The core of the profile bending machine: The profile roller
The profile roller is a central component for processing profiles. They are interchangeable, so that a wide variety of profile types can be processed on a profile bending machine.
The challenge of profile bending
Profiles are long materials with a constant cross-section. They are produced as open, closed or solid profiles. Open profiles are flat strips, L-profiles, U-profiles, C-profiles or double-T beams. Closed profiles are round, rectangular, square or special profiles. What they have in common is that they are hollow on the inside. Solid profiles are, for example, railway rails or round semi-finished products for turned products.
With open or closed profiles, bending is a particular challenge. If the stress on bending is not controlled, there is always a risk of buckling with these profiles. Then it is usually unusable. In order to produce round or complex shaped profiles of consistent quality, a special design is required which reliably prevents buckling during the bending process. This is the performance of profile bending machines with integrated profile roller.
Special features of the profile roller
Profile rollers are solid, precision-manufactured steel bodies with hardened surfaces. They are designed for maximum compressive strength. This is necessary because the point stresses that occur during bending can be very high. The rotatability of the profile roller ensures that it does not cause any friction during the bending process. In addition, the rotatable profile roller keeps the long material movable during the bending process. This makes it possible to produce radii of practically any size. Hardened surface, precision manufacturing and rotatability together ensure that the profile is not damaged during the bending process.
A profile roll always has exactly the negative shaping of the cross-sectional geometry of the long material to be processed. This means that the contours of the roller and profile fit together exactly. This ensures low point loads and optimum distribution of the bending stress.
Before the bending process, the roller should always be checked for cleanliness and condition. Adhering dirt, burrs or grooves in the roller are inevitably transferred to the profile to be machined. Damage is then unavoidable.
Mode of operation of the profile roller
Profile rollers are components of three-roller bending machines. They are arranged in a triangle. The outer rollers are rigid. The middle one can be lowered between the two outer rollers. During the bending process, the middle roller moves lower and lower. The profile can be pulled linearly through the bending machine during the bending process. This produces particularly large bending radii. A slow, gradual bending process ensures a clean result.