Rollers from a profile pipe: types, principle of operation and self-assembly. Rolls for a profile pipe: types, principle of operation, self-production Do-it-yourself rolls for a profile

In what ways can you give a professional pipe a square or rectangular section the shape of the correct arc? How can they be arranged homemade rollers for profile pipe? And what solutions does modern industry offer? Let's try to answer these questions.

Why is it needed

Let's give some examples.

The arched canopy is not only beautiful, but also practical: snow will never accumulate on it.
The curved canopy over the porch looks much better than simple design with one slope.
The arched greenhouse is exceptionally durable, perfectly resists snow and wind loads.

By the way: assembling greenhouses from profile pipes is a good business, requiring only the notorious pipe bending rollers and a welding machine.

Types of rollers

What are they actually like?

Mechanical

The simplest design is mechanical three-roll rollers. It is these machines that can most often be found on sale; their price starts from about 15 - 20 thousand rubles. How are they arranged?

In full accordance with the name, the design is based on the drawing of a professional pipe with three rolls. One of them can be displaced relative to the other two in the direction perpendicular to the plane that unites them; a screw mechanism is used for displacement, which allows even a person with quite ordinary physical abilities to develop significant effort.

One of the rolls is equipped with a handle that allows it to be rotated and thereby pull the bent pipe.

Several modifications are possible to improve performance pipe bender:

Combining the rolls with a common chain will ensure their synchronous rotation thereby preventing pipe slippage.
A gear train can be used instead of a chain.
The use of hardened rolls increases their resource several times.
In addition, the rolls can be interchangeable, which will allow bending both profiled and round pipes without jamming.

Electrical

In this case, part self made transferred to the electric motor.

On sale you can find two versions of electric pipe benders:

In more simple solutions the electric motor is only responsible for pulling the pipe. The positioning of the bending roll is done manually.

Advanced models of rollers use electricity both for pulling and for shifting the roller (of course, through a gearbox that increases the force many times).

hydraulic

This category includes both powerful industrial machines weighing tens of tons and relatively compact devices. Them common feature- the use of a hydraulic cylinder: by pumping oil pressure in it, you can develop a huge force on the deforming roll.

bending radius

Regardless of the pipe bender device, the general pattern: the greater the thickness of the pipe (its section parallel to the bending radius), the greater the minimum bending radius. Here are the values declared for their machines by one of domestic manufacturers— they are quite typical.

Without pipe bender

It is technically possible, but the result is likely to be unsatisfactory.

The bending instruction is not so much complicated as it requires a large amount of preparatory work.

A template is made from wood or plywood with a surface shape that matches the arc you need.
A loop is attached to the template - a latch into which one of the ends of the pipe is inserted.
Further work, in fact, comes down to the application of brute force at its second end. Various levers can be used to increase the force.

crazy hands

A variety of diagrams and drawings of rollers for a profile pipe with your own hands in last years literally flooded the internet.

We will immediately disappoint the most economical readers: some of the parts will have to be ordered.

What exactly?

The rolls themselves. They can be cylindrical, or with grooves for bending round pipes.
Cages for bearings.
When using a chain drive - sprockets.

Of course, without reference to a specific design, giving advice on assembling rollers is a thankless task.

The drive handle must have a rotating handle. Otherwise, the first calluses on the hands will appear after a few meters of the stretched pipe.
Bearings are better to take self-centering. Mounting both bearings of each roll exactly on the same axis at home is an unrealistic task; the slightest misalignment will increase the pulling force.

It is quite often necessary to bend metal pipes at the desired angle or along a given contour, preferably without loss of strength qualities and internal working sections. In pipeline systems - a great opportunity to do without unnecessary connecting parts, in structural structures made of profile pipes - a certain freedom of design and design thought.

We specifically introduced this section in order to cool down the natural ardor of our fellow citizens a little to do everything with our own hands: a handicraft mechanical or hydraulic pipe bender, rollers for it from random metal tubes, and damaged metal rolled metal - entertainment, of course, worthy for a real man, but it’s easier to look for ready-made profile products that just need to be brought to condition.

