roll bending accessories di acro

8/9/2019 Roll Bending Accessories Di Acro

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machines

LD & HD ModelsDesigned for the productionof larger, heavier gauge parts.The drop arm and the lower rollare positioned pneumatically onall LD machines and hydraulicallyon the HD models.(See pages 20-21 for standardand optional accessories).

Model V-1006The unique design of thecantilevered rolls mounted in avertical position, allows the partsto simply drop from the machineat the end of the rolling cycle,greatly increasing productivity. Itsshort, sturdy rolls are ideally suitedfor narrow parts such as clamps,brake bands, hole saws, lightfixtures, etc.

If you would like to seeour machines in action,

call us or check out the videoon our web site!

www.acrotechinc.com

Every model in Acrotech’s unique line of Two RollBending Machines is designed and built for productionand precision. These machines will roll a variety ofmaterials and configurations into cylinders with virtuallyno flats on the ends!

Models 1212, 1618 and 1824Built to meet the demands of production involving small, light gauge parts.Pneumatic lock-up is standard on all models for increased productivity.120V 1PH standard wiring simplifies installation. 220 or 440V 3PH wiringis also available.



Three Roll,Pinch-Type System:

Material

Steel Rollers

Flat area

Adjustment A d j u s

t m e n t

Two Roll,Steel Urethane System: Rotation of both rollsproduces accuratecurving and rollingof complete or partial

cylinders in one pass!

MaterialTop shaft

Slip-ontube

Bottomshaft

K•Prene®urethane

Three Roll,Pyramid-Type System:

Material

Steel Rollers

Bending Roll

Adjustment

Basic Machine ConstructionThere are two basic frame designs:

1) Horizontal 2) Vertical

LD, HD, 1618, 1212 & 1824 Modelsdepict a typical horizontal roll-bending machine . Its major partsinclude the bottom, urethane-covered roll, the top (steel) roll, andthe overarm, which can be opened and closed to facilitate theremoval of a finished piece part. (See page 17 for models).

Model V-1006 depicts a typical vertical roll-bending machine .The operation of this machine is basically the same as that of thehorizontal one, except that in this case, piece parts are loaded andunloaded vertically. In general, the vertical machine is faster than thehorizontal one, but it is limited to rolling piece parts that are shorter.(See page 17 for models).

In every case, steel plate and steel weldments are used in the frameof the machine. This provides sufficient rigidity and, at the same time,resiliency, necessary to roll parts of varying thickness.

Two Roll vs. Three Roll ProcessNote that the drawbacks of the three roll systems, whether pinchor pyramid type, are that the work piece is not confined during thebending process, i.e., bending takes place “in the air.” When rollingparts this way to some desired shape and tolerance, several passesmight be required with roll adjustments necessary after each pass.This is relatively slow and requires considerable skill on the opera-tors’ part.

The Two Roll PrincipalThe Two Roll Principle method is comprised of a steel top roll anda urethane bottom roll. A segment of this top roll is pushed intothe urethane bottom roll, and this deflecting volume of urethanefunctions the same as hydraulic fluid in a hydroforming process,exerting very high pressures against the steel roll. When sheetmetal is inserted between two such rolls, the urethane wrapsthe sheet metal tightly against the steel roll (similar to a radiusforming urethane press brake die), and since the urethane rolleris driven, the sheet metal is roll formed into a precise radius.

Allowing for natural spring back of the material, this radiusremains uniform irrespective of whether the shape of the partbeing formed is a complete circle, or is only a segment of a circle.In most applications this will eliminate the necessity of eitherpre-forming or cutting off the ends. The flat spots on the leadingand trailing edges are very minimal (approx. one to four materialthicknesses, depending on the type of material). Otherwisedifficult-to-roll sheet metal parts, such as those with perforations,cut-outs, uneven feeding or trailing edges, embossed parts, etc.can be formed without kinking or fluting. Finally, the relativelysoft urethane surface will not mar or scratch finished surfaces.

