Working here at Baileigh, we get to talk to people from many different industries, and get to see many different rolling applications. From Engineers and their Industrial applications like building bridges and giant structural steel to small weld shops doing ornamental projects and spiral staircases we see it all. My personal favorites are ornamental and architectural applications.
These machines have several different names depending on where you are from and who you are talking to. Some common references include roll benders, angle rolls, ring rollers, pyramid benders, section benders, tube and pipe rollers, and profile benders. The list can go on and on.
All of Baileigh’s roll benders come equipped with our “standard” roll sets. This tooling consists of a series of large hardened spacers in several different sizes and thicknesses. This allows the user to configure the tooling to fit any material with a square edge. This standard tooling allows you to roll square, rectangle, flat bar, angle, C channel, I beam, some solids, and some extrusions. Tube and pipe rolling requires special roll sets for each individual size.
Roll bend tooling is available in hardened steel (smooth and knurled) or nylon. Nylon roll sets help to minimize any scratching or tooling marks on the rolled material. They are popular with stainless or anodized aluminum section and angle bending applications.
Here are some common questions we field on a daily basis.
How does a roll bender work?
A roll bender works by introducing pressure and creating “pinch” as material is being driven or rolled through the roll sets. This force is applied to the material by changing the distance between roll center lines with either the top roll (single pinch) or bottom rolls (dual pinch).
Is section and bending hard to learn?
Absolutely not! Angle bending is a simple process that can be learned by even a novice in a couple of hours.
How many rolls are driven?
Our manually adjusted (top roll) benders have 2 driven rolls on the bottom. Hydraulically adjusted roll bender utilize 3 driven rolls. Keep in mind that the more difficult the material is to bend, the more “traction” is needed to move the material through the tooling. This is one of the major advantages to a hydraulically adjusted roll former.
How do I repeat parts on a roll bender?
It depends on what type of machine you have. Our hydraulic machines feature a digital readout with a memory. This memory setting allow the operator to set a single stop point for the adjusted roll. When the desired radius is achieved, just push a button and it will save that location. This number indicates how many inches (or millimeters) of pinch you are creating. The greater the pinch, the tighter the radius of your finished material.
There are several ways to repeat parts on a manually adjusted roll bender. You can make a template of some sort and roll your material to match the template. Also standard is a scale attached to the top roll that shows how many millimeters of force have been applied to the rolled material. When you reach your desired radius, remember that number and roll to that same spot next time.
What is the difference between a single pinch angle bender and double pinch angle bending machine?
A single pinch machine applies its force through the adjustment of the top roll in relation to the fixed lower rolls. A double pinch machine’s top roll is fixed, and pinch is crated by forcing the bottom rolls up around it. A double pinch machine has the ability to reduce the amount of “flat” material left after the roll bending process is completed as the material can be pre-bent much the same as a plate roll or slip roll.
How do you coil material?
Coiling is a simple process whereby the lateral guide rolls are adjusted away from the machine, causing the material to push away from the framework of the machine as it operates. Doing so causes the finished material to loop around and “coil”.
Can I use this angle bender both vertically and horizontally?
All of our roll benders can operate in either the vertical or horizontal position. This adjustability allows you to lay the bender on its back (horizontal) for large radius work where overhead space and operator efficiency come into play. Baileigh pyramid benders require no changeover to operate in either mode.
While I hope this has been informative for you, the information here is only the tip of the iceberg when it comes to section bending and roll forming machinery. The possibilities when profile bending is as limitless as the imagination. Should you have any further questions or comments regarding the information contained within this blog, or just want to receive some more information on Baileigh Industrial angle bending machines, feel free to give our qualified sales team a call. We would love to hear from you and help get your ideas off the ground!