PLATE ROLLING PROCEDURE

Operator:

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Our operators possess a minimum of one to two years of experience. They must also be knowledgeable about maintenance requirements and equipment operation.

The forming process may require one or two persons, depending on the weight of the part. An experienced operator or a helper suffices. The machine can be operated by either one or two individuals. If two people are involved, they must communicate effectively to perform the task.

Equipment:

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Before use, the operator must inspect the equipment to ensure proper operation. The machine requires checks for service, including greasing, hydraulic fluid levels, and leaks.

Drawing Review

The operator must review the drawing to understand the specific task. They need to know the following:

1. Material type and wall thickness

2. Blank size of the plate (width and length)

3. Radius or diameter

4. Weight

5. Special instructions

The aforementioned details must be understood to perform the task effectively.

Determine Capacity

Estimating capacity requirements is done by the operator and management. Management utilizes section modules to establish capacity. Manufacturing charts are also available. This step is vital for safe production of the part.

Preforming Ends

The plate is placed into the roll, and each end is pre-formed to the specified radius. It is essential to ensure that each end is pre-formed correctly and verified with a template.

Wrapping

After pre-forming, continue rolling the plate into a cylinder, which may require multiple passes. Once rolled to a butt fit, tack the seam. The operator can reroll after tacking.

Rerolling

After welding, the operator may need to reroll the cylinder. Open the roll and place the cylinder into it. As the roll turns, the operator should measure roundness in various places and apply pressure as needed.

Take notes on your setup procedure for future reference. This will assist later and contribute to overall efficiency.

Contact Paramount Roll to learn more about our plate rolling procedures.

Jeff Visser recalls the day he was introduced to the plate rolling process as a rookie operator in a job shop renowned for its rolling expertise. He spent months shadowing experienced technicians who shared valuable insights, such as adjusting rolls to reduce pressure. Eventually, he was tasked with operating a machine independently, setting up new jobs each day and overcoming various challenges.

As production manager at BEPeterson in Avon, Massachusetts, Visser ensures his operators, especially new hires, continuously learn by shadowing experienced workers. Since many plate rolling operators are nearing retirement, he hopes to pass on his knowledge to the next generation through presentations at events like PlateFab: Workshop & Tours, organized by the Fabricators & Manufacturers Association.

The editors of The FABRICATOR sat down with Visser to discuss the fundamentals of plate rolling. According to him, two crucial pillars stand out: understanding material properties and knowing how pressure from plate rolls impacts those properties.

The FABRICATOR: What critical elements of material properties should new operators understand?

Visser: Many new operators are unaware of the differences between materials like aluminum, steel, and stainless steel. Different grades of metals behave differently when rolled. For instance, aluminum grades range from T0 (very soft) to T6 (harder), and operators might encounter problems if they treat all aluminum grades alike.

Similarly, various steel grades show significant differences in tensile strength. It is essential for operators to understand these distinctions to avoid complications.

The FABRICATOR: Can you elaborate on how these differences affect plate roll setup?

Visser: Setup varies based on the type of plate roll. Using a common initial-pinch, three-roll system, the outboard roll moves up and down while the other rolls adjust to create the necessary pressure for forming.

Plate rolls must grip the material effectively, which is why the leading and trailing edges of the plate remain unbent during forming. Prebending these edges is an essential step before rolling.

Plate rolling largely revolves around controlling forming pressure. Softer materials typically require less pressure compared to harder materials. The operator must adjust roll positions based on the specific material grade being used to ensure effective results.

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For new operators, grasping these concepts can be challenging, but understanding material properties is crucial. For example, while T0 aluminum exhibits limited springback, T6 aluminum might spring back significantly after rolling.

When rolling overlaps in thin materials, operators must account for springback to maintain appropriate joint thickness during welding.

The FABRICATOR: How does plate rolling differ from press brake operation?

Visser: The type of plate roll influences this comparison. A variable-geometry plate roll features a movable top roll, whereas a fixed-top-roll design functions differently. In press brakes, bends occur consistently at the same location, while plate rolling may require adjustments for effective forming.

The FABRICATOR: What unique challenges arise from the hourglass and barreling effects during rolling?

Visser: The goal is maintaining parallel pressure across the roll. However, the structure of the plate roll can cause uneven distribution of pressure, leading to barreling or hourglass shapes. Operators must adjust pinch pressure or shim as necessary to correct these issues.

Ultimately, the plate rolling process remains an art requiring understanding of material behavior and experience to achieve the desired results, regardless of technology advancements.

A Plate Rolling Menu

The plate roll is one of the oldest technologies in metal fabrication, albeit not a typical mature technology. Various plate roll configurations have emerged in workshops over time.

During the PlateFab: Workshop & Tours event, Jeff Visser and Steve Bonnay presented basic operating principles of common plate rolling configurations.

Initial Pinch, Three Roll

This widely-used system involves introducing the plate to rolls A and B for gripping, followed by roll C performing the first prebend. The plate is then turned 180 degrees to prebend the opposite edge before all three rolls are used to close the cylinder.

Double Pinch, Three Roll

Initially, roll C is lowered while roll B is raised to grip the plate between A and B. Roll C then forms the first prebend, followed by positioning the plate between rolls A and C to perform the second prebend before forming the cylinder.

Double Pinch, Variable Geometry

This configuration features a top roll that moves vertically rather than being fixed. After introducing the plate, rolls B and C are moved horizontally to perform the necessary prebends before rolling the cylinder.

Double Pinch, Four Roll

Known for speed, this system grips the workpiece without removal between prebending and rolling stages, improving efficiency.

Urethane, Two Roll

Best for high-volume environments with thin applications, this setup uses a mandrel on roll A for shaping the cylinder radius. After setup, the operation becomes straightforward.

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