Making a sheet bending machine with your own hands is not so difficult, but craftsmen, both amateur home-made workers and individual entrepreneurs who live by their labor, still use it little. Meanwhile, the price of only ready-made additional roofing elements - valleys, ridges, eaves strips - and drainpipes with gutters is several times higher than the cost of the material. The same applies to paintings (roofing sheets, completely ready for laying) with double-seam edging. And that's just roofing work.
Meanwhile, many craftsmen still prefer to either buy ready-made parts, losing money, or make do with a punch the old fashioned way, losing money. potential clients– modern products should not have a bad look. What's wrong here: economics, technology, prejudices? Or maybe just ignorance? Maybe you just need a clear drawing of a sheet bending machine that you could build yourself in a shed, and use it for a long time and successfully? Let's try to figure it out.
Among the main indicators (efficiency, productivity, simplicity of design), it is also necessary to determine durability, subject to stable performance results. At the height of the season, when the day feeds the year, there is no time to bother with repairs or adjustments, and with occasional use once a month, not every month you can do without special equipment, see below.
The minimum requirements are for a jack-of-all-trades who does roofing and tin work on a case-by-case basis when there are orders; Buying an industrial machine like this is expensive and won’t pay off. But then a homemade sheet bender must withstand at least 1200-1500 working cycles per season without deteriorating the quality of bending. There are more important point– corrugated sheet. More precisely, its independent production. It is worth special mention.
Qui prodest?
Translated from Latin - who benefits? Producing corrugated sheets yourself, at least for yourself, is a very popular material. Let's try to figure it out.
A manual pass-through type sheet bender (see below) costs about $2000. It seems that in a day or two a ton of 0.55 galvanization worth $1000 can be converted into 250 square meters. m of corrugated sheets, which would cost $1,400 to purchase. It would seem a direct benefit; especially if you don’t wait for a sale (the market is full of offers), but put it into action yourself. Yes, but not so.
Corrugated sheeting is not rolled in one pass - the corners sometimes end up being overtightened. Intercrystalline bonds in the metal are broken; The rough area of the bend cannot always be identified by sight or touch, but soon a crack will spread from it. Who will give an order now without a guarantee? Please correct it. For our own, of course.
You can reduce the pressure, but then the wave will be non-standard. The customer may not know the standards, but he will immediately see that the material is not the same. Put it, be as polite as everyone else, or - goodbye, I’ll turn to someone else. And I’ll tell my friends and acquaintances. Should I roll each sheet in several passes, changing the clamp or rollers? What kind of productivity and profitability are there?
A line (actually a rolling mill) for corrugated sheeting is a complex unit, see fig. Pay attention to the number and configuration of rolls. The purpose of such a system is to disperse residual stresses across the sheet so that they do not go beyond acceptable limits. Therefore, the wave is formed gradually.
Such equipment costs at least $20,000 and is made in China. Stable quality finished products guaranteed only for specific steel grades specific manufacturer. Power consumption – from 12 kW. Those. need specialized production area with a corresponding limit on electricity consumption and, although one operator is sufficient for maintenance. Is there an unsatisfied demand for corrugated sheeting in your operating area (simply, in the surrounding areas available to you) that allows you to pay for it all in an acceptable time frame? And are you ready to start a very serious business with fierce competition?
Note to masters
Of course, it’s not easy to “recapture” $2000 for an individual master. Therefore, let’s try to figure out how to make a sheet bending machine yourself. Not for corrugated sheeting, but for a variety of roofing and tin work, on which you can also make a good living and raise some money to start something more serious. Non-standard little things fundamentally cannot be unified, but are always needed. And a homemade sheet bender can be a very good help here.
About purchased handbrake
To put an end to the “company” (the article is not an advertisement) and move on to homemade products, let’s briefly look at what you can buy if you still need it. The market is clearly dominated by TAPCO and VanMark. And the domestic SKS-2, produced in Orsk, is almost unknown. In terms of price, they are all about the same; The width of our working area is 2.5 m versus 3 m for foreigners, but this is not a defect. 3 m is designed for the inch system of measures (10 feet = 3.05 m), and in metric 2.5 m is just more convenient.
