metal slitting machine line

what factors produced BURR in steel slitting?

Burr formation in Rotary steel slitting:

Rotary steel slitting is now widely used for distributing a wide strip into a some of the narrow strips or for modification wide sheet metal stock. However, with a conventional slitting process, burr formation on the slit edge is inevitable.

Burr formation is a common sheet metal defect and Burr control / deburring is an important issue for industrialist and engineers. It is produced in all shearing & cutting operations. In sheet metal parts burr is usual but after a specified limit, it takes a form of defect. This leads to rework and the quality problem of a part. So controlling this defect is the issue of quality as well.

This post describes what are the possible causes & how can we prevent it. Except die & punch clearances, there are still many factors which affect the burr formation.

As all the sheet metal industries are heavily affected by the burr problem, indicating the study of all the possible causes and remedies. This paper also clears that what practices can increase the tool life & how long we produce “burr-free” parts. It includes the selection of the best materials and methods for „press tools‟, „tool

BURR IN STEEL SLITTING

BURR IN STEEL SLITTING

Study of all factors causing BURR

Sheet metal parts play an important role in the automotive industry. Different types of reinforcement, body parts, and door parts are manufactured in sheet metal scope. With every manufacturing process, there are some defects associated with the same. In the same manner in sheet metal components there are also many types of defects arises in different processes. But out of these defects, the most common and prominent defect is a burr. This defect has no.of cost-effective impacts as follows.

  1. Adding unnecessary processes i.e. rework
  2. Production loss
  3. Quality issues
  4. Risk of a defect being passed to “customer”
  5. Affecting 5-S

Application of sheet metal components includes Aircraft industry, Automobiles, Construction work and many other applications such as appliances.

Causes of Defects Burr In Sheet Metal

Identify Cause  /Reason  /Countermeasure

Identify Cause: Operator awareness

Reason: The operator is not locating the part in specified location gauge. Feeding of double

parts/sheets which can damage the sharp edge of die and punch. This leads to burr formation.

Countermeasure: Training has to be provided

Identify Cause: Skill of Operator

Reason: The operator should be capable to grasp the given training. Due to the absence of skill, he will repeat the mistake thus it increases the chance of an accident.

Countermeasure: The operator should be according to process criticality

steel Slitting-burr

steel Slitting-burr

what factors produced BURR in steel slitting?

Identify Cause: Raw material grade & thickness

Reason: Due to die & punch clearance is dependent on raw material thickness. So it is important to feed actual sheet thickness material. If we select a sheet having less thickness from actual then in this condition clearance between die & punch will be more and at the time of cutting proper shearing & breakage will not be produced. Thus burr will be formed. As well if we will use higher sheet thicknesses then less clearance will be maintained or no clearance thus cutting process will be interrupted and heavy accident will go on.

Countermeasure: Proper control on raw material should be taken place by the RI department. Also, quality & production supervisors should be ensuring about the RM before feeding in a tool. For proper implementation of the above idea, this should be converting into a system.

Identify Cause: Part handling

Reason: The method is directly related with Man i.e. operator

resource. In absence of proper handling or part loading method into the tool may cause of burr. Sometimes part trim/edge get damage due to unsafe part handling or movement.

Countermeasure: An operator should be sufficiently trained

 

 

 

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Stainless Steel High Precision Slitting Line

LOTOS SOLUTIONS FOR STEEL SLITTING PROBLEMS:

STEEL SLITTING PROBLEMS include; edge waves, crossbow, knife marks, burrs, camber, and inconsistent slit widths. some of these issues may be creat by poor material quality, but more often caused by disorders which happen in the system during the coil slitting process. LOTOSFORMING discuss slitting problems and present solutions to reduce possible problems.

PROBLEM      /   POSSIBLE CAUSE

What arises Problems during metal slitting?

How to avoid slit-in coil slitting problems?

Many issues can happen in steel slittings such as poor edge quality, edge burr, edge wave, camber, crossbow, knife marks, and slit width.

  • Too much BURR generated from slit process
  1. Too Much side pressure
  2. Wrong main shaft angle
  3. Excessive blade penetration
  4. Dull or incorrectly resharpened blades
  5. Slitter shaft vibration in high speed

Burr is an edge fault that accrues during slitting. The primary cause of burr is a horizontal knife clearance that is very tight or very weak. A wrong clearance spontaneously causes a poor-quality edge. In fact, one of the specifications of a poor-quality edge is a burr.

