INNOVATIVE CONTRUCTION PHILOSOPHY IN BENDING MACHINE

In a globalised world it may seem trivial to underline the origin of a product, but nowadays it’s important to assure clientele that entire production is all studied, designed and assembled in Italy. Especially in these times of worldwide crisis in industry it is important to point out that the company has continued to develop, refurbishing with a new high quality management system, SAP, worldwide leader in software solutions for business. Furthermore, a lot of energy has been spent in finding new technical solutions in the manufacture of the machines, in testing new products for special processing and in continual updating of the CNC-i numeric control–core and real added value of all bending machines.

LAMIERA 2010 exhibits a synthetic but significant series of high quality products manufactured by the company that has been UNI ISO 9001 certified for many years. The construction principle applied by most manufacturers consists in two angle rolls, mounted on pivoted levers on a central pin, that follow an orbital path, a third fixed roll overlays these two rolls, in a central position in relation to the other two.

CNC bending machines geometry is very common because production costs are less. However, this system has certain equally evident drawbacks, due to the forces involved, that subject the structure to considerable stress concentrated in a single point: the central pin. This is the weak point of the entire system, because, even if largely over-dimensioned , it will never have the necessary stiffness to ensure an even distribution of the stress it is submitted to.

The company has built and patented an innovative drive and support system of the roll-carrier shafts on slides with a linear stroke, which is much more precise and stiff than the system previously described. To this important development the possibility is added to be able to apply independent supports, that restrain the ends of the shafts greatly restricting deflection. The slides with their straight-line stroke act as the base to assemble the supports, so that also during adjustment of the slides, the shafts are always rigidly restrained on three points.

Possibility to bend section bars with a double pipe bending strength, compared to a bending machine with conventional drive system at the same cost.

The possibility to have an immediate saving on the purchase of a bending machine, which is much smaller, but appropriately dimensioned for the steel bending needs required.

Considerable saving on cost and on the handling of fixtures, much less cumbersome and with higher dynamics in the operations.

Tube and pipe rollers

The tube and pipe roller or roll bender machines consists of manual or electronic driven single pinch ring roller machines (noting some have a hydraulic top roll with DRO) and hydraulic driven double pinch models with two hydraulic bottom rolls. The company has a very diverse line of angle roll bender machines to bend tube, pipe, angle iron, solids, squares, and much more.

The manual pipe bender machines consists of two manually driven ring roll benders for bending up to 1-1/4" tubing. These are great tube roller machines for the hobbyist or metal artist. The company also has several ring roller machines that are electronically driven with variable speed inverter drives. These ring roller machines have greater capacities and are easier to operate with two driven bottom rolls. These powered tube roller machines can bend vertically or horizontally for larger section angle bends. All versions in this category have manually adjusted top rolls and are considered single pinch style machines.

The single pinch angle rolls bender line with hydraulic down feed of the top roll has digital positioning readouts for repeatability. The tube benders in this category have three driven rolls for extra power. These roll bender machines are perfect for production fabrication settings where the fabricator is making hay hoops, spiral stair cases, and much more.

Finally the company offers two versions of double pinch angle rolls, hydraulically driven roll benders with hydraulic positioning of the two bottom rolls that are coupled to two separate digital readouts. These angle roll machines have three hydraulically driven rolls. We also have two angle bending machines that have hydraulically driven rolls, hydraulically positioning bottom roll, as well as hydraulically driven lateral guide rolls. These ring roller machines are for bigger section bending projects or for more structural applications. A double pinch bender allows the operator to pre-bend and post-bend the material saving the fabricator time and money. These roll bender machines are easy to use, cost effective, and built for decades of service.

Features:

· Bending capacity to 6″

· Bend any angle to 180° with independent material spring back compensation for each bend

· Bend to CLR as small as 2.5D

· Ideal for producing consistent quality bends in large diameter pipe, tube, squares, rectangular, solids and other profiles

· PLC touch screen control offers easy access to operating modes, programming, system diagnostics and multiple language capability

· Patented quick-change tooling system with multiple radii available

· Remote foot pedal for hands free operation

EMO HANNOVER - 19 September 2011

On 19 September 2011 the EMO Hannover, the world's premier trade fair for the metal working technology will be opening its gates. For six days the city of Hannover will be the center of attraction for production specialists from throughout the world, the meeting point for the entire international sector.

Round about 2 000 companies from 40 countries will be showcasing the entire spectrum of products and services almost for the metalworking technology - spotlighting their performance capabilities and innovative vigour for the highly qualified experts. This year's EMO Hannover is presenting its products and events under the motto "More than machine tools".

Whether as an exhibitor or a trade visitor, a journalist, technically oriented youth or a representative of the political and academic communities, on our website you will find all the important information you need on EMO Hannover 2011.