For people who are far from such purely mundane topics, let me explain:

A pipe bender is a mechanical device that can bend pipes of any size and configuration. There are only three industrial options for the type of drive:

manual: the simplest in terms of the principle of operation and complex in the process of operation; the template of the final deflection of the pipe can be changed, but the physical efforts to perform shaped work remain equally large;
hydraulic: a variant of a semi-professional pipe bender with alloy steel rollers, which allows you to roll pipe profiles up to 80 mm without losing the strength properties of the pipe, crushing and stretching the working section;
electromechanical: industrial machine tool production, which produces most finished structures from rolled pipe.

Pipe bender rolls are simply two shafts made of high-strength material, round in cross section, between which the material being processed (in our case, an ordinary steel pipe) is “rolled”, taking a given shape.

Do-it-yourself pipe bender or buy ready-made

The question is funny because it touches on two absolutely different areas: financial and psychological. It is easier for many of our compatriots to buy a ready-made pipe bender, not to suffer with the calculation of rollers and loads, but simply take the instructions and quickly bend all the pipes that are available in the suburban area.

Most important question, always getting up when buying expensive equipment - the price. For reference, we will inform you: a high-quality tr hydraulic pipe bender costs in the range of 22-35 thousand rubles. Perhaps your entire structure, erected from bent profile pipes (canopy, garage, summer kitchen) are cheaper. A manual pipe bender with six bend profiles and jacking will cost 9,500-12,000 rubles.

Agree, if you do not plan to build up all your lands with openwork greenhouses and complex gazebos architectural forms, then such equipment costs are clearly unnecessary. Our natural intelligence begins to work and, as a result, the traditional Russian answer: we will do it ourselves.

How to make a pipe bender for a profile pipe with your own hands

We considered the entire range of profile steel pipes, their structural advantages and scope of application separately. Now we will try to bend them with our own hands along a given radius of the final product.

It is very important to avoid the following technical defects:

cracking; such a metal profile will have to be thrown away;
compression or tension of surfaces at points of potential load on a structural element;
deformation of the original profile, leading to a violation of the resistance of the metal (corrosion and mechanical) in the bending units and fracture of the supporting structure.

If you are ready to make the unit and rollers for such work with your own hands, honor and praise be to you. The simplest handicraft pipe bender with electric rolling rollers (any electric motor with a gearbox is suitable) and a clamping device made of ordinary steel pipe. It is mounted on a conventional car jack and, judging by the reviews, gives high-quality arched products.

We appreciate the technical findings of our “Kulibins”, but we recommend buying ready-made rolled metal of any configuration or making it to order according to your drawings and ideas, without particularly bothering your hands and head.

One of the most used machine tools in metallurgical production is a rolling machine (rollers). Using a rolling machine, you can carefully bend a metal sheet or pipe, give an oval shape to other metal products. In addition, these machines have wide use in the jewelry industry, as well as the food and chemical industries. Crushing rolling mechanisms are used to produce flour, and in the chemical industry, refining and sheet-bending mechanisms are used. Do-it-yourself rollers for a profile pipe can be made at home according to pre-drawn drawings. Moreover, such a machine will practically not be inferior in its technical specifications factory-made products.

The working parts of the rolling machine are cylinders. Giving the necessary shape to the metal is carried out by rotating cylinders and passing the metal between them. As a rule, rolling machines have from 2 to 5 shafts, but models with 3 or 4 shafts are the most popular and practical.

Shaft 3 is responsible for giving the necessary shape to the metal, and the distance between the rear and upper shafts provides the radius of rounding of the workpiece. The product is stretched and reduced in cross section by passing between the shafts. This is sufficient high temperature heating, as well as pressure, which is created using shafts. To obtain from a workpiece in the form of a cylinder, the rear and front shafts are adjusted in parallel, in the event that a product in the form of a cone is required, then the rear shaft is placed at a certain angle to the front.

According to the methods of bending, the following types are distinguished:

Crossbow. They specialize in the processing of pipes of a certain diameter;
Spring. They are characterized by the presence of a spring that allows you to bend the plastic without its deformation and additional damage;
Segment. Pipe deformation occurs under the action of a certain segment;
Dornovye. They are mainly used for processing thin-walled pipes.