  • Top knives chipping
  1. Too Much side pressure
  2. Too little blade overlap
  3. Radial runout in the top knife
  4. Top knife jumping out during operation

Extensions to the COIL STEEL SLITTING PROBLEMS :

  • Blade life too short
  1. Blade incorrectly resharpened (burred cutting edges – heavy burrs)
  2. Excessive blade penetration too deep – too shallow
  3. Too much side pressure
  4. Excessive cant angle
  5. Radial runout
  6. Axial runout or wobbling in lower knife

 

  • Ragged edge on ONE side of steel strips
  1. Cant angle much too steep
  2. Blade penetration too deep
  3. Blade cutting angle incorrectly selected and/or sharpened

 

  • Ragged edge on both sides of a cut
  1. Blade angle incorrectly selected
  2. Cant angle much too steep
  3. Blade penetration too deep
  4. Blade cutting angle incorrectly selected and/or sharpened
  5. Incorrect offset
  6. Radial runout
  7. Heavy vibration at high speed

 

PROBLEM THAT OCCURS IN METAL SLITTING?

  • Scallop slit line
  1. Axial runout on a lower knife

 

  • Web folds between blades are not cut
  1. Negative cant angle
  2. Blades improperly reground
  3. Side pressure too light

 

  • Tearing of web  at a cut point
  1. Incorrect trim removal
  2. Blade penetration too deep. Web not truly tangent to the top point of a bottom knife

 

All you need to know about Solve Steel Slitting Problems :

  • Interrupted slitting
  1. Nicked or damaged cutting blades
  2. Radial runout of either top knife or bottom knife or both
  3. Side pressure too light

 

  • Web breaks
  1. Nick on any edge of a knife (usually a top knife)
  2. Web tensions too high
  3. Web not truly tangent
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Advantages of Roll Forming :

Advantages of Roll Forming :

  • One important of advantages of Roll Forming the roll forming process allows operations such as punching, notching, and welding to be performed in-line. Labor cost and time for secondary operations are reduced or eliminated, reducing part costs.
  • Roll form tooling allows for a high degree of flexibility. A single set of roll form tools will make almost any length of the same cross-section. Multiple sets of tools for varying length parts are not required.
  • Roll forming can provide better dimensional control than other competing metal forming processes.
  • Repeatability is inherent in the process, allowing easier assembly of roll-formed parts into your finished product, and minimizing problems due to “standard” tolerance build-up.

Advantages of roll forming relative to extrusion methods:

  • practically all metals can be roll-formed
  • roll forming can eliminate secondary operations multiple-stage operations such as notching, punching, and post-painting.
  • economically features

Roll Forming Line Process

To check the advantages of Roll Forming, we must first understand what is Roll Forming Process? Roll forming steel is essentially a continuous bending operation performed on the metal strip at room temperature. Tandem sets of rolls progressively shape the metal until the desired cross-sectional profile is achieved.

Roll forming is ideal for producing parts with long lengths or in large quantities. It can also produce parts of multiple lengths from the same tooling. Virtually any material that can be formed using sheet forming techniques can also be roll-formed. Roll forming may also be an excellent solution whenever the consistency of the cross-sectional profile is critical.

Benefits of Cold Roll Form Process

Roll forming has benefits & advantages over braking and extruding such as roll forming can produce more parts with more uniformity and stability all over the length of the part. High productivity rate as compared to other manufacturing processes. Able to combine multiple manufacturing operations in-line with the roll forming stations greatly reducing total manufacturing costs

  • Reduces handling, packaging and shipping costs
  • Produces parts of various lengths from the same roll sets
  • Able to produce parts with different hole patterns from the same roll sets
  • Capable of eliminating supplemental operations 
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Roll Forming Machine Basics Parts

How do Roll Forming Machines work?

 

All Roll forming machine in the industry has the same basic design, a roll forming machine includes:

DE COILER: to load raw material coil on that and open coil to a sheet, based on forming speed.

Feeding roller and leveling: after recoiler material should be straightening and leveling before forming to has a better result from forming steps. so we add leveling station in the first part of a machine but mostly is used for more than 1 mm thickness.

Pre-punching and marking: some of the wholes should punch before forming based on design, also upon requirement. we will add marking roller before forming stations.

Forming stations: the number of stations come from our experienced design DPT, based on thickness and shape each drawing need different forming stations number.

Torque head or final guide: in any roll forming machine last station before cutting should be torque head, to modify length twisting and turning to have a final 6-meter length in standard accuracy and shape.

Cutting or saw machine: at the end of forming machine we install the cutting system that’s hydraulic or mechanic saw, and it can be flying to make non-stop cutting. it’s up to forming machine speed and budget requirement.

Electronic cabinet: in developed manufacture such as LOTOS use PLC CONTROL to program and set machine.this is the machine brain for control and manage to punch, cutting, speed, feeding.

In LOTOSFORMING we select match HDMI, DRIVE, PLC, ENCODER with machine electronic motor to reduce PLC error as much as it can.

Roll forming Systems Machine Development:

In 2019 any roll forming manufacturer doesn’t use CAD/CAM design software cannot produce long term performance roll forming machines. roll forming design is one of the difficult machinery in the industry that definitely need CAD/CAM software to analyses and simulation steel with each station before producing. running roll forming machine nowadays most of the manufacture use PLC control to have less tolerance in final products.

So to have developed manufacture for roll forming machine, such as LOTOSFORMING, should have a great design team with enough experience on CAD/CAM software in roller drawing.

Roll Forming Tolerances :

To compare roll forming producing tolerance with old way machinery with shearing and break machines, for sure roll forming accuracy is really much higher than any other way. during the forming station also should care about material reaction and spring back to reduce tolerance,

The advantages of Roll forming Lines Machines  

Except for benefits we explained in previous comments and posts:

  1. Roll forming is energy efficient, cause informing station we won’t use any heating during forming, most of forming machine work in normal room temperature.
  2. Also based on CNC control it also reduces worker in a factory.
  3.  Before we design roller we will calculate input material width to make waste as less as it can.

 

 

 

 

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Roll Forming Process

what is mean Roll Forming Process?

Roll Forming Process is a type of rolling involving the continuous bending of a long strip of sheet metal (typically coiled steel) into the desired cross-section. Roll forming involves uncoiling a long strip of metal and sending it through several stacks of rollers set up in a long line. It performed at room temperature, hence the moniker ‘cold’, which is often dropped. Roll forming at room temperature maintains or even improves the properties of the feedstock material. The strip passes through sets of rolls mounted on consecutive stands. each set performing only an incremental part of the bend until the desired cross-section (profile) obtain. Roll forming is ideal for producing constant-profile parts with long lengths and in large quantities.

Cold Roll Forming Process : 

Cold Roll Forming Process is a bending process where the bending occurs gradually in several forming steps from an undeformed strip to a finished profile in roll forming machine. The process is very interesting for the sheet metal industry due to the high speed in which the profile can produce by a roll forming machine. High strength steel has, in recent years, become more common in cold roll forming. These materials have advantages but also disadvantages that affect the design of the process. The cold roll forming process a highly efficient process use to produce profiles for many applications, for example, vehicles, buildings, and domestic machines, and etc. Therefore, it’s market share is increasing every year. Many of the above products are already today made of high strength steel and the usage of these materials will likely continue to increase.

Metal Cold Forming  :

Cold Roll Forming Process widely use in construction, automobile, railway, aerospace, and other fields. As a kind of common metal skeleton in construction. the forming quality of C-channel steel is particularly important. However, with the shape of forming products becoming more and more complex, the requirement for forming process is becoming higher and higher. In industrial production, technicians also generally design roll flowers by the trial-and-error method. which causes a large number of human and financiallosses.

Cold roll forming is a process of metal slow deformation due to its special forming length. The front part of the sheet always forms faster than that of the back part. In cold roll forming a profile form in several forming steps from an undeformed strip to a finished profile. The forming process complicates due to the fact that. the forming does not only occur in the tools but also between each forming stand. When creating the tools the tool designer must decide how many forming steps the profile demands. The number of steps depending on the shape of the cross-section, tolerance, thickness and material properties. It is important to minimize the number of steps as this reduces the cost of the cold roll forming machine. Then the process can be a competitive alternative also for smaller production volumes. Therefore the knowledge of how high strength steel affects the number of forming steps is important.

Rolled Steel Roll Forming Machine:

Cold Rolled Steel is steel which has been rolled at room temperature, below its recrystallization temperature. This increases its strength and hardness and decreases its ductility. In addition to the improvement of mechanical properties, cold rolling results in more control over the shape and dimensions of the finished product. Cold Rolled steel has an improved surface finish and tighter tolerances compared to hot rolled steel. It commonly uses for parts requiring cold forming, such as crimping, swaging or bending. It can use for Shafts, machinery parts, bolts, and pinions, and gears, as well as in the creation of furniture, appliances and other consumer goods. Cold Rolled Steel can purchase online and at any Metal Supermarkets location. It can be cut to your exact specifications.

YOU CAN SEE THIS VIDEO FOR ACCESS MORE INFORMATION :

 

 

Roll forming

Roll forming

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