How to make homemade rollers for a profile pipe? How to make rollers for a profile pipe with your own hands: ideas and nuances How to make rollers for a profile pipe.

Make rollers for profile pipe with your own hands, using drawings and knowledge of the principle of operation of this useful device, is quite real. Using such a device, which has high versatility, you can independently produce bent structures of any degree of complexity from professional pipes.

The main working bodies of the rollers, which have a mechanical effect on the processed profile pipe, are rotating rollers, the number of which can vary from 3 to 5 pieces. It is in the gap between the rolls that the plastic deformation of the professional pipe occurs.

Types of devices with rotating rolls

Rolling of a profile pipe, as a result of which its initial configuration is changed, can be performed on equipment various designs. Such devices can differ according to the type of drive used and according to the main technical characteristics. So, rolling rollers can have:

manual drive (the use of such devices for rolling profile pipes requires significant physical effort);
electric drive;
hydraulic type drive mechanism.

The simplest (and, accordingly, inexpensive) devices with which the profile pipe is rolled are manual profile benders. Along with their reliability and ease of use, they also have a number of significant advantages. The structure consists of the following elements:

a massive frame that serves as a reliable foundation for the entire structure;
rollers that perform feeding and receiving functions (data structural elements, with the help of which rolling is performed, are interconnected by means of a chain transmission);
a set of clamping mechanisms (clamps) designed to fix pipes of various sizes.

Such a different the simplest design, is also equipped with a special pipe, which acts as a guide for the bent workpiece. It should be borne in mind that the use of such a machine requires significant physical effort from the performer. Besides, this device does not allow for rolling with high productivity and is most often used for simple work at home. That is why the design scheme of this machine is used in order to make a profile bender with your own hands. Such a simple design profile bender allows you to roll profile pipes with high quality and high efficiency.

An electric profile pipe rolling machine, even a self-made one, provides a higher productivity of the technological operation. This is explained by the fact that for the implementation of the main operation - pulling a professional pipe through the rollers - an electric drive is responsible, the power of which can be quite large. That is why electric rollers for a profile pipe, which you can do yourself using drawings, are used by both small organizations or home craftsmen, and manufacturing enterprises.

However, of course, the hydraulic roll forming machine is distinguished by the highest power, which is quite difficult to make with your own hands. Devices of this type, designed for rolling profile pipes, are used mainly on industrial enterprises where it is necessary to carry out such a technological operation with high productivity.

Homemade devices for rolling pipes

It is practically impossible to do without such a device as a device for rolling professional pipes in those situations when you decide to do repairs yourself, during which you will have to deal with. To do this, you can purchase a serial device for a similar purpose or use a self-made profile bender, the design of which is not very complex. It also makes sense to ask the question of how to make a profile bender for the reason that serial models are quite expensive, so their purchase (especially if they are required only to perform home renovation) is not always appropriate.

In order to make high-quality home-made rollers, you can study theoretical information, watch a video on this topic, but the main thing is to follow the recommendations of those who have already achieved good results in solving this issue. Of course, in order to make your own roller, you need to have not only the relevant knowledge, but also certain skills in the manufacture and use of various technical devices.

Homemade rollers can even be made from improvised materials, which are almost always in any garage or home workshop. At the same time, the efficiency of such rollers, if they are manufactured taking into account all the recommendations, will be slightly lower than that of mass-produced models.

Machine shaft drawings:

Clamping shaft Lower shafts Support for the 307th bearing

How to make a profile bender yourself

To make a roll forming machine with your own hands, you must adhere to the following sequence of actions.

First of all, a base or frame is made, for which large diameter pipes or steel channels can be used.
Serious attention should be paid to the manufacture of the vertical support of the machine, the material for which can be a U-shaped profile. It is at the top of such a support, which should be different high reliability, a node deforming the pipe is installed - a roller mechanism. For mounting a vertical support, Bottom part which is securely fixed under the bed, you will need a clamp of the appropriate size. With this method of attaching the vertical support, the deformation force exerted on the bent profile pipe will be evenly distributed over the two feed rollers.
To rotate the feed rollers, a chain drive is used, which can be assembled using a chain and sprockets from an old bicycle for this. Asterisks, which in their geometric parameters must strictly correspond to the characteristics of the chain used, are fixed on the supply and driven shafts. When installing the chain feeder for your homemade machine it is necessary to ensure a good tension of the chain and only after that proceed to fix the handle of the feeder. Naturally, the drive mechanism of your pipe rolling machine must provide easy rotation of the feed and driven shafts.
The self-made rollers themselves, which will put pressure on the bent profile pipe and thereby take the main load during the operation of the machine, are best made from steel that has undergone a hardening procedure.