There are also stationary rolling mechanisms. Processing can be done at home. The main disadvantage of such mechanisms is extreme discomfort during operation, since such machines do not have fasteners and must be held with a free hand during operation.

Before creating a homemade rolling machine, it is necessary to understand that the dimensions of the mechanism significantly determine its final cost. Therefore, it is necessary to take into account in advance the dimensions of the parts that will most often have to be processed. Machines that are used on an industrial scale have shafts that can bend pipes of various diameters at an angle of 180 degrees.

Areas of use

Most of the parts processed on rolling machines are cylindrical in shape. Therefore, their application is very diverse: downpipes, chimneys and ventilation systems. Therefore, home-made stationary rollers of small sizes are very convenient to use directly at the construction site. In addition, do-it-yourself rollers do not cause damage. polymer coating sheet metal.

Rolling mechanisms

The most common orders for the rolling mechanism operator are the manufacture of gutters and ventilation systems. For such orders, as a rule, a thick layer is not required. Therefore, in this case, it is recommended to use rotary mechanisms that have a wide range of processed thickness of metal products: from 0.1 to 120 millimeters. Plastics, plastic types of metals and rubber compounds are also processed on such devices.

Differences between common models

Machines that have 3 and 4 shafts differ from each other in the following parameters:

For three-roll models sheet feed speed should not be higher than 5 meters per minute. They are also unable to process metal sheets thinner than 6 millimeters. Three-roll models do not have the exact coordinates of the clamping point of the machined surface, which makes it much more difficult to control the workpiece. But the advantages of such models include low cost.
Four-roll machines different high reliability, due to good adhesion between the shafts, such machines provide increased safety during work (due to the impossibility of slipping metal surface). The metal feed rate is more than 6 meters per minute. Four-roll machines are distinguished by the automation of the workplace. Due to the complexity of the machines and ensuring safety in the workplace, such devices have a fairly high price.

Variety of rolling machines

Manual machines. The stationarity and practicality of using this type of machine cannot but bribe. Simplicity in operation and independence from power sources make such devices truly indispensable. A clamp and several shafts, which are driven by a chain drive, are fixed on the machine bed. Of course, it must be understood that such rollers are not intended for large-scale or industrial use, otherwise the service life of such devices will be quite short. At correct use manual rolling machines can be distinguished whole line advantages:

Low cost;
Possibility of dismantling the upper shaft;
Available adjustment of the lower and rear shafts;
Small dimensions;
The reliability of the device due to the simplicity of the design.

Such mechanisms are widely used by jewelry workshops. The rotating cylinders are made from carbon alloy steel for added strength.

Hydraulic Models. They have a hydraulic drive, which is characterized by high power. It has high performance and high weight.

Electrical units. They are distinguished by high performance due to the use of high power electric drives. The principle of operation is identical to manual rolling machines, the difference lies only in the presence of an electric motor.

Requirements for homemade rollers

Rolling machines at home must meet the following requirements:

Mobility. The machine should not be bulky and have a lot of weight to ensure its mobility;
Profitability. You should not use a high power machine unless absolutely necessary, because powers of 20-25 kW can damage the wiring. 1.5 kW is the best option, with good throughput and low energy consumption.

Assembling the machine on your own

When assembling the machine with your own hands, you need to prepare everything necessary tools, pre-prepared machine drawings and materials. It is desirable to have experience in the mechanization of devices and apparatuses, as well as to take into account a certain sequence of actions:

Manufacturing starts from the ground up. That is, from the bed. As a bed, you can use a small frame assembled from pipes;
In the upper part of the profile, as a rule, deformation elements are installed. For its reliable fixation, a threaded clamp is used. The support is made in the form of the letter P, followed by fixing the lower part in the frame;
For the rotation of the device, the use of a transmission chain is necessary;
After mounting the chain on the sprockets, it must be tensioned and work on the assembly of the feed handle must be carried out;
For the production of rollers the best material is steel;
A prerequisite for such a mechanism is the ability to adjust the gap between the shafts;
To fix the rollers to the frame, experts recommend the use of rolling bearings.