Display Categories:

· Machine tools for cutting, splitting and milling

· Sheet metal, wire and tube working machines, metal forming machine tools

· Machine tools for thermal, electro-chemical and other processes

· Surface finishing technology, thin-film processes

· Software for entire manufacturing technology area

· Control systems

· Components for flexible automation

· CAD/CAM

· CNC bending machines

· Quality management systems

· Robotics and automation

· Material flow and storage technology

· Industrial electronics, sensor and diagnostic technology

· Precision tools, diamond tools, measuring tools

· Metal forming machine tools

· Tube benders

· Machines and systems for tool and mould construction, rapid prototyping, model construction

· Instrumentation and control technology

· Coolants, lubricants

· Welding, cutting, hardening, heating

· Mechanical, hydraulic, electrical and electronic accessories for manufacturing technology

At EMO Hannover 2011 we again will offer trade visitors a series of events, supplying them with additional information. Also Tauringroup, leader in metal bending machines, will show its new products in this exhibition.

One of the theme of the conferences is new manufacturing production technologies for the aerospace sector. The aerospace industry has become a significant technological and economic motor for the manufacturing location Germany over the past years. High market requirements with regard to minimal fuel consumption, high cargo capacities and extended range of airplanes lead to a growing demand for light and high-strength structures at the same time. For the first time, the Institute of Production Engineering and Machine Tools (IFW) at Leibniz Hannover University will be hosting its prestigious conference entitled "New Production Technologies in the Aerospace Industry" at the EMO Hannover. The event is co-organised by the nationwide Machining Innovations Network (MIN). EMO visitors from the aerospace industry will be offered a top-class forum for acquiring new information and exchanging news and views about the status of research work on an international level.

Further insights:

http://www.emo-hannover.de/homepage_e

ROLL BENDER

A roll bender is a very robustly built and powerful pipe roller capable. This can be used in any fabrication shop or out in the field on job sites, considering it only requires 220 volts of single phase power to operate. It can be operated in both the vertical mode for small rolling projects, as well as in the horizontal mode for large rolling projects as there are feet on the bottom and back of the machine.

Roll benders work by "pinching" the flat workpiece between two rolls and bending it as it comes in contact with a forming roll. This bends the workpiece into a cylindrical form, where it is welded together to produce a cylinder. Caps are then welded on to produce tanks.
The upper roll is in a fixed position, the lower roll has adjustable movement to perform the gripping function. These are the "pinch" rolls. The third roll (the forming roll) is also adjustable.

Truly built to do the job year after year, these machines are designed with all three rolls driven. This insures easy material feeding and constant pull through of the workpiece.

With a manually or air adjusted drop hinge, the top shaft is automatically raised to release the pressure on the rolled sheet when the tail hinge is lowered. The rear forming roll is adjusted manually on some standard models.

This pipe bending roller has a motor to direct drive gear transmission for positive transfer of power to the drive rollers. The transmission is overload protected by a variable speed inverter drive unit. The variable speed is controlled by a speed pot and becomes very handy when rolling various types and sizes of metal section. This ring roll bender comes standard with foot pedal controls, segment rolls, and lateral roll guides that are very handy when coiling is required. The top roll position is manually descended and the position is indicated on a scale for repeatable bends every time. Optional rolls can be purchased for different profiles like tubing, pipe, angle iron and much more.

Ring rollers are built to a very high quality standard using only the best components on the market. The powered models come with heavy steel plate frame designs, heavy bases, and industrial grade transmissions with overload protection as standard. These ring rollers offer more quality for the investment and will perform decades of service. It is typically in stock for shipments within 72 hours or less.

The technical specifications and standard equipment are:

· Driven Rolls

· Variable Speed

· Rolls are hardened

· Steel bending

· Rolls shafts are a special steel material that is hardened and ground

· Standard Rolls

· Angle Rolls

· Horizontal and Vertical Working Position

· Foot Pedal

· Users manual

BENDING MACHINE TECHNOLOGY

The company distinguishes itself from the rest in its technological innovations and its tradition of anticipating the demands of the future and responding to them with solutions of tomorrow. The history of the company shows that since the foundation in 1970, new ideas, new application domains and consistent progress in technology have dictated the growth and future of the company. The products are used in the automotive, auto component, white goods, electronics, process plant, chemical plant, cutting tools, railways, shipbuilding, power transmission and other industries.
The company offers an extensive range of bending machines and solutions for tubes, sections, wires and rods. Simple models for batch production in job shops and sophisticated CNC models for high productivity are all available. These metal bending machines produce repeatable, high quality bent for many industries.
They have been producing angle rolls and pipe bends for the fabrication industry since 1970.
They produce a wide range of angle rolls from the smallest model 30 mechanical drive up to the largest model 360 hydraulic roll . All angle rolls are manufactured using a fabricated steel frame and equipped with standard electrics and hydraulic components. Some of the optional equipment includes: CNC bender, digital displays, central and side supports for large spirals, and many types of special order tooling.
The CNC controlled mandrel bending machine meet the highest demands on quality where design, performance and fabrication are concerned. They are the perfect solution for serial production as well as for flexible single production of tube and pipe bending parts. All functions are automated and the speed of all axes can be programmed free.
Depending on the model, tubes and pipes with an outside diameter of up to 170 mm can be bent economically and fully automated. The small benders are equipped with a servo-electric bending drive. In contrast the big machines are driven hydraulically with proportional- valve regulation.
Using the latest control techniques, even the most complicated tube shapes can be produced at minimal throughput times and maximum finishing precision. Operation is done either by means of a panel PC with graphic user guidance or a operator panel with function keys and graphic display.