But the Uralian is a passing type; you can, for example, pull gutters up to 90x90 mm. The traverse is raised/lowered using eccentrics, no need to turn the flywheels. Supplied with cutting knife. User reviews are not only favorable, but enthusiastic. The general tone is “an irreplaceable hard worker.”
History repeats itself. About similar situations in live Nikita Khrushchev spoke on CT after his trip to America (when he was there hitting the UN podium with his shoe and threatening to make everyone’s motherfucker). They say that in the States they know how to sell any obscene rubbish, but here we cannot properly serve the necessary good things.
Bending machine designs
Drive
Bending and pressing equipment with a mechanical drive (a flywheel with a friction clutch and a crank or a falling load with a system of blocks, cables and levers) has high efficiency, but is still a thing of the past. The mechanics give a sharp impulse (blow) at the beginning of the working stroke, and towards the end it weakens. For bending/pressing, just the opposite is needed.
The efficiency of an electric drive decreases rapidly as the size of the workpiece decreases. To form corrugated sheets on the mill described above, 12 kW is enough. To make a flange on a roof picture, you can’t get by with less than 1.5-2 kW. The point is that external characteristic electric motors AC(except for three-phase ones with a wound rotor - complex, expensive, requiring regular maintenance) quite tough. Due to the resistance of the bending metal, the engine does not increase the torque on the shaft, but on the contrary, the rotor slip increases and the torque decreases. And energy consumption increases.
The hydraulic drive, in theory, is ideal - the hydraulic cylinder itself automatically adjusts its force to the resistance of the part. But precision hydraulic systems are complex and expensive. Even an experienced designer would not undertake to distribute the force of, say, a car jack evenly along the entire length of a meter-long bend, nor would he be able to synchronize the work of two or more using improvised means.
The handbrake remains, and this is not so bad. If you design a sheet bender in such a way that, as in swing rowing or powerlifting, the strongest and most enduring muscles work (biceps, latissimus dorsi, thighs, calves), and the reaction (recoil) of the machine presses the feet to the floor, then the work, due to its cyclical nature, will not will be exhausting. But a skill will be developed that will give accuracy and productivity.
For example: The average person running up a flight of stairs can develop about 1 hp in 1-2 seconds. But already on the third flight, the muscles will switch from oxygen to glycogen, lactic acid will begin to be released, and fatigue will hit the body. You need to take a break to move on.
Note about sports: The rowers are lean, because the “kendyukh” makes it difficult to give a full push with the body. But for weightlifters, the “callus,” on the contrary, helps them maintain balance when jerking. But the muscle function of both is largely similar.
Schemes and purpose
Listogib is a rather general concept. The design of a sheet bender depends on its purpose. According to the nature of the work, you need to choose a homemade scheme, see fig.
At pos. A - a method familiar to everyone who has done at least a little plumbing. This way you can simply bend sheets up to 0.5 m wide by hand. If the bend length is no more than 200-250 mm, then the base can not be attached to the workbench, but together with the pressure beam and the part can be clamped in a vice. The bend turns out well if you press the traverse lower, as shown in the force diagram, and move it slightly forward, as if smoothing the bend. Most designs of homemade sheet bending machines are based on this principle; we'll get there yet.
Due to the elasticity of the metal, it is not possible to bend the sheet exactly 90 degrees, so spacers made from a strip of metal are used, as shown in the inset. Why are there channels on the cut and not corners? Next we will consider this issue; The seemingly simple design has significant nuances.
Pos. B shows how a press brake works. Press like a press: bed-die-punch-hydraulics-impact-ready. These are used only in industrial production with a developed labor protection system: complex, expensive, require qualified care and are extremely dangerous. A sheet that slips due to improper filling or equipment malfunction can cut off a person’s arm or head.
At pos. B – broaching (pass-through) sheet bending machine. By changing the relative position of the rolls, you can set the bending radius of the sheet. The walk-through sheet bender can be either manual or electrically driven. Those that go on general sale are usually multifunctional:
- Smooth rolls are intended for tinsmithing work - bending blanks for casing shells, sections of wide pipes, etc.
- The rollers can be replaced with complete profiled sheet-bending rollers designed for pulling roof extensions - ridges, valleys, gutters and flanges.
