Why does sheet metal need leveling?

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Why does sheet metal need leveling?

Enterprises, industries and businesses focus on three things: quality, delivery time and efficiency. Only the company that controls its processes will succeed in the competition for a long time The same applies to the metalworking industry. Raw materials suitable for further processing are the key factor here.

Stress relief plates are critical for all downstream production processes in sheet metal manufacturing However, internal stress is almost an inevitable by-product of the processing process. In particular, laser cutting is notorious for producing and releasing these stresses. The cutting laser generates a lot of heat when it strikes the material. This, in turn, creates large temperature gradients, resulting in internal stresses. In addition, this cutting process also hardens the edges. Result: the part is deformed. These are problematic when it comes to efficient downstream treatment. The only solution: you must level the sheet metal.

What is a roller leveler?

Roll leveler: the traditional roll leveler is usually used in the coil processing production line. Roll bending is used as a means to selectively stretch the strip beyond its yield point. In the roller leveler, the material is continuously bent back and forth on a series of small work rolls. The diameter of the work roll and its spacing determine the actual bending radius, not the work roll itself.

In the field of forming technology, roll leveling generally refers to bending with rotating tools. In other words, roller leveling is a bending process using rollers. It is an excellent way to flatten metal plates quickly and easily. This method reduces stress and flatness defects by elastic-plastic alternating bending. When using a roller leveler, the panel undergoes a series of alternating bends. The leveling rollers of the machine are arranged in a staggered manner from the feed inlet to the outlet. Therefore, a roller can always be located between two opposite rollers, so that the material undergoes large alternating bending, and then gradually becomes smaller. This bending process is similar to a decreasing sine wave.

Work introduction of roller leveler

The alternating bending motion when using a roller leveler enables a flat part with little internal stress. This is essential for efficient and trouble-free downstream processing. It is important that the bending of the part at the machine feed is greater than the existing maximum bending. This is the only way to ensure that alternate bending has the best effect on the flattened material. The internal stress and flatness defects are eliminated during the leveling process, and the leveled parts are formed. At the same time, the roller leveler has no effect on the flat part of the part. These remain the same.

In addition to bending the material back and forth on a series of rolls, the roll leveler also has the ability to selectively stretch the material from one side to the other. The roll leveler consists of a series of backup devices perpendicular to the work roll. These backups can be adjusted vertically so that the work roll can deflect during leveling. By deliberately bending the roll, part of the strip is forced to take a longer path through the machine. As a result, some parts of the band are permanently elongated relative to their length, while others are elongated with little or no elongation.

Basic knowledge of leveling and “yield strain”: understanding the leveling process

Basically all leveling machines/leveling processes, whether using rollers, compressive force, or stretching materials, stretch strips. When it comes to flattening, it is all about an extension. In any case, all levelers are designed to make some parts of the strip longer than others. The main difference between one system and another actually lies in the amount of elongation they can produce, how they do it, and how much of the material passing through its section exceeds its yield point.

A key recurring problem is the importance of exceeding the material yield point in order to effect permanent changes. This material will remain “elastic” until its yield value is exceeded. Once you let the material exceed the yield point, the material will enter the “plastic” state, and everything before that will be forgotten.

For example, if you have ever bent a piece of metal or wire, and it has been bent, you have exceeded its yield strength. If it can be restored to its original shape, then you have not exceeded its yield strength.

In a word, the roller leveler is one of the fastest, simplest and most economical leveling methods. It ensures high quality sheet metal parts. This is a key factor in sheet metal processing.

Strip and plate processing machine roller leveler supplier

Leveler is the core equipment of strip and plate processing machine, therefore TX has been dedicated to developing and producing the top quality precision leveler for coil strip, plate, and machine part. TX’s leveller is capable to process all kind of ferrous and non-ferrous material with thicknesses from 0.1 mm to 25mm, and width 2500 mm max.

According to the type and range of materials to be processed, TX roller leveler can provide the optimal solution with the proper diameter and numbers of roller, roller spacing, speed and etc, with the purpose to remove most of defects like coil set, cross bow, edge wave, and center buckle, dents, curvature, camber and so on. To achieve the highest precise flatness for the material.

If you have any questions about us, welcome to send an email to contact us and we will get back to you as soon as possible.

Contact TX Machinery

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