ANGLE ROLLS

Angle rolls are made from high-strength chrome-nickel alloy steel, and are the largest diameter shafts of any comparable machine. These heavily proportioned shafts help minimize deflection, resulting in improved bending. The roll shafts are journalled in oversized SKF roller bearings for greatest efficiency and long life. The standard tooling is a combination set for bending machine both leg-out and leg-in, flat bar on flat and on edge, T-bar stem-out and stem-in as well as stem-down, small square bar and even small solid round bar. Normally, no additional spacers are required.
Roll bender machines all come with standard section roll dies on all three shafts. These dies can readily address most square profile applications that an engineer would run into and even round profiles if distortion of the tube or pipe is acceptable. Where no distortion on round tube or pipe applications is acceptable section roller dies for your particular tube and pipe bender size are available. Even though the section roller dies that come standard with the machine can address most square profiles on the market custom section dies are available for square profiles reducing setup time when changing over applications. Custom profiles rolls for extrusions are addressed on a daily basis so forward a sample and a drawing to us so we can offer a feasibility review along with a quote for the custom roll bender rolls.
Standard equipment on all bending machine models are:
• Hydraulically powered rear bending roll adjustment
• Electronic digital readout for rear bending roll position
• Hydraulic drop end
• Hydraulically powered lower pinch roll adjustment, with easily adjustable pinch pressure control with gauge
• Dual rotation controls - console mounted and remote hand control on trailing lead
• Cone bending attachment
• Rolls hardened to 50Rc
• Roller bearings on all roll shafts
• Powered tilting of the rear bending roll for cone rolling
• Simple manual tilt of the lower pinch roll
• Emergency stop cable at front and rear of machine
• Hydraulic oil, tools, and manual

ALUMINIUM 2012 - 9th World Trade Fair & Conference 09 - 11 October 2012, Messe Düsseldorf, Germany

ALUMINIUM trade fair provides an overview about the entire aluminium industry. It is the international meeting place for suppliers of raw material, semi-finished and finished products, surface treatment and producers of machinery, plant and equipment for aluminium processing and manufacturing like bending machine and angle rolls. Light-metals trade, consultancy and expert opinions. More than 20,000 international trade visitors look for new solutions and technologies, not only from producers of the raw material but also processors, refiners, suppliers for the automotive or building industry e.g. producers of sections, suppliers of the latest technologies for e.g. extrusion, heat treatment, casting, sawing or surface refinement.

Further insights:

http://www.aluminium-messe.com/

BENDING MACHINES AND ANGLE ROLLS

Bending machine is versatile, it is easy to operate and is well suited for bending pipe, tube, aluminum extrusions and other sections.

Standard features include double pinch hydraulic forming rolls, hardened precision threaded shafts, and dual adjustable lateral guides.

The design is the result of years of experience and is aimed at providing the highest level of performance, accuracy and consistency throughout the life of the bending machine with the additional advantage of being virtually maintenance free.

The lateral guide rolls are hydraulically powered and can be adjusted to work very closely to the bending rolls, minimizing the distortion of non-symmetrical profiles. Moreover, the guide rolls are equipped with the tooling to bend angle leg-in.

Angle rolls machines are used for bending tube, angle, or shapes into coils, circles or large arcs using a wide variety of materials. By simply adjusting the third roll you change the size of the arc or circle. Tube bending sizes require specific rolls. There are rolls for any application including CNC bender controlled.

Profile rolls often called angle rolls. We used the same technology as our 3 and 4 roll plate bending rolls which results in a stronger and higher quality machine than most other manufacturers but still at a very competitive price.

The rolls can bend almost every profile and section in steel, stainless and aluminum and are virtually maintenance-free.

The components are:

• Heavy steel manufactured frame, machined on CNC machining centers for the best accuracy
• 3 direct driven rolls, with hydraulic planetary motor to eliminate gear boxes, connecting arms synchro devices and clutches
• 2 forming rolls for reduction of flat ends
• double roll spherical bearings SFK or equal = maintenance-free and maximum rigidity
• hydraulic motors attached directly to each planetary drive, eliminating the loss of torque
• Modular tooling which can be configured to roll most standard sections. Special tooling can be ordered for rolling pipe, tubing or channels the hard way.

Bending a spiral

Hi, i recently found this nice article about how to make a spiral staircase using a tube bending machine.

For stair handrails it is advised to use a box section, for instance a semi-circular profile.

Start by setting up the machine measuring the radius of your staircase: the machine uses a series of drive rollers that are set out to achieve a degree of pipe bend required.

The pipe is pulled through these angle rolls and then made into an arc.

Here you can find more about his article:
http://www.mustknowhow.com/index.php/mustknowhow/how-to-bend-handrails-for-spiral-staircase