- Also, many models are equipped with a support, a clamp and a traverse for manual bending of sheets.
These are the kind of sheet metal benders that sell for $2000 or so. Many are equipped, or can be purchased later, with shaped rollers for corrugated sheeting, but, as has already been discussed, you cannot “drive a shaft” for sale on them. You can roll a piece if you need it now, but there is no point in buying a whole sheet.
Note: There is another interesting type of sheet bending device, but due to its high usefulness and relatively low cost, a separate section will be devoted to it.
Let's take on the sheet bending machine
Let's start making our own sheet bending machine by developing the simplest specifications. And we will calculate the latter, in addition to the longevity criteria described above, based on the expenditure of muscular energy that an average-sized adult man is able to produce day after day without deterioration in health. Of course, simplicity and low cost of design are also not in last place. Also, in terms of weight and dimensions, the machine must allow transportation in a passenger car and use directly at the work site. It turns out:
- The width of the bendable sheet is up to 1 m.
- The thickness of the bendable sheet is up to 0.6 mm galvanized; up to 0.7 mm aluminum and up to 1 mm copper.
- The number of operating cycles without readjustment and/or repair is at least 1200.
- Bending angle – at least 120 degrees without manual adjustment; This is necessary for folds.
- The use of special steels or non-standard workpieces is extremely undesirable.
- Welding - as little as possible; parts/assemblies lead from it, and the welds are fragile and quickly tire from alternating loads.
- Metalworking on the side (turning, milling) is also as little as possible, it costs money.
Let's face it: drawings of finished structures that meet all these requirements are not found in publicly available sources. We will try to improve one, widely known, and, in principle, very successful.
Let's bring it to mind
Cut
The design principle of this sheet bender is clearly visible in the cross-section (see the figure on the right and the list of items). Its main advantage is good ergonomics. With such a working stroke, the muscles work as they should and the feet are pressed to the floor, which will give a stable result even for an inexperienced operator. And the maximum bending angle is 135 degrees, which has a large margin for any conceivable and inconceivable elasticity of the sheet being bent.
- wooden pillow;
- support beam – channel 100-120 mm;
- cheek - from a sheet of 6-8 mm;
- workpiece;
- pressure beam (clamp) – welded from angles 80 and 60 mm;
- traverse axis – 10 mm pin;
- rotary traverse – angle (?) 80-100 mm;
- handle – 10 mm rod.
The material of all parts is ordinary structural steel. But already here it is conditionally shown that it is better to replace the traverse from the corner with a channel of the same standard size. Why? Let's take a closer look, this is important for what follows.
The reaction (recoil) from the sheet being bent to the traverse (and the clamp, but more on that later) is uneven across the width. In the middle, where each elementary (tiny; this is a hint of differentiation and integration) section of metal is surrounded on all sides by the same metal, it is maximum. At the edges, where there is no side support, it is minimal.
The second point is that the sheet, although thin, is of finite thickness. Stresses in the workpiece will spread and be reflected on the edges. As a result, the diagrams of the load on the traverse and the clamp will take the shape of a bow with a string. On the free (distant) edges of the corner shelves, such a load will produce a tensile force, but metal does not work well in tension - it quickly gets tired of it. A DIYer who has built such a machine soon discovers that the corner in the middle is bent and the fold in the middle is swollen.
The side flanges of the channel are wedge-shaped, and it has fillets that are more developed than in the inner corner of the corner. This, firstly, smoothes out the diagram - the bow string is barely taut. Secondly, the seemingly extra side flange of the channel absorbs tensile stresses, which are converted into compression at its free edge. And the metal holds compression - wow!
The result of the calculation is impressive: if a traverse from a corner can withstand at most a couple of hundred bends, then a channel of the same width can withstand more than 1200! What is 200 bends? One or a little more roofing at best. At the height of the season, when customers are standing in line, the machine gets damaged and the work stops. And 1200 operations means the season will last. In winter, there will be time to straighten it, or replace the traverse, or, after calculating the proceeds, buy a “company” with a guarantee of service life.
Detailing
The next figure shows details with a list of positions. Here, not only do some shortcomings need to be eliminated, but some things can be further improved.