Getting Parts WithDifferent RadiiIn all cases the radius of the rolled part is controlled by the radiusof the top roll and the natural spring-back of the material(So ACCurATE IS ThE PrESSurE of ThE Two rollSySTEM ThAT If, In A GIvEn run, PArTS wITh wronGrADuIuS STArT CoMInG off ThE MAChInE, ThE ThInGTo Do IS To ChECK ThE MATErIAl quAlITy, noT ThEMAChInE SETTInG). In other words, the machine has a “zero tolerance”, meaning thatvariations in the free diameter of the rolled part are due only tothe variations (hardness, temper and thickness of material) in thenatural spring-back of the material.

Some of the disadvantages of a Three Roll,Pinch-Type or Pyramid-Type system include: The ends of blanks must be pre-formed on other

equipment (or cut off which means material waste).

Flat areas may form between cutouts and perforations ina part, eliminating the possibility of making such openingswhile the piece part is flat, requiring more complex process.

Fluting or kinking of material will occur especially in partswith cutouts and perforations.

It is practically impossible to roll prefinished (polished,painted, enameled, etc.) material without the possibilityof damaging finished surfaces (cracking and scratching).

The Art of Roll BendingRoll-bending or curving, as defined here, designates the manufactureof sheet-metal parts that are rolled or curved into cylindrical shapesor shapes that have a smooth radius associated with them.



Model Model

Acrotech Di-Acro Std. Metric Std. Metric Std. Metric Std. Metric Std. Metric hp.1212 - 12 ga. 2.7mm 12" 305mm 3-1/2" 88.9mm 9" 229mm 22 670.6CMPM 1.01618 M1835 16 ga. 1.5mm 18" 457mm 3-1/2" 88.9mm 6" 152mm 15 457.2CMPM 1.01824 - 18 ga. 1.2mm 24" 610mm 3-1/2" 88.9mm 6" 152mm 15 457.2CMPM 1.0

LD-1418 A1835 14 ga. 1.9mm 18" 457mm 3-1/2" 88.9mm 9" 229mm 23.2 707.1CMPM 1.5LD-1118 A1840 11 ga. 3.1mm 18" 457mm 4" 102mm 9" 229mm 23.2 707.1CMPM 1.5LD-1224 A2440 12 ga. 2.7mm 24" 610mm 4" 102mm 9" 229mm 23.2 707.1CMPM 1.5LD-31618 A1850 3/16" 4.8mm 18" 457mm 5" 127mm 9" 229mm 19.8 603.5CMPM 3.0LD-1024 A2450 10 ga. 3.4mm 24" 610mm 5" 127mm 9" 229mm 19.8 603.5CMPM 3.0LD-1230 A3050 12 ga. 2.7mm 30" 762mm 5" 127mm 9" 229mm 23.2 707.1CMPM 1.5HD-31624 B2460 3/16" 4.8mm 24" 610mm 6" 152mm 12" 305mm 16.0 487.7CMPM 5.0HD-1030 B3060 10 ga. 3.4mm 30" 762mm 6" 152mm 12" 305mm 19.5 594.4CMPM 3.0HD-1236 B3660 12 ga. 2.7mm 36" 914mm 6" 152mm 12" 305mm 19.5 594.4CMPM 3.0HD-31630 B3070 3/16" 4.8mm 30" 762mm 7" 178mm 12" 305mm 16.0 487.7CMPM 5.0HD-1036 B3670 10 ga. 3.4mm 36" 914mm 7" 178mm 12" 305mm 16.0 487.7CMPM 5.0HD-1248 B4870 12 ga. 2.7mm 48" 1220mm 7" 178mm 12" 305mm 19.5 594.4CMPM 3.0HD-31636 B3680 3/16" 4.8mm 36" 914mm 8" 203mm 12" 305mm 16.0 487.7CMPM 5.0