It is worth it or not to make a rolling machine with your own hands - it's up to you! It should be noted that the cost of finished units ranges from 500 to 1000 USD. Then, in calculating the profitability of the application, take the cost of the planned design, which may be several times cheaper than the new unit.

What are rollers for and what is it? If a profile pipe is used in the design, it may be necessary to make it a semicircular or arbitrary curvilinear shape. For this, rolling is used. In specialized factories, this is a common practice.

More about rolling

You can make the pipe take a different shape with a simple burner. This approach is often practiced, but the employee faces a number of difficulties:

there is a need for a large lever to change the shape;
you need emphasis and, as a result, a lot of physical strength;
it is almost impossible to make the product even, this is due to inaccurate movements and improper distribution of efforts.

To get the best result, it is worth using rollers. With their help, the profile pipe can be easily transformed with your own hands. The photo and video show the features of working with the tool. To get acquainted with the result of the work of the tool, drawings are presented.

1 The type of machine is designed for radius bending of profile pipes.

Characteristics of a standard machine:

The maximum section of the pipe is 40x40x2, 50x25x2 mm.

Minimum circle diameters:

30x30x2 - 650 mm,
40x20x2 - 650 mm,
40x40x2 - 1800 mm,
50x25x2 - 800 mm.

Drive type manual.

Hardened rollers - all 3 pcs.

Price: 25000 rubles.

2 The type of machine is designed for radius bending of profile pipes, round pipe and stripes.

Specifications universal machine :

The maximum section of the pipe is 40x40x2, 50x25x2 mm.

The maximum section of a round pipe is 32x2.8 mm.

Strip 40x4 mm.

Minimum circle diameters of profile pipes:

20x20x2, 25x25x2, 15x15x1.5 -560 mm
30x30x2 - 650 mm,
40x20x2 - 650 mm,
40x40x2 - 1800 mm,
50x25x2 - 800 mm.

The maximum arc diameter is unlimited.

Drive type manual.

Hardened rollers - all 3 pcs.

Price: 30,000 rubles.

At the request of the Customer, for an additional fee, the machine is equipped with a dial indicator for the manufacture of more accurate all subsequent blanks.

For an additional fee, the machine can be equipped with an electric drive 220-380V

Warranty 2 years

Contacts:

Tel: 8-919-831-25-14

Saratov region Engels

Delivery across the Russian Federation.

Industrial and domestic rollers

Not all modifications of this amazing tool can be used at home. How do you think how a profile pipe is made? Of course, with the help of rollers. This is done in the following way. A sheet of metal is twisted into a cylinder, the seam is welded. Next, the pipe is passed through the rollers. Under the action of high pressure, the desired profile is obtained.

To do the job, you need a lot of effort, so the profile pipe is produced on special equipment. Rollers installed in factories weigh more than ten tons. How to do this work with your own hands?

We do it ourselves

Houses will require other rollers, not so heavy. Drawings and photos of some modifications are presented on the site. To do the work yourself, you need a small, mobile tool. Home rollers are mechanical and electric. Here you have to choose between saving electricity and the amount of effort expended.

Electrical appliances "eat" electricity, but the profile pipe is made by hand much faster, it turns out like from a factory. Mechanical analogues are not inferior in results, but the worker has to apply effort to change the shape of the workpiece. In case of electrical appliance There is another pitfall. Its power is so high that the aluminum wiring simply does not withstand and burns out. This is worth remembering. Electric rollers are available in different versions, but those with a motor power of 500 to 1500 watts are popular.

Handheld devices are no less in demand. You can make them with your own hands. This will require three rollers made of durable steel. Two of them are located on the same plane. A handle for rotation is attached to one of the rollers. The third is lowered from above using a simple worm gear. The profile pipe changes shape as a result of punching its surface during rotation. Drawings of the scheme of devices are presented here.