- clamp – corner 40-60 mm; M8-M10 screw with knob and heel;
- cheek;
- support beam;
- bracket – corner 110 mm;
- pressure beam;
- traverse axis;
- traverse
Pressure beam
First of all, about milling the lower surface of the clamp onto a plane. It is needed for any design, and the permissible unevenness is no more than half the thickness of the sheet being bent (minimum! We will consider it equal to 0.2 mm). Otherwise, the sheet will creep (flow) under pressure - and again there will be a pot-bellied fold.
So for anyone who has ever done anything with metal, advice on smoothing the clamp with a file or grinder will only cause a grin. It needs to be sent for milling. Moreover, AFTER the welding of the entire assembly, when everything that could have happened has already happened. Otherwise, the work and payment for the router will be in vain.
Further, everything that was said above about the load on the traverse is also true for the clamp. And its most loaded part - the leading edge - is not supported by anything. It is impossible to reinforce or replace the entire assembly from a corner with a channel: the bend angle will be no more than 90 degrees.
As a result, after the same 100-200 operations, the machine will “open its mouth” (or “smile”, if you prefer white rather than black humor) and the same swollen bend. The clamp will not bend upward; in this respect it is well fortified. But the metal on the leading edge will simply flow from fatigue.
A cross-section of the clamp design, which is equal in durability to the traverse, is shown in the inset at the top right. The base is a steel strip 16x80 mm. The front edge is milled at 45 degrees, and a chamfer of at least 2.5-3 MAXIMUM thicknesses of the steel sheet being bent is removed using the same milling cutter, i.e. 1.5-2 mm. From the upward deflection, the clamp is reinforced with a six-point angle for welding. Milling, again, after all welding work.
The idea is this: if in the previous design the leading edge worked half in bending (which for metal is even worse than tension), then in the new one it works only in compression. At the same time, the general support on the edge will not allow it to leak soon.
Note: if somewhere nearby in a landfill an ancient ruined lathe– the problem of the traverse with the clamp is solved once and for all. From the frame you can cut pieces of the desired configuration, made of special steel and excellent precision.
In terms of the number of working operations for manufacturing, both clamps are equivalent: cutting, drilling, welding, milling. The material consumption of the new clamp is higher than the old one; Three standard sizes of workpieces are required for both. But the durability ratio is the same as for the two types of traverses described above.
Table mount
The next point is clamps. The author of the design, of course, clearly understands the role of the stiffeners, but fragility and rapid fatigue welds seems to have been overlooked. And the working stroke of the traverse gives a variable tensile force on the clamps with lever arms of 10:1 or more. If the clamp breaks, the work is over, even if everything else remains perfectly straight. The machine will lift itself, not bend.
Why not give up clamps altogether? And then cheeks will not be needed, and welding is for both. How to do this?
- Extend the support beam laterally beyond the table.
- Select U-shaped eyes at its ends.
- Fasten to the table with bolts somewhere around M10 with shaped nuts - claws.
The second option is holes in the legs without threads. The bolts are turned over and tightened with wing nuts. A little more expensive, but more convenient to use.
Cross-beam fastening
Here the question arises: how to attach the traverse, since the cheeks are no longer there? And they are not needed. Firstly, the design is non-removable, and the traverse will have to be changed once a year. Secondly, remember, we need an accuracy of about 0.1 mm, otherwise the fold will swell. How soon will the pin break a simple “hole” in the cheek by a large amount? The question is rhetorical. And at the same time I apologize to my fellow engineers: I, of course, know that someone has a hole somewhere, and in metalworking there is a hole.
But how then to attach the traverse? Butterfly door hinges; lower right inset in Fig. They do not require insertion (they were designed specifically for metal doors), and two of these hinges hold the door armored against a burst of Kalash or F-1 grenades. It takes six healthy men to put one on.
As for accuracy, most butterfly loops easily pass the “choke” test. If you quickly separate the loop, you can hear a smacking sound from the air replacing the vacuum formed when the pin was pulled out. That is, the fit of the parts is very tight, but they rotate easily.
The butterflies are secured with countersunk screws. If you put it on a red lead, the traverse will stand indestructible. Opening angle – 160 degrees. Probably, the inventor of butterfly hinges once made a homemade sheet bender. It's a joke.
