Standard profile tubes of square or rectangular cross section, due to the high bending strength and low weight are widely used in building. In case of exceeding the permissible load values that occur during strong bending, products are deformed and broken. Eliminate the negative effects of allowing the use of pipes with a reinforced profile.
Machine amplification profile pipe
Under amplification involve the formation of edges at the corners of square or rectangular profile during rolling on the rollers of special shape.
Pipes with a reinforced profile characterized by a high flexural strength, are used to create curved structures of any complexity.
Strengthening the profile is carried out on the specialized equipment.
Application area
To obtain the desired configuration of the profile tubes are sequentially processed on machine tools for amplification profile, forging unit and benders.
Bender enables bending profile pipes in the longitudinal cross section of a given radius. These products are used during installation of canopies, gazebos, canopies.
Gain - a necessary step to prepare a shaped tube fabrication curl by cold forging. The forging unit to create a decorative elements of tubes with a square or rectangular cross section, the most intricately bent. products obtained different of volume, light weight, low price.
Design
The machine is to enhance the profile of the principle of operation and design largely resembles a normal rolling machine.
Further movement of the frame and the actuator, the main machine units to reinforce profiled pipes are:
- Lower (reference) shaft - 1 pc. Is a leading, it can move the pipe.
- Upper shaft - clamping. Implements profile deformation - presses the tube to the lower shaft.
Infeed and adoptive shafts securely mounted on the massive base (body), it must provide stability during operation of the installation. feeding mechanism ensures shafts rotate around its axis.
process technology
Amplification process is performed on the elementary machine in series, with two pipe units:
- 1st step - installation of pipe rollers.
- 2nd step - hire the first 2 symmetric sides.
- 3rd step - reinstallation tube (turn 900).
- 4th step - the second rolling 2 sides symmetric profile.
Gain profile performed on cold forging machine equipped with rollers for squeezing the profile pipe before bending to curl.
rolling process depends on the wall thickness of core tube and the brand of the material from which they are made
drive mechanism
There are different kinds of wire arrangements according to the principle of work:
- manual;
- electric;
- hydraulic.
Machine with manual transmission characterized by simple design, compact, designed for a small amount of work. Work on it will only physically developed person. Will deform the metal by means of muscular strength.
The machine with electric drive to enhance the profile of the pipe just takes a lot of space. He works on motor performance - high.
Equipment with hydraulic drive are too bulky. It allows rolled profiled products with a maximum size. Designed for large volumes of work.
Functionality
Increased interest in multi-functional use of stationary type units that are equipped with:
- rollers to strengthen shaped tube;
- rolls for rolling all blanks in the form of artistic elements;
- forging unit for cold forging.
All operations are carried out without readjustment oborudovniya and tool change. The modules allow to produce various decorative forged elements of different size and shape desired.
An example of a multipurpose plant is amplification unit with rolling crow's feet (PGL), are mass-produced, adapted for multiple operations:
- amplification of the type "crow's feet" (crimping, squeezing);
- rolling the ends of the workpiece.
After this treatment, the tube is completely ready for the manufacture of a decorative curl on the forging box.
Making the machine with their own hands
Not always a good idea to get a professional machine. For a one-time work will approach the simplest settings made with their own hands. The main thing is to have the drawings, carefully examine the device and the principle of operation of the machine, choose the high-quality materials for the preparations and the necessary tools for assembly.
scheme
Schematic diagram for the machine rental 2 types sectional profile sections. On its basis it is possible to get an idea about the design and pairing the basic units and the principle of pipe processing. In this case, the upper shaft is leading.
accessory components
Components valtsevatelya rolling should not have chips, dents, have decent margin, made of certain steel grades.
Shafts, axles machined on a lathe. Some components can be purchased at the store or take with other mechanisms, such as:
- self-aligning roller bearings (4 pcs.);
- asterisks (4 pcs.);
- chain of a bicycle, moped.
To assemble the frame (base) required metal (channels, pipes), sheets 5.10 mm thick. The stand provides the stability of the installation during operation.
Rollers (2 pcs. each type) to enhance the profile better carve stainless steel, for a small amount of work is suitable and St3, St10. The blanks subjected to tempering rollers.
The rollers and the axes must exceed several times the hardness of treated tubes. Otherwise, the rollers have to be frequently replaced with new ones. The hardness of the rollers on the professional installation of at least 52 HRC.
Instruments
When assembling the machine required skills (as well as related equipment):
- turner;
- welder;
- locksmith.
Fixing welding in some places it is possible to replace the threaded connections.
Tools required:
- drill with a set of drill bits;
- wrenches of various sizes;
- level for the nomination line of the horizon;
- vernier caliper, measuring tape.
The design of incoming parts
Along the edges of machined rollers special rollers that are securely fix the position of the pipe during rolling.
Get the size of rollers for pulling the profile can be set from professional installations. Drawings rollers and axes on the received size is not the most difficult to develop. Below is an example drawing.
Rolling each profile size is performed rollers of appropriate size. Make a model with removable elements is not easy, for this reason the rollers to enhance the profile of the pipe at the assembly of the machine with his own hands is recommended to do multi-stage. This will allow for the processing pipes of different sizes without having to reinstall the rollers.
The two axes are the same size, but different lengths. On the longer axis (leading) is fixed handle movement. Below is a drawing of an axis with a seat by the handle.
assembly works
The frame is created gradually as the assembly of the other parts. The individual base elements are joined together by welding or large-sized bolts.
The distance between the upper and lower axis depends on the rollers diameters. In absence of precise assembly drawings dimensions between axes determined empirically:
- rollers mounted on the axis;
- vymeryat distance between the axes;
- holes drilled in the side walls of the chassis for installation of bearings;
- then harvested in the axis direction, engaged in the installation of the bearing.
Compound axle and rollers carried out in several ways:
- by means of splines, size of about 8x8 mm;
- welding through pre-drilled countersunk non-through openings formed to drill large diameter.
The second method is available if there is a device for manual arc welding or semi-automatic.
Further axis is inserted into the bearing, which is previously fixed in the journal box beforehand welded to the frame wall on the inside. Security of attachment - the maximum. In the first place with the roll axis set in the side wall of the frame, where it is supposed to arrange a chain transmission. Then inserted into the axle bearing fixed to the second side wall of the carcass.
After installation of the main frame reinforcing elements:
- welds;
- threaded connections.
Assembling the chain mechanism in practice, so it is with the definition of the place of sizes:
- mounted on the lower axle 1st sprocket;
- the upper axle - 2nd sprocket;
- try on chain scheduled location More 2 sprockets.
The rollers must rotate without difficulty stretched chain. The handle is welded to the drive axle in the last turn.
For the movement of the feeder in the form of a worm gear is necessary to stock up on the gears of the correct size.
recommendations
Specific requirements for the alignment of rolls: they should be located in the same vertical plane and be strictly parallel. Any misalignment will lead to non-uniform compression of the profile, which will significantly reduce the quality of hire.
The machine is made in the home specifically to enhance the profile pipes, should not be in the process pose a danger to humans. When the assembly should be:
- Maximum reliably capture all the moving parts. Exclude them bouncing in the process.
- Provide protective flap.
Correctly assembled improvised installation professional models are not inferior in quality of products.