HD-1048 B4880 10 ga. 3.4mm 48" 1220mm 8" 203mm 12" 305mm 16.0 487.7CMPM 5.0HD-1160 B6080 11 ga. 3.1mm 60" 1520mm 8" 203mm 12" 305mm 16.0 487.7CMPM 5.0HD-1672 B7280 16 ga. 1.5mm 72" 1830mm 8" 203mm 12" 305mm 22.9 698.0CMPM 1.5

V-1006 V 10 ga. 3.4mm 6" 152mm 4" 102mm 8" 203mm 22.0 6.68CMPM 0.75

Capacity mild steel

Working lengthof rolls

Diameter of top roll

Diameter of bottom roll

Rolling speedf.p.m. Motor

Roll Benders Specifications

Understanding One Pass RollingThe One Pass Acrotech method permits rolling segments of cylinders or complete cylinders from all types of sheet metal – finished, embossed,perforated, wire mesh, regular or irregular shapes up to ¼" thick in a SINGLE PASS. This can be done at production rates ranging from 100 to350 parts per hour on standard machines, to 1200 parts per hour on special machines.Parts 2” wide to full width of the machine roll to the same diameter.

The Two Roll rolling and curving machine has a rather unique construction feature. This is what we call the anti-deflection system and this systemeliminates the possibility of rolling bell-mouth parts, which is caused by roll deflection. The center shaft can deflect under pressure, while the outertube stays parallel. The two bearings used between the tube and center shaft are of double roller spherical type and are self-aligned bearings. Thisfeature is used both in the top roll and the lower urethane roll. Conventional Three roll machines will normally crown the rolls, trying to eliminate thebell-mouth condition.

The force package of the Acrotech Two Roll machine will consist of either a pneumatic or hydraulic package. The machine itself consists of a setof linkage that is powered into position by a hydraulic or pneumatic cylinder. Once the linkage is into position, it actually over-centers and mechani-cally locks the roll into position, thereby eliminating the need for the hydraulic or pneumatic system to provide the pressure. What this means is themachine is mechanically locked into position and this position cannot change with the entry of material, thereby giving you a repeatable part diameter.The drive package is a very simple and low maintenance system consisting of an electrical motor and gear reducer and a chain drive to another set ofsprockets, further reducing the rolling speed and then directly to the urethane roll. The reason we are powering the urethane roll is to eliminate anyslippage that would be caused by rolling oily material. The urethane roll itself is not affected by grease or oil; therefore, de-greasing of the sheet stockis not mandatory.

The Two Roll rolling and curving machine is a machine that is aimed at the high production market. Since each diameter part must have an individualsleeve or shaft developed to produce this part, it is not feasible to use this style of machine in an atmosphere where there are a very low number ofparts produced and a very high number of sizes. Rather, we are looking for a market where there are a high number of parts to be run.

Roll Bending Spring-Back Example:Commercial quality hot rolled and cold rolled steels in the 1020 carbon range have a wider tolerance of spring-back and are, therefore, subjectto more variation than the lower carbon steels in the 1010 carbon or lower range. This means that with commercial quality steels, a change canbe expected from one shipment to another, or even within the same batch of material being used. This change in spring-back will alter the freerolled diameter of the finished part. With the precision roller, compensating for spring-back variations can be accomplished by changing thediameter of the slip-on-tube being used.

Acrotech cannot be responsible for the variation in spring-back due to different material thickness or temper from the materialsubmitted for development or subsequent materials used.



Air Tanks Architectural DesignsCatalytic ConvertersChemical or Nuclear Industrial ContainersChimney FluesCommercial Vehicle PanelsCompressor Casing for Air ConditioningElectric Motor Casings

Exhaust SystemsFan BladesFire ExtinguishersGas or Fluid TanksHole Saw BladesLighting FixturesMisc. Ducting ComponentsMisc. Rings and Bands

Motor and Blower HousingsName PlatesPipe ClampsPressure Vessels & TanksSleeve BearingsTank Heater ElementsWashing Machine TubesWater Heaters

Acrotech machines best fit into an OEM type fabrication / manufacturing facility where high volume, consistent partsare required at low cycle times. Some applications include:

Roll Bending Applications

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Tooling Slip on Tubes – when the diameter required is larger thanwhat the top shaft will produce, a Slip-On Tube is used. The tubes are

developed per part size and increase the forming diameter capability ofthe top shaft. Quickly change the tube by simply slipping them on andoff the top shaft as needed. A Slip-On Tube will be required for eachspecific part.Slip-On Tube Support – facilitates removal of finished piece-part.