Assembly
Finally, in front of you is an assembled sheet bending machine:
- support beam;
- threaded (M10) flywheel;
- pressure beam;
- processed sheet;
- clamp (see previous);
- traverse
Just one remark can be made here. Perhaps the author of the design had flywheel nuts lying around somewhere in his stash, that’s why he installed them. In fact, in order to place the next sheet, you only have to raise the clamp by 2-3 mm. Well, by 30 mm, if you need to remove a picture with a fold already molded on the other side. Do you remember the M10 thread pitch? That is, you don’t need to turn the flywheels for a long time, like a gun when aiming. Wing nuts or even ordinary ones with welded collars are enough.
Note: after welding the knobs, it is necessary to drive the threads “completely” - holding the nut in a vice, and using the first and then the second tap, or a single-pass machine tap. The welding makes the thread look so bad that oh...
Video: example of a finished homemade sheet bender
Zig machine
A Zig machine is, of course, not a robot in the form of a screaming Hitler with an outstretched hand. A creasing machine (see figure) or a zigging machine is a device for creasing, or zigging. And zigovka is the pulling out of flanges or special potholes - zigs - on sheet metal blanks. Have you seen the rigid edges on buckets and basins? These are zigs. The actual machines are also often called zigovkas for short.
Sealing machines, as follows from the definition, also belong to the category of sheet-bending equipment, only special ones. They can be electric or manual. The latter are desktop stationary (in the figure) or portable (mobile), with a clamp. You can carry these with you in your tool bag.
Zigmashina is an indispensable assistant in tin roofing work. You can zig not only round shell blanks, but also sheets. Try using the best manual sheet bender to make a bend for the already mentioned double fold. This kind of zigging is achieved in one pass; with some skill - right on the roof. What else can be achieved by zigging using standard pairs of rollers can be seen in the following figure. Letter designations are standard; they correspond to the type of operation performed. The bevel machine costs three to five times, or even ten times less than a factory manual sheet bender.
Video: working on a zig machine
What to whom?
Let's summarize - which sheet bending machine is best for whom:
- For an amateur DIYer - bending with improvised means, as described, or homemade by hand, if you have a supply of scrap metal and a desire to tinker.
- For a general-purpose craftsman on the job, who from time to time receives orders for sheet metal or roofing, a homemade manual one like the one described plus, if there is some excess funds, a zig machine.
- A roofer or tinsmith - a professional who has a stable flow of orders - a branded manual one with a zig machine.
Today, corrugated sheeting is increasingly becoming popular among those who build modern buildings, erect fences, reliably strengthen partitions, and renew the appearance of old buildings. Also, with profiled steel, wide possibilities for constructing an original roof for a residential building or office building. Due to the high quality of rolled steel, corrugated sheets can be used during the construction of structures such as warehouses and hangars.
Creating a high-quality building coating by rolling a strip through guide rollers is quite simple. Thanks to technology and equipment, it is possible to organize production in available areas.
Sheets of corrugated sheets can be used as a material for the following purposes:
walling different types structures;
roofing for buildings for various purposes;
production of formwork;
installation of partitions and fences.
Do-it-yourself assembly of a machine for making corrugated sheets
An automatic line for producing corrugated sheets is a very difficult task to assemble with your own hands. However, it is quite possible to independently create a manual machine on which blanks can be bent to the desired angles and thus make sheets of corrugated sheets.
Here you should take into account that on a home manual machine it will not be possible to produce profiled sheets of too large a thickness - the possible maximum is approximately 5 mm.
Drawings of machines for working with corrugated sheets
How to prepare supports and table for feeding workpieces
To make your own rolling machine, you first need to assemble a frame to accommodate all the equipment components. In this case, it is enough to install reliable supports. They need to be secured to a solid foundation - preferably a concrete floor.Next you need to start assembling the table, along the surface of which the workpiece will be fed into the machine. The table should have a length that is several times longer than the length of the finished product. There must be enough free space on the surface to accept finished product. The optimal table surface material is aluminum sheet.