The whole process of manufacturing a manual profile bender is shown in detail in the photographs below.

We select sprockets and grind the shafts We weld the carriage and fasten crescents for bearings We mark and cut out the walls of the housing
We weld bearing carriage supports This is how the carriage should “ride” We are trying to assemble the body
We select a screw with a tool thread We make a screw fastening on top of the carriage This is how this assembly looks from below
We weld the amplifiers We fix the ears to assemble the case We use cotter pins for quick disassembly
We assemble the chain drive We make their handle ring spanner We paint the finished profile bender

Often in household during various repair work it is necessary to bend a piece of pipe in a special way, and in this case you need to think about how to make rolls for a profile pipe with your own hands. Naturally, the easiest way is to buy professional rollers in a hardware store, but not everyone will have extra money for this device.

You can also make the pipe material take the desired shape using a conventional burner. This method is not rarely practiced, but the master faces some difficulties:

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

To get a quality result, you need to use rollers. With the help of them, the profile pipe can be easily transformed with your own hands.

Ordinary rollers are a design that has a special lever that puts into operation several steel shafts, passing through which the metal pipe receives the necessary curved shape. To make rollers with your own hands at home, you need to have the necessary drawings on hand and know the principle of the device thoroughly. Home-made rollers for bending profile pipes will have good performance and decent quality if the assembly technique is strictly followed.

Types of rollers and features of work

The most popular are hand-operated rollers. This universal device most often has a relatively small weight and compact size. The master should not have questions with their placement in their home workshop.

Manual rollers are used for bending various profile blanks, they do not have an electric drive and, accordingly, can work in almost any conditions. As a rule, this hand device It is made of a strong metal frame and feed rollers, made in the form of small cylinders.

The rollers are connected to each other by a chain drive, which sets them in motion. In addition, there are small clamps on the rollers. So that the rollers can produce the desired profile deformation, they are additionally equipped with a special transfer tube.

To do necessary work on this machine, the master needs to make some physical effort, because they are not used in large enterprises. It is most convenient to work on rollers equipped with an electric drive. The metal pipe to be bent is pulled through working area with a powerful electric motor. By appearance machines are remotely similar to manual models, the only difference is that in a special compartment installed electric motor. As a rule, electric rollers are used in industrial production.

Hydraulic rollers

The next type of pipe bending roll, which is installed on manufacturing enterprises equipped with a special hydraulic drive. These machines are quite large and have sufficient power, which makes it possible to work with almost any type of metal. Hydraulic rollers perform a large amount of work in a fairly short time.

The difference between homemade rollers

By by and large, the home master does not need to have on hand professional equipment equipped with an electric motor or hydraulic drive. These devices are very complex structure, and also require self installation the presence of expensive components.

As a rule, in Everyday life are faced with the need to perform the deformation of various profile products very rarely. Therefore, at home, it is enough to have a manual machine, which at the same time can be made very simply with your own hands. All you need is the right tool workplace and a certain set of components.

In order for a home-made structure to easily cope with the task and serve the owner for many years, it is necessary during assembly follow some rules.

All components for the device must be chosen as durable and high-quality as possible, without any flaws. Often all the necessary components can be found on the farm.
Before starting work on manufacturing, you need to carefully study the drawings, which will create a complete picture of the principle of operation of manual type rollers.

If you strictly follow all the stages of work, and choose only high-quality elements, then the bending device will turn out to be durable and reliable.

You need to start making a roller with your own hands from the frame. He must make the most tough and durable. For its assembly, it is desirable to use tubular metal, but a channel of the required section is also suitable.