Adjustable in height, this accessory supports slip-on tubes to preventpinching curved cylinders against lower roll when removing finishedparts.Small-OD Mounting Fixture – required for rolling parts smaller indiameter than the standard top roll.Small-OD Shaft Assembly – available in various lengths and diam-eters for rolling material to a diameter smaller than standard top roll.Must be used in conjunction with Small-OD Mounting Fixture.

Auto Timer – for controlling partial curvature of material 90°,U-bends, etc. Can be used in conjunction with Part Ejectors forautomated rolling and part ejection. (not shown)Reversing Control – gives added flexibility for special jobs.(not shown)Part Ejector – for increased production, part ejectors and partfeeders can be developed for most parts.Motorized Roll Position Control – speeds the set-up from one jobto another. (not shown)

Additional Safety Features – can be custom built per customerrequests. Features such as light curtains, special guarding…etc

Tooling Slip on Tubes – when the diameter required is larger than whatthe top shaft will produce, a Slip-On Tube is used. The tubes are developedper part size and increase the forming diameter capability of the top shaft.Quickly change the tube by simply slipping them on and off the top shaft as

needed. A Slip-On Tube will be required for each specific part.Slip-On Tube Support – facilitates removal of finished piece-part.

Adjustable in height, this accessory supports slip-on tubes to preventpinching curved cylinders against lower roll when removing finished parts.Small-OD Mounting Fixture – required for rolling parts smaller indiameter than the standard top roll.Small-OD Shaft Assembly – available in various lengths and diametersfor rolling material to a diameter smaller than standard top roll. Must beused in conjunction with Small-OD Mounting Fixture. Permits rollingdiameters as small as one inch.

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OPTIONAL ACCESSORIES

OPTIONAL ACCESSORIES

LD & HD ModelsStandard E uipment and Optional Accessories (See page 17 for models).

Roll Position Control - single hand wheel provides quickparallel roll adjustment.

Rotating Counter - indicates roll position in increments forrepeat set up. (not shown)

Automatic Overarm – Operates sequentially with K•Prene®roll raising and lowering. Automatically locks in place.

Automatic Overarm Guard – protects operator from movingoverarm.Push-Button Control and Signal Light – buttons controlroll and overarm cycle. Light indicates when machine is readyfor operation.Guarded Foot Switch – leaves operator’s hands free to feedmaterial.Electricals – are UL Compliant. (not shown)Safety Knee Bar – provides additional safety for the operator.

Tripping the bar stops roller rotation, lowers overarm,disengages rolls, and shuts off power simultaneously.Electro-Hydraulic Control (HD) – for roll positioning andautomatic overarm; all models have motor driven rolls.(not shown)Electro-Pneumatic Control (LD) – for roll positioning andautomatic overarm. (not shown)Bearings – pre-packed and sealed in upper and lower rollassemblies. Each shaft is fitted with heavy-duty, self-aligningspherical roller bearings. (not shown)

Anti-Deflection System – prevents bowing in upper andlower roll assemblies, and provides for perfect cylindrical parts.(not shown)Feed Table – Machine Supported; units are adjustable forheight and feed angle and includes finger guard.

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STANDARD EqUIPMENT

1618, 1824 & 1212 ModelsStandard E uipment and Optional Accessories

Floor Stand

Motorized Roll Drive

Lower Roll Steel Core, Grooved K•Prene® Urethane

Manual quick-Release Lever

Single–Lever Roll Engagement – Adjustable

Adjustable Feed Table with Finger Guard

Guarded Electric Footswitch

Pneumatic Lock-up

Electricals are UL Compliant

STANDARD EqUIPMENT

roll bending accessories di acro

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