You need to place a special bar on the table, which will fix the workpiece on the table using bolts. A manual lever will also be attached in the same way, thanks to which sheets of material are fed across the table into the machine for corrugated sheeting and the desired feed angle is set.
How to install rolling shafts and run the device
It is quite difficult to assemble such a part of the structure as rolling shafts with your own hands, so the easiest way is to buy ready-made ones. Today it will not be difficult to do this - you will find them at least in the market.Using brackets made from metal angles, the shafts are fixed to the machine frame near the hand lever.
We do not tighten all the bolts to full strength - now our homemade manual machine for making corrugated sheets can be used for the first running-in of the material. If the corrugated sheet produced by the machine has the required shape, we fix the parts in place and tighten all the bolts firmly. If the shape of the corrugated sheet does not meet our requirements, we adjust certain details and repeat the procedure.
It must be remembered that a machine for producing corrugated sheets is equipment that is dangerous to operate. This machine is equipped a large number cutting and piercing elements, which, if safety precautions are not followed, can cause injury to the operator. Therefore, it is allowed to work on the machine only in protective clothing and safety glasses.
Production of corrugated sheets, very attractive business the idea is just a matter of equipment. Construction materials become more expensive every month. They are always in demand, especially such as corrugated sheets. It is used on any construction site How:
- facing material;
- frame for prefabricated non-residential facilities (for garages, warehouses, hangars, domestic premises);
- fencing the territory;
- roofing material;
- permanent formwork for monolithic construction of buildings;
- material for auxiliary, decorative design (canopies, awnings, valleys, ridges, ebbs, siding and complex products).
The machine is equipped with structures that allow the production of high quality corrugated sheets
A manual sheet bending machine is an inexpensive, compact and versatile equipment for the production of corrugated sheets. The quality of production is in no way inferior to factories. Low cost is primarily due to low productivity. Manual labor is always famous for its high quality and low productivity. The structures of the beams and supporting elements are made of highly durable metals. This allows for a long service life to work with metal sheets up to 1.5 mm thick. The cam clamping mechanism allows you to operate the machine with one hand without disturbing the geometry of the workpiece. The equipment allows you to work with rolls of galvanized metal sheets without preliminary cutting. The equipment set includes a steel, roller knife made of durable metal alloys. It allows you to cut products yourself. The length of the sheet can be changed at the request of the customer. The operating principle of the machine is quite simple. A strong steel beam bends a wave of the required shape using a controlled force. The force and shape are pre-adjusted to the thickness of the workpiece sheet. Control is carried out by sensors that stop the metal bending process at the right moment. The machine operator must first configure all equipment controls before producing corrugated sheets. A special scale controls the travel of the traverse and the bending angle. The process is carried out cyclically until the production of the profile sheet is completed. Manual roll forming equipment allows two workers to produce about 120 sheets of corrugated sheets of size (1100mm X 2500mm) in one shift. In production, the machine for self made will never leave scratches on the polyester coating of the sheet. The next benefit of working on such a machine is the lack of energy supply for its operation.
Corrugated sheeting is indispensable in any construction industry
Corrugated sheet for lately gained high popularity among building materials. And at certain nodes construction project, has become an indispensable material. Important information about corrugated sheets. It has acquired several types in different fields of application:
- roofing;
- carrier;
- wall;
- facing;
- sandwich panels (wall and facing corrugated sheets in a pair, and between them a thermal insulation layer of foam plastic or polyurethane).
- durability throughout the entire operation;
- mechanical strength;
- light weight;
- simplicity in installation work;
- relatively low cost;
- aesthetic appearance.
The equipment necessary for the production of corrugated sheets is divided into three main groups:
- Manual machine for the production of corrugated sheets;
- Automated and semi-automatic production lines;
- Mobile equipment.
In the second case, all technological operations are performed with minimal participation of technological personnel or completely without requiring human participation.
Automatic and semi-automatic lines are also available in mobile versions. Such machines are convenient to use in the construction of modular buildings or arched structures at remote construction sites, when the cost of delivering finished profiled sheets is very high.
Example of a manual machine for corrugated sheeting
Finally, a manual machine for the production of corrugated sheets is driven by human muscle power. Typically, such machines are used for the manufacture of small products or various additional elements. This machine is extremely easy to use and it is on this that we will dwell in detail further.
