SECTION ROLLING PROCEDURE

SECTION ROLLING PROCEDURE

Operator:

Our operators have a minimum of one to two years’ experience. They also need to know maintenance requirements and operation of the equipment. 

The forming process requires one or two persons depending on the weight of part. One experienced operator or a helper. This is machine can be ran by one or two persons. If by two, both persons communicate with each other to perform the task.

Equipment:

Before use, the operator must inspect the equipment and check for prober operation. The machine needs to check for service (greasing, hydraulic fluid, and leaks). 

Drawing review 

The operator must review the drawing to understand the task at hand. The operator know the following:

  1. Material type and wall thickness

  2. Size of part (od of tube or pipe)

  3. Arc length

  4. Angle of bend

  5. Bend radius 

The following must be known to perform the task at hand.

Select tooling

Tooling selection is based on the drawings. The operator chooses tooling based on the section (angle, square tube, pipe, beam, channel, or any special shape) required.

Determine Capacity

Estimating capacity requirement is determined by operator and management. Management will use the section modulus to determine capacity. There are manufacturing charts available. This is important for a safe production of the part.

Installing the tooling

There are three shafts on rolls. The tooling is properly placed on each shaft and secured. Machine is ready to perform the task at hand.

 

First article 

Place a section into machine. Roll the section making a best effort to achieve a good part. Make adjustments accordingly until the part is right. Have the part QC’ed. Make notes of the first article. This helps the operator set the machine for production. Once the machine is set and the first article is signed off, then it time for production.

 

Production

 

After set up production can start. However don’t assume that every part will be correct. Not all material will bend the same. It is important to intermediately check parts.

Take notes of your set up procedure for future use. This will help later on and add to the bottom line

 

 

 

PLATE ROLLING PROCEDURE

PLATE ROLLING PROCEDURE

Operator:

Our operators have a minimum of one to two years’ experience. They also need to know maintenance requirements and operation of the equipment. 

The forming process requires one or two persons depending on the weight of part. One experienced operator or a helper. This is machine can be ran by one or two persons. If by two, both persons communicate with each other to perform the task.

Equipment:

Before use, the operator must inspect the equipment and check for prober operation. The machine needs to check for service (greasing, hydraulic fluid, and leaks). 

Drawing review 

The operator must review the drawing to understand the task at hand. The operator know the following:

  1. Material type and wall thickness
  2. Blank Size of plate (width and length)
  3. Radius or diameter
  4. Weight
  5. Special instructions 

The following be known to perform the task at hand.

Determine Capacity

Estimating capacity requirement is determined by operator and management. Management will use the section modules to determine capacity. There are manufacturing charts available. This is important for a safe production of the part.

Preforming Ends

The plate is put into the roll and each end is pre-formed to the specified radius. Each end must be      pre-formed correctly and checked with a template.

Wrapping

After pre-forming continue to roll the plate into a cylinder take multiple passes. Once rolled to butt fit the seam and tack. The operator can reroll after tacking.

 

Rerolling

After welding the operator may have to reroll the cylinder. The roll is opened and the cylinder is placed into the roll. The roll turns and the operator measured roundness in several places and applies pressure where ever needed. 

Take notes of your set up procedure for future use. This will help later on and add to the bottom line

 

Contact Paramount Roll to learn more about our plate rolling procedures

INDUCTION BENDING PROCEDURE

INDUCTION BENDING PROCEDURE

Operator:

Our operators have a minimum of one to two years’ experience. They also need to know maintenance requirements and the operation of the equipment. 

The forming process requires one or two persons depending on the weight of the part. One experienced operator or a helper. This is a machine that can be run by one or two persons. If by two, both persons communicate with each other to perform the task.

Equipment:

Before use, the operator must inspect the equipment and check for proper operation. The machine needs to check for service (greasing, hydraulic fluid, and leaks). 

Drawing review 

The operator must review the drawing to understand the task at hand. The operator knows the following:

  1. Material type and wall thickness
  2. Size of part (od of tube or pipe)
  3. Arc length
  4. Angle of bend
  5. Bend radius 

The following must be known to perform the task at hand.

Select tooling

Tooling selection is based on the drawings. The operator chooses tooling based on the section (angle, square tube, pipe, beam, channel, or any special shape) required.

Determine Capacity

Estimating capacity requirements is determined by the operator and management. Management will use the section modulus to determine capacity. There are manufacturing charts available. This is important for the safe production of the part.