The deforming element of the frame must be assembled in a U-shape, and a nut must be fixed to its upper part by welding. By producing this work, you need to use a clamp, it must be threaded. Then you need to screw the nut into the appropriate stud, the section of which must fit in its diameter.

At the end of the nut, you need to fix it by welding round steel heel. For convenience, you can install a hydraulic jack. It must be fixed at the bottom of the base of the bed, that is, so, the deformation will occur under the action of the incoming force on the feed rollers located in the upper part.

Then you need to make a functional and reliable mechanism filing. To do this, you need to use a metal chain. You can take a bicycle chain. One of the stars must be fixed on the deforming shaft, and the other on the driven one. Then, without fail, it is necessary to carefully tension the bicycle chain, and only after that you can try to rotate the corresponding handle.

To carve the rollers yourself the right sizes, ordinary alloy steel can be used. Prepared rollers must be hardened. Do not forget that the rollers obtained in this way must be much stronger than the material with which you will work on the machine in the future.

Rollers are fixed on the machine using rolling bearings. They need to be fixed as firmly as possible so that they do not bend or come off during operation. bending machine.

To make a device on your own, with which it will be possible to easily deform a metal pipe, you do not need to have any special knowledge. Any House master, having even a little experience in construction, can do this in a short period of time.

The most important thing in this case is to have the whole right tool and material. If the device is made of high-quality components, in compliance with all the rules, then it will be possible to solve absolutely any task, even very complex ones.

During the assembly of this equipment, it is imperative to set radial adjustment. This will make it possible, if necessary, to quickly change the size of the gap between the working parts of the device. You also need to think about the possibility of adjusting the angular clearance, which will greatly facilitate the work on the drum.

When working on a roller, you need observe safety precautions. In addition, the machine itself should not pose any danger. When assembling the device with your own hands, you need to protect all working parts as much as possible, thus preventing all possible risks of injury. In some cases, a home-made roller can even surpass factory machines in its characteristics.

Bend metal pipes at the right angle or along a given contour, preferably without loss of strength qualities and internal working sections, it happens quite often. 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.

Profile pipe - an element of many building structures and frameworks. It is used in the construction of industrial and residential buildings. The main characteristic that distinguishes it from other types of pipes is not a round cut shape. A profile pipe is produced from a sheet welded and bent along in desired form. If necessary, you can make rollers for a profile pipe with your own hands - you will find drawings and explanations in this article.

Production of a profile pipe by rolling

Assortment of profile pipes

In the factory, two methods are used for the production of profile pipes from a metal sheet:

hot method, at which the longitudinally welded round pipe is heated;
cold method, in which rollers for a profile pipe are rolled over unheated metal.

The basis for the production is carbon, low-alloy, less often stainless steel. Modern factory equipment will allow you to get a profile with high precision seams and bends, since the process is controlled by transmitting data from a computer and receiving them from sensors that take readings with an accuracy of thousandths of a millimeter. Home-made rollers for a profile pipe cannot provide such detail, but they cope with the task of producing elements for home construction and household work. In this technique, consumables are made for fences and canopies, greenhouses and technical buildings, gutters and cable channels. It is not recommended to make a profile pipe for large-scale buildings at home. Factory equipment makes it possible to subject each manufactured element to test tests and check both the quality of the seam and the accuracy of profile calibration. The absence of such equipment does not give the master the opportunity to guarantee the quality of a homemade product.

Assembly of a machine for the production of a profile

The use of curved profile pipes

Do-it-yourself rolling machine for a profile pipe looks like a design for bending pipes. It consists of the following elements:

carrier frame;
roller system;
pressing form:
stop and levers for actuating the rolling mechanism.

In fact, these are two different mechanisms and only the frame can be similar. All structural elements are assembled from durable elements and welded: any flaws and negligence can result in an industrial injury. The machine itself is firmly fixed on the surface.

It is almost impossible to provide the necessary pressure manually: it is desirable to provide a press for creating a profile pipe with an electric drive.

In the machine for giving a rounded profile, the main thing is a press that twists a sheet of metal. This pressure only solid construction: the entire period of welding, the pipe must be kept motionless. To simplify the work, the metal is heated and then rolled. After welding, the already round pipe is checked for the quality of the connection: an insufficiently even and clean seam will disperse when the rolling of the profile pipe from a round shape to a rectangular or square one begins.