Manual machine for corrugated sheeting - what are the advantages of such a solution?
Currently, many machine-building enterprises produce such equipment, and anyone can buy a manual machine for corrugated sheeting. Its main advantage is that such a machine does not require external sources energy, since human physical strength is enough to activate it.
In order to set up the production of profiled sheets on a manual machine in a matter of hours, you only need a small room (although even this is not necessary, just an ordinary shed is enough) and two workers familiar with the structure of the machine.
A manual machine for making corrugated sheets is indispensable for a small construction company, which is often faced with the need to use a small number of products from profiled sheets. It is simply not practical to order them because the cost of delivery to the site is too high.
With the help of such a machine, it is possible to produce directly on the construction site various additional elements necessary, for example, when installing a roof. A manual machine for the production of corrugated sheets is so simple that it requires virtually no maintenance other than periodic lubrication.
The advantages of such a machine include its relatively low cost. A manual machine for corrugated sheets, the price of which is about 2000 US dollars, will pay for itself after producing 750-800 m² of profiled sheets, which is approximately its daily productivity. And this does not take into account the cost of delivering this corrugated sheet to the construction site if it is purchased. But you can also buy a machine that has already been used. It will cost several times less, and will last for many more years, since the forces acting on its main components are negligible and their wear is minimal.
Disadvantages of a manual machine for corrugated sheets
A manual machine for the production of corrugated sheets also has some disadvantages. First of all, this is the short length of the resulting corrugated sheet. It is usually 2.0-2.5 m. With large sizes of the working plate, uneven bending of the profile in the form of an arc is possible, which occurs due to different compression forces in different parts of the pressure lip.
In addition, it is worth noting that on a manual machine for corrugated sheets it is possible to produce only one brand of corrugated sheet. However, machines with a replaceable matrix are now being produced, which makes it possible to produce corrugated sheets with different shapes and trapezoid heights. In this case, the bending dies must be replaced manually.
And the most main drawback is that using a manual machine you can produce profiled sheets only from galvanized steel. When deformed, the polymer coating of the metal may become covered with small cracks, which will subsequently lead to premature corrosion of the corrugated sheet.
This problem is solved with the help of special modern manual machines for processing thin sheet steel with a polymer coating. However, they cost significantly more than standard options. In addition, galvanized profiled sheets can be painted. At the same time modern technologies applying paint and varnish coatings, such as, for example, powder painting, creates a decorative and protective layer that is in no way inferior, and maybe even superior in quality, to a polymer protective and decorative coating.
Design and principle of operation of a manual machine for making corrugated sheets
The manual machine for profiled sheets consists of three main units.
The main working body is a bending mechanism installed on a special frame. The bending mechanism itself, in turn, consists of hinges and gears that can be rotated using manual levers, as well as a replaceable bending matrix and a pressure beam.
In addition, each manual loom has a feed (back) table. A sheet steel blank is placed on it, which is moved in the required direction and “tucked” into the bending mechanism. A special roller knife is also installed here, usually included with the machine. It is made from high-strength steel, the quality of which allows cutting 25 km of steel with a thickness of 0.5 mm. If necessary, the knife can be sharpened or replaced.
Finally, one more element is absolutely necessary - a receiving table with special stops. They can be customized depending on the specified dimensions of the profiled sheet that needs to be produced. A plate is also installed here, with the help of which the required bending angle is set and the steel sheet is fixed.
The entire process of manufacturing profiled sheets on such a machine consists of the following steps:
- The steel sheet is placed on the table and fixed with a special clamp.
- Using a matrix, a steel beam forms a trapezoid or wave profile (the bending force is adjusted depending on the thickness of the metal of the workpiece).
- Mechanical control sensors stop metal bending at the right moment.
- The travel of the traverse and the bending angle of the metal are controlled using a special scale.
- After bending, the steel roll is unwinded and the process is repeated again from steps 1 to 5.
- Once the required length is reached, the steel is cut with a special guillotine knife.
The design of the cam mechanism of the manual drive makes it possible to operate with one hand. The presence of a roller knife and the installation of an unwinder make it possible to use rolled thin-sheet steel without preliminary cutting.
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Profiled metal sheets or corrugated sheets are often used in construction. The material is both reliable and inexpensive. As a rule, corrugated sheeting is used when installing a temporary structure (for example, a warehouse hangar). The material is also used in the process of roofing installation and cladding work. The production of corrugated sheets does not involve large expenses. Some construction companies carry out the production of material directly on the sites.
Types of equipment for the production of corrugated sheets:
- mechanical sheet benders;
- pneumatic;
- hydraulic;
- magnetic;
- semi-automatic;
- automatic production lines.
Mechanical sheet benders
To produce a profiled surface of a metal sheet, the cold stamping method is used. But first you need to select several sheets with a previously applied zinc or polymer coating.
There is a special machine on which corrugated sheets are made in piece quantities. In particular, it can be used to bend additional elements - ridges, valleys, aprons and small sheets of corrugated sheets.
To operate such a machine, human muscular strength is required.
Let's consider the technical capabilities of metals for processing:
- The thickness of the steel should not exceed 1 millimeter;
- The maximum length of the sheet should be about 2 meters;
- The bending angle should be 150 degrees.
Place the sheet on the equipped table, press it with a bar and use a lever to bend it desired profile. A manual machine for the production of corrugated sheets is relatively inexpensive and does not take up much space. This machine is not suitable for bending profiles on polymer sheets, as the protective layer can be damaged. Vulnerable areas will become covered with rust and the sheet will leak.
Mechanized sheet benders
Mechanized equipment is represented by pneumatic, magnetic and hydraulic machines. The scope of application of mechanized equipment does not differ from the field of mechanical equipment. However, the reviews are much better. The sheet bender has an electromagnetic workpiece clamp. This allows you to bend steel, copper and aluminum profiles. For example, a manual machine for corrugated sheeting does not bend the workpiece along its entire length and does not automatically determine the angle of 360 degrees.
The pneumatic machine includes a punch. Using this device, a metal sheet is pressed into the matrix. Compressed air is required to operate the punch. The power of such a machine is significantly higher than that of a manual one. This allows for a 90 degree bend angle, as well as automatic calculation of length and thickness.
Using hydraulic equipment for profiled sheets, you can get various types profiles (read: " "). At the same time, the production of large volumes of corrugated sheets is ensured. Hydraulic press operates on the same principle as pneumatic. Sheet bending for corrugated sheets can include numerical control. Presses vary in their performance. If you are using semi-automatic or automatic devices, you can select punch and die settings. This allows you to see the sheet model in the graph and set the work speed. As a rule, only large factories can afford such expensive equipment. Private company or individual entrepreneurs rarely can afford to buy a press. Therefore, they use a manual machine to make corrugated sheets.
Corrugated sheet manufacturing technology
In order to produce a large batch of profiled sheets with different characteristics, the cold rolling method is used.
The production line includes:
- unwinder;
- rolling machine;
- scissors;
- receiving device;
- automatic process control system.
Using universal technologies for the industrial production of profiled flooring, it is possible to produce all profiles on one sheet.
The advantages of this method are:
- No rolls or errors in geometry.
- Exact geometry of each profile.
- Uniform metal stress along the length and width, as well as high quality work (profile lines do not crack).
Manual machine for the production of corrugated sheets, look at the video:
It is quite profitable to produce and sell corrugated sheets. That is why the machines are so popular among various enterprises.
The equipment is installed in separate workshops, in which certain requirements must be met:
- Using a lifting device that places the rolls on the unwinder. This process cannot be carried out manually.
- The minimum temperature in the workshop should be +4 degrees. This is due to the fact that polymer coatings crack at lower temperatures.
- Availability of space for rolls, manufactured orders and other materials.
If you decide to use profiled sheets for roof installation, then do not forget about sound insulation. Because when it rains, metal makes quite a lot of noise. Profiled sheets can be purchased directly from manufacturers. In addition, you can contact specialized stores that, in addition to selling the material, will provide it free shipping. If you purchase corrugated sheeting at a factory, then most likely you will transport the material yourself. In any case, before purchasing profiled sheets, it is important to view photo and video materials on the Internet. From them you will learn, for example, how a manual sheet bender for corrugated sheets works.
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