Installing the tooling

An induction bender requires very little tooling. Most of the tooling is part of the machine therefore conventional. However, there are two tools that are interchangeable. The clamps on the arm. And the reaction rolls. This makes this machine desirable because there is no tooling required to charge for it.

Machine Operation

The material is placed into the machine. A copper coil that matches the section is connected to the induction heater transformer. The radius arm is clamped to the section. The induction heater is then turned on and a high DC current is induced into the coil. The coil is now trying to move the molecules in the material, therefore, creating friction heating it to a specified temperature. Temperature is determined by frequency. Once the desired temperature is achieved a clear heat ban accrues around the section. At this time variable speed hydraulics will conveyor the section through to coil to the desired radius. In some cases, quenching is required.

 

First article 

Once the part is finished the part is QC’ed. If the part does not pass then the part is reworked by cold bending processes and reQC’ed. Then adjustments can be made in the machine to minimize rework 

Production

After set up production can start. However, don’t assume that every part will be correct. Not all materials will bend the same. It is important to intermediately check parts.

Take notes of your setup procedure for future use. This will help later on and add to the bottom line

 

If you have more questions or would like to learn more about how we Induction bend here at Paramount Roll, please contact us

 

What is Mandrel Bending?

What is Mandrel Bending?

Mandrel bending is an industrial bending process used for Hollow Section Steel (HSS), in which the interior of the HSS is supported using a piece of tooling called a mandrel. In this process, the mandrel – a small metal shaft slightly smaller than the HSS inside – is placed inside the HSS, helping the operator bend the HSS to bend with very little distortion at the location of the bend. Mandrel bending offers extremely high-quality bends compared to other bending methods.

How Does Mandrel Bending Work?

By inserting a steel mandrel into a straight HSS, technicians preserve the interior dimensions as the HSS is bent into a rounded form. The rod is nearly as thick as the pipe workpiece, mitigating the risk of wrinkles, pinches, or collapsed diameter in the bend. This process has very tight bends, such as U-bends, without compromising the integrity of the HSS or sacrificing the quality of the bend.  Mandrel bending requires specialized machinery. 

The process involves several steps:

  • Technicians cut and clean the HSS in preparation for bending. 
  • The HSS interior is lubricated.
  • The mandrel gets loaded onto the machine and held in place with a rod.
  • HSS pipe gets loaded onto the machine by sliding it over the mandrel.  
  • A series of hydraulic wheels draw the HSS around the bend, with the bend occurring at the front of the end of the mandrel. 
  • The machine pulls the pipe slowly through the bend until the bending operation is complete, removing the mandrel from the pipe in the last few degrees of the bend.

With the mandrel inserted, the hollow HSS cannot collapse as it enters the bend. The final result is a very high-quality bend with minimal variation in the internal diameter of the pipe. 

The Importance of Mandrel Bending                          

Press bending and roll bending processes leave deformations in the bent HSS that can compromise the strength, functionality, and aesthetic qualities of the final product. The uneven surface also increases the risk of corrosion. In vehicle exhaust systems, these deformations may reduce overall system flow, which can cause overheating or poor air quality control. 

 

Mandrel bending creates smooth, rounded corners that maintain their interior diameter. This process ensures the HSS maintains its full integrity, improving its efficacy and service life. 

Mandrel Bending vs. Other Bending Methods

OTHER BENDING METHODS

Crush bending is a similar process to mandrel bending. While it doesn’t offer the same quality as HSS mandrel bending, it is more cost-effective if you have quality and is good for tighter radiuses than other bending methods. Crush bending applies pressure to the outside of the HSS or HSS to bend it into shape in a similar manner to mandrel bending, but without the interior support to preserve the internal diameter of the HSS. This method commonly leaves deformations and wrinkles, resulting in lower structural integrity and negative impacts on fluid flow.                                                

 OTHER BENDING METHODS

Though more expensive than crush bending, mandrel bending is generally preferred for any system that requires high-quality construction. This includes exhaust systems, coolant lines, process systems, and other systems that must safely transport heated or pressurized fluid.

Paramount Roll: A Leader in Mandrel Bending Solutions

At Paramount Roll & Forming, we specialize in high-quality metal forming services, including custom metal bending, custom metalworking, mandrel bending, and much more. Since 1962, our team has served clients across industries ranging from aerospace to public art. Contact us today to see how our specialized metal forming capabilities can benefit your project. 

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