If you do not plan to make products for sale, homemade rollers are what you need. It is very cheap, the device is compact, and if necessary, you can also screw the drive - it will be an electric device. It is important to calculate the power that will be required during rolling.
http://www.youtube.com/watch?v=b4NSJo-FZNY
If the pipe is not profiled, then it can be bent. For this, a groove is cut right size. If you plan to use an electrical appliance, then in its manufacture you should also calculate the gearbox. Thanks to the optimal gear ratios, the forces on the motor shaft are minimized.

We are all a little Kulibina

It is human nature to create. The desire to do something on their own does not leave even the laziest people. When designing rollers, it is worth remembering safety.

The only tool that can change the shape of a profile pipe are rollers. And since they are bent hardware often used in construction, this tool is simply irreplaceable. Rolls for a profile pipe are different types, including you can make them yourself.

Roll types

Structurally, this tool for forming arc-shaped profile pipes can be divided into types, according to the source of the applied force.

Electric rollers are the most productive, they are characterized by the largest number of bent products produced per unit of time compared to other types. Productivity increases due to the presence of a working electric motor, with which the formation new form pipes going fast enough.

Main structural elements electric pipe bender:

base, which is a metal frame;
from 3 to 5 rollers that rotate by means of an electric motor;
power plant in the form of an electric motor;
deforming clamps.

Manual rolls for bending profile pipes are considered a practical portable tool. Thanks to comparatively small sizes and the absence of an electric drive, they are installed in any suitable place, even where space is limited. The design of manual rollers for bending a profile pipe is similar to the design of electric ones, with the only difference that they do not have an electric drive, and the feed rollers are interconnected by a chain transmission, which deforms the pipe with the help of clamps.

Manual pipe benders are characterized by design flaws. Despite the fact that such rollers are very convenient for performing a small amount of work, their operation requires a considerable amount of physical strength. bend metal pipe transmitting power to clamps and chain transmission to one person is not so easy. If an employee is not physically fit developed person or fatigue has accumulated from the frequent repetition of operations, such a tool in production will be unproductive. Therefore, such hand tool useful only in the manufacture of small batches of bent products.

Hydraulic rollers are considered the most powerful technique in comparison with the above-described counterparts of bending tools. Hydraulic Press in combination with a clamp, it transfers such a powerful force to the profile pipe that it bends like a reed. Such a unit can rightly be called a "heavyweight". The bending force in a particular case is increased by a hydraulic complex, which is easily maintained and controlled. If, in addition to the existing equipment, an electric motor acting on the feed rollers is added, the efficiency of the unit will increase significantly - the possibilities of productivity and power will be combined.

Note! Such a device can be improved even more. If the feed drum is replaced with a profiled shaft, then several profiled pipes can be bent at once in one go. Thanks to the properties of a hydraulic press and an electric drive, such a machine can process any number of products.

Unfortunately, hydraulic rollers weigh a lot. This disadvantage is manifested in the fact that if it is installed somewhere, then this place will remain working for the unit on long time- it will be very difficult to move him from his place. In order to understand the device of the tool and the principle of deformation of the profile pipe, you can see the drawings of the rollers below with the dimensions applied.

The principle of operation of the rollers

To bend a profile pipe on rollers, special knowledge and skills are not needed. The employee needs to do just a few operations:

The pipe rests on two feed rollers.
With a certain force, the pipe is pressed against one bending roller of your choice.
The transmission mechanism is turned on.

As a result of the passage of the profiled pipe through working area it bends at the planned angle. In case of an insufficient degree of deformation, the workpiece is once again passed through the working elements of the tool, while it is necessary to control the clamping force.

Making homemade rollers

Today, do-it-yourself rollers for a profile pipe are often found in everyday life. A wide channel is used for the bed. The bending mechanism can be made from a U-shaped structure using a hydraulic jack or by welding with a nut top plate.

If a jack is used, it should be located under the frame, and the force should rush from above to the feed rollers.
In another case, the pipe is bent with a threaded clamp. The stud is screwed into the nut, and welded to the end desired shape heel.

When feeding the pipe, you can use a regular bicycle chain. Sprockets are welded onto the drive and driven shafts and the chain is pulled. A handle is attached to the drive shaft.

Note! In terms of hardness, the feed rollers must exceed the profile pipe, so they are hardened.

Video

We invite you to look at a homemade pipe bender: