necessary to manufacture curved metal structures. They are used to create a frame for canopies, awnings, roofs of houses and arbors. Rollers for a profile pipe will help to solve this problem. These are devices that can be purchased in specialized stores or do it yourself. Consider the purpose of these devices, their varieties and specifications.
Only roll rolling on a special machine is the way to achieve such a result. Rollers are a mechanism consisting of several metal shafts and an energy source that sets them in motion.
Types of rollers
To give the rolled product the required shape, devices with the same mechanical part and different drives are used.
The choice of energy source depends on several factors:
- how much load is required to bend the metal;
- how often the equipment will be used;
- under what conditions is it planned to operate the pipe bender;
- own knowledge, experience in the field of design and work with iron.
Let's briefly consider the features of each type of drive.
hydraulic
Designs of this type are the most powerful and productive. As a rule, they are used by factories and factories engaged in mass production of curved profiles. Hydraulics is difficult to install on your own, but it creates a force sufficient to bend several large-section pipes at once.
At home, the design of a hydraulic profile bender is economically justified if it is planned to manufacture tens or hundreds of thick arched profiles.
Mechanical / lever
The products are portable and light weight. They are easy to carry from place to place and transport in the back. Increased pressure on the drive device is achieved by increasing the length of the lever. But, only profiles with a cross section of no more than 40 × 20 mm can be bent manually. These parts are suitable for the construction of the roof of the house and yard buildings. Arched profiles are used to make greenhouses covered with cellular polycarbonate.
Electrical
Using an electric motor to pass blanks through the shafts not only speeds up the process of pipe bending, but also saves the home craftsman from hard physical labor. The performance of electrical devices is high at low financial costs.
Assembling the machine on your own requires knowledge in the field of mechanics, electrical engineering and kinematics. Attention should be paid to security issues.
The principle of operation of the rollers
Rolling a profile pipe is a process of giving it a bend of a certain radius. To achieve this, it is necessary to place the workpiece between the rollers, which are located below and above. The workpiece is fed into the device and pressed down from above. After that, the shafts begin to rotate, moving the pipe forward and deforming it in the direction of the upper shaft.
If the degree of bending is insufficient for the project, then the degree of pressure is increased. The product is rolled through the rollers until the desired shape is achieved.
How to use rollers
This device consists of several static and moving parts:
- The base is a strong, heavy and stable frame, to which all other components and mechanisms are attached.
- On the frame there are rollers that act as a receiving and feeding device. The rollers are connected to the transmission to the power plant.
- A clamping device is attached to the base, which regulates the bending parameters. As a rule, manufacturers use a threaded clamp.
- A guide made of a metal sheet, reinforcement or steel profile is fixed on the frame. This part is necessary so that the workpiece does not bend in the horizontal direction.
Regardless of the energy source connected to the guide rollers, all devices work the same way. After turning on the equipment, the end of the profile is inserted into the hole between the rollers and fed forward. The captured workpiece passes along the shafts, where it is deformed. To reduce the radius, the clamp is twisted and the arch is re-run.
Is it better to buy or make your own?
The products manufactured at the factory have one thing in common - a high price. It far exceeds the cost of purchasing ready-made arches or ordering this service from professionals. With a competent approach to business, home-made pipe benders are superior in quality to factory counterparts.
The decision whether to make an expensive purchase or make a machine with your own hands follows after studying the market situation and assessing your capabilities.
What are on the market
The economic market provides a wide choice, differing in different parameters. Machines can have several rollers and even directions for simultaneous bending of several workpieces. The working area is equipped with a folding or adjustable shaft.
The drive is output to the upper and lower shafts or only one level. Electric and hydraulic devices provide for the possibility of manual rotation with an indication of how much effort is required for this.
Modern models of pipe benders are classified according to the following criteria:
- actuator;
- dimensions;
- type of metal being processed;
- profile wall thickness;
- diameter (mm) of rollers;
- maximum workpiece length.
Almost all machines have the option of reversing the rotation of the rolling mechanism.
DIY assembly
Tube bending rollers are a simple device. You can even make it from improvised materials left after repair and construction. In most cases, when deciding how to make rollers, novice craftsmen tend to choose a mechanical type design. It is easy to design and assemble with the help of welding, which is in every home.
Small in size, the machine is easy to move around the site, there is no need to build a separate room for it.
Drawing
Before you make a solid and functional machine for bending a profile, you need to make detailed drawings, the dimensions of all parts should be applied with high accuracy.
Roll patterns can be made on graph paper or on a computer. The choice depends on design skills. Based on the drawn up drawings, the need for building materials and tools is calculated. An estimate is made, equipment is selected and the missing property is purchased.
Materials and tools
To assemble homemade rollers, you will need the following tools and supplies:
- welding machine;
- grinder or cutter with discs for metal;
- roulette;
- electric drill;
- a set of screwdrivers and wrenches;
- square;
- core;
- oil level;
- hardware (corners, bolts, nuts, rivets);
- channel or I-beam;
- shaft blanks;
- profile pipes.
When choosing material for construction, it should be remembered that metals and alloys for rollers must be much stronger than steel of shaped pipes.
What is included in the design
The bed is made of thick and heavy rolled products.
The strength and mass of the base must correspond to the applied force when rolling the profiles. The assembled frame must be stable and strong so as not to sway during operation.
The clamping system is assembled in the shape of the letter "P". A threaded hole is made on the top crossbar to create clamping force. Another option is to weld a nut over the round hole. Subsequently, a bolt is inserted into it to adjust the clearance between the rollers.
The rollers themselves are equipped with rolling bearings, which are mounted on strong axles. The rollers are turned on a lathe, undergo a hardening cycle in oil.
The drive is made from bicycle sprockets and a chain. The sprockets are welded to the driven and driving shaft, after which they are connected by a chain. A gate with a sufficient force lever is welded onto the drive sprocket.
Filling with sand or water?
When the workpieces are given a strong bend, they are flattened and the geometry of the section is violated. In order to prevent this, hollow profiles are filled with a dense material that does not change volume under pressure.
The simplest solution is to fill the blanks with sand. It is spilled with water, rammed, and then plugs are welded onto the ends.
With water it is more difficult, since the plugs must be airtight. If the assembly takes place in winter, then the best solution would be to fill the pipes with water, close them with plastic plugs and freeze. This method is used in the manufacture of wind musical instruments.
Spring selection
Springs are used to reduce the effect of vibration from the electric motor on the rolling system. With strong vibration, workpieces can be shifted along the horizontal axis. The springs must be stiff to prevent the motor from swaying and at the same time reduce shaking. It is recommended to use at least 4 springs to fix the motor frame.
Cut and cook
The manufacturing process of rollers is carried out in the following sequence:
- Carrying out measurements and drawing markings in accordance with the schemes.
- Cutting rolled stock into blanks, cleaning the field for welding.
- Turning and hardening of shafts, installing bearings in them, attaching sprockets, fixing on the axis.
- Welding the frame with a rolling and clamping mechanism.
- Drive installation. It can be permanent or removable.
- Checking the performance of the machine.
In conclusion, the metal is cleaned of rust, its primer and painting. Moving parts are lubricated.
Process video
Watching a video of how to make rollers yourself will help novice craftsmen to easily cope with this work.
