Last time we took a closer look at the problems associated with the roll forming process, we found that the working material is usually not the culprit.
If the material is excluded, what could be the problem? No changes have been made, and operators and installers claim they did nothing differently. Fine…
In most cases, the problem can be related to the setup, maintenance of the machine, or electrical problems. Here are some items you might want to include on your checklist:
You may be surprised to learn that most material problems are directly related to machine malfunctions or misconfigured rolling and stamping tools. Ensure that operators and installers on all shifts maintain and maintain good installation drawings.
Don’t tolerate those notorious, secretly hidden pocketbooks! The cost of resolving issues related to opinion is very high, especially with regard to tools and machine settings.
Now we come to the most difficult problem of roll profiling – lubrication. You want to permanently eliminate lubrication problems because in most operations the purchasing department controls this aspect of profiling.
This is usually the first position the red pen selects other than the material. But wait! Why do I need to apply some kind of lubricant and then take it off? Why would anyone waste time, energy and money on this? So why are we spending all our hard-earned money on specialty lubricants?
Steel mills usually coat the roll with some sort of oil to prevent rust. However, this oil was not designed for casting.
Physics briefing. From a brief look at the physics of material surfaces, we know that metal surfaces are very rough, even though they appear smooth to the naked eye.
Map the peaks and valleys to get a better idea of how polished surfaces will look under the microscope. We also know that harder materials penetrate softer materials according to Hertz’s formula for pressure between elastomers. Add friction to the equation and you get peak shift.
Over time, the tops collapse, break off and are pressed into the material of the coil. The effect, as you probably already know, is that material is deposited on the roll surfaces, especially on high-wear grooves. Obviously, this affects product quality and tool life.
hot. In addition, the profiling process generates heat through friction and molding without affecting the microstructure of the material; however, in some cases, such as flow welding, the heat can cause shape changes and other problems in the cross section. A large amount of roller grease acts as a coolant.
Consider the final product. When choosing a flowable lubricant, the finished product and its application must be considered.
A small amount of wax residue on hidden parts may be acceptable, but what happens if you use the same lubricant on your roof? Your credibility will fall, that’s all. It is best to discuss the application with a specialist and remember that the right lubricant can pay huge dividends; however, the wrong lubricant can cost you dearly in many ways.
Develop a waste management plan. In addition, you must think of lubrication as the entire system. This means that you need to consider the environment, OSHA and local regulations in order to take advantage of your lubrication and avoid problems.
Most importantly, you need to develop a waste management plan. The program not only guarantees compliance with the law, but also improves the efficiency of the process. The next time you walk through the factory, take a look around. You may find any of the following:
It is imperative that efforts to improve and maintain flow forming operations must extend to lubricants. Don’t forget to focus on the maintenance aspect of the lubricant – the constant use of mold lubricants and their proper disposal or, even better, recycling.
FABRICATOR is the leading stamping and metal fabrication magazine in North America. The magazine publishes news, technical articles and success stories that enable manufacturers to do their job more efficiently. FABRICATOR has been in the industry since 1970.
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Post time: Aug-23-2023