Workpiece processing process

The finished straight-seam pipe is rolled hot or cold. At home, it is difficult to organize hot rolling, so the process is often carried out on already cooled metal.

The pipe is placed under a press of rollers that form the required shape.

Rolling is carried out gradually with a decrease in the distance between the upper and lower rollers. Sudden pressure leads to internal folds in the metal, which will affect the strength of the knees. The last rolling achieves the planned diameter and contour of the cut.

The pipe is checked for cracks and deformation of the metal in the bend area after each rolling. Zone special attention- the area of \u200b\u200bthe seam, it is the most vulnerable.

After processing with rollers, the pipe is calcined: this measure eliminates the stress of the metal layers and increases the strength of the structure as a whole.

Profile pipe bending

Masters rarely decide on independent production profile pipe, preferring to purchase finished material factory production. The profile pipe belongs to inexpensive consumables, so the need for bending with my own hands no. A machine for bending profile pipes with your own hands is a more demanded equipment, since the element is sold in direct form, and ordering bending according to your own drawings is an expensive service. Curvilinear or rounded profile is used for construction and erection decorative elements as more aesthetic. Frames and cornices, arcs of greenhouses and arches of gates can be made with your own hands. The simplest rollers for bending a profile pipe are assembled in a few hours. They will not provide industrial volumes and accuracy, but production costs individual elements will cut.

Bending quality requirements

The simplest way bending of profile pipes - incandescence and pressure. In this way, you can even create sharp corner, but you should not count on the accuracy and strength of the knot. Folds on the inner surface of the knee and cracks on the outer are guaranteed. Bending without defects is achieved only by gradually rolling the pipe on rollers and calculating the minimum diameter. The maximum bend angle is not standardized, the minimum is limited by safety requirements. A standard factory machine for bending a profile pipe sets the minimum diameters of a rounded bend; you can also focus on the same indicators when creating a home-made machine:

pipes 20x20x2, 25x25x2, 15x15x1.5 - 56 cm;
pipes 30x30x2 - 65 cm
pipes 40x20x2 - 65 cm;
pipes 40x40x2 - 180 cm;
pipes 50x25x2 - 80 cm.

Machine drawings for home use

The simplest deforming structure can be assembled right in the yard or technical room, fixing all the elements on a dense shield or directly on the fence. Elementary models will help out if you need to bend several pipes in a single shape, for example, for mounting the upper arches of a greenhouse. Regardless of the selected bend diameter and the dimensions of the pipe itself, you will need:

A frame that follows the contour of the required arch. It is cut from a single piece of wood or assembled from a number of planks. According to this stencil, the pipe will bend.
An emphasis on one side of the frame. The gap between the stop and the stencil is made corresponding to the diameter of the processed pipe. The smaller one will make it difficult to install the element into the device, the larger one will not fix the knee firmly.
A block with which the pipe is manually pressed against the template.

Working with such a pipe bender is difficult: all efforts will have to be done manually. But the design will ensure accuracy when bending: it is possible to make several elements with an identical deformation angle on it.

The pipe bender for permanent use is assembled on a durable U-shaped frame. The following elements are required in his system:

two rotating shafts fixed on the rail, along which the profile will pass during rolling;
an extrusion shaft located above them, during the rolling of a profile;
clamp or jack providing pressure;
a chain with which a set of rollers will move.

To assemble rollers for a profile pipe with your own hands, you will need welding machine and engineering skills. Inaccuracies in calculating the diameter of the functional shafts will make the device inoperable.

Video: working with a manual profile bender

Assembling a bending device with your own hands is a complex, time-consuming and expensive process. Against the backdrop of moderate prices for equipment, it is worth thinking about the rationality of the acquisition. Perhaps, for bending several elements, it is more profitable to contact the workshop, and for permanent work, purchase a factory model with a quality guarantee.

Rollers for a profile pipe are a tool that is not known to everyone. What is it and what is it for?

A little about the profile pipe

Traditional round tubular products are more familiar to the layman. They are used for water supply systems, drainage systems, as a cable sheath and much more. The profile pipe has an unusual shape.

The profile of the tubular product may have different shape However, the following types are the most popular:

Oval. Products of this profile are found in radiator systems and as elements of decorative structures.
Square or rectangle. This profile is used in the construction of load-bearing structures. This is explained by the high strength of the products under transverse load. The weight at which a conventional pipe is bent, a rectangular or square profile pipe can withstand without changing shape.

Mounting methods for load-bearing structures

When mounting load-bearing structures, the joining of elements is carried out in two ways:

By Welding. Connection of elements by welding differ in durability and durability. This is especially important in places where there is a lot of pressure on the connection.
With bolts. Such a connection is more profitable, since not everyone has a welding machine. Elements of greenhouses, canopies and racks can be connected with bolts.

Bearing parts, on which a large load is planned, are best done using I-beams or channels. These elements are not so beautiful, but they have high strength compared to a profile pipe.

Creating curved surfaces

AT load-bearing structures the profile pipe plays the role of a horizontal, vertical or inclined support for balconies, ceilings or roofs. But for canopies, canopies or greenhouses, you need to create a curved surface.

This is explained by several reasons:

Aesthetic perception. Rounded shapes have a calming effect on the vision and psyche of a person.
Wind and precipitation. The streamlined shape does not interfere with the wind, so with strong gusts of a rounded surface, practically nothing threatens. In addition, precipitation in the form of rain and snow does not linger on round shapes.

For creating curved surface you need to bend the material. You can perform this action when heating individual sections with a gas burner.

This is the easiest way to bend, but it has some disadvantages:

First of all, its implementation requires a large lever, a strong stop of the tubular product and great physical effort.
Secondly, in this way it is impossible to achieve uniform bending.

You can create an even sector of the circle using rollers.

Types of rollers

For the production of a profile pipe and its bending at home and in a factory, completely different tools are required.

factory production

rolling- this is the main technological operation in the process of manufacturing profiled tubular products.

The whole loop looks like this:

Flat blanks are rolled into a cylinder, the joint is welded.
The resulting product is rolled through rollers, where the desired profile is formed under high pressure.
The quality of the seams is checked.
Products are calcined to relieve residual stresses from deformation.

For the production of large volumes, factories use the appropriate equipment. For example, in a full-fledged rolling mill large enterprise Rolls for a pipe bender have a weight of several tens of tons, and the force applied to them can reach several hundred tons. In this case, not a manual drive is used here, but equipment with an electric drive.

home production

Do-it-yourself rolls for a pipe bender must meet completely different requirements:

Ease. The equipment should move without much effort.
compactness. AT small room the large dimensions of the machine will only complicate the workflow.
economy. Powerful electric motors can be used to quickly roll workpieces. However, such consumption of electricity requires large expenditures for its payment. In addition, to operate such equipment, it is necessary to have appropriate wiring that can withstand high power.

At home, two types of rollers are used: electric (with motors up to 1.5 kW) and manual.

Manual rolls for a profile pipe are the easiest option. Such a device consists of three steel rollers, two of which are located on the same horizontal, and the third roller is lowered between them according to the principle of a clamp using a screw mechanism. A handle is attached to one of the rollers lying on the same line, which sets it in motion. The principle of operation of such a mechanism is as simple as its device: a profile pipe is laid on two rollers, it is pressed from above by a third roller, which bends the pipe under pressure. By turning the handle on one of the rollers, the pipe is rolled through the rollers. As a result, a smooth bend is obtained along the entire length.

If transverse grooves are made on home-made rollers for a profile pipe, then it will be possible to bend a round non-profiled pipe.

Do-it-yourself rollers for a profile pipe can be used for the manufacture of elements of greenhouses and canopies in a small volume. For the production of a large number of structures, such a device is not suitable.

It is much easier to bend a profile pipe on electric rollers. A simple mechanism consisting of a low-power electric motor and a gearbox is engaged in broaching and deformation of the pipe. Big ratio transmission on the gearbox ensures the operation of the mechanism with a low power motor.

Using various drawings rollers for a profile pipe, you can not look for suitable equipment, but make it yourself.