Standard profile pipes of square or rectangular section are widely used in construction due to their high bending strength and low weight. In cases where the permissible load values are exceeded, which occur during strong bending, the products are deformed and torn. To eliminate the negative consequences allows the use of pipes with a reinforced profile.
Profile pipe strengthening machine
Reinforcement means the formation of ribs at the corners of a square or rectangular profile during rolling on specially shaped rollers.
Pipes with a reinforced profile are characterized by high bending strength and are used to create curved structures of any complexity.
Strengthening the profile is carried out on specialized equipment.
To obtain the desired configuration, profile pipes are sequentially processed on machines for strengthening the profile, a forging block and a pipe bender.
The pipe bender allows you to bend profile pipes in a longitudinal section along a given radius. Such products are used in the installation of canopies, gazebos, visors.
Strengthening is a necessary step in preparing a profile pipe for making a curl by cold forging. The forging block allows you to create decorative elements from pipes with a square or rectangular section, curved in the most bizarre way. The resulting products are distinguished by volume, lightness, low price.
The machine for reinforcing the profile by the principle of operation and design is in many ways reminiscent of a conventional rolling machine.
In addition to the frame and the motion drive, the main components of the machine for strengthening the profile pipe are:
- Lower (support) shaft — 1 pc. It is leading, with its help the pipes move.
- The upper shaft is clamping. Carries out the deformation of the profile — presses the pipe to the lower shaft.
The feed and take-up shafts are securely mounted on a massive base (case), which must ensure the stability of the installation during operation. The feed mechanism ensures the rotation of the shafts around its axis.
The amplification process on the simplest machine is performed sequentially, with two pipe installations:
- The first step is to install the pipe on the rollers.
- 2nd step — rolling the first 2 symmetrical sides.
- 3rd step — reinstalling the pipe (rotate 900).
- 4th stage — rolling of the second 2 symmetrical sides of the profile.
Profile reinforcement is performed on a cold forging machine equipped with rollers for squeezing the profile pipe before bending it into a curl.
The rolling process depends on the wall thickness of the profile pipes and the grade of the material from which they are made.
According to the principle of operation, there are different types of wire mechanisms:
The machine with a manual drive is characterized by a simple design, compactness, and is designed for small amounts of work. Only a physically developed person can work on it. You will have to deform the metal with the help of muscle strength.
The machine with an electric drive for strengthening the profile pipe also does not take up much space. It works from an electric motor, the performance is high.
Hydraulic equipment is too bulky. Allows you to roll profile products with maximum dimensions. Designed for large volumes of work.
Increased interest is enjoyed by multifunctional modules of a stationary type, which are equipped with:
- rollers to strengthen the profile pipe;
- rollers for rolling out the ends of blanks in the form of artistic elements;
- forging block for cold forging.
All operations are performed without readjusting equipment and changing tools. Modules allow you to make various decorative forged elements of different sizes and the required shape.
An example of a multi-purpose plant is a commercially available crow’s foot (PGL) amplification unit adapted for several operations:
- reinforcement of the «crow’s feet» type (crimping, squeezing);
- rolling the ends of the workpiece.
After such processing, the pipe is completely ready for the manufacture of a decorative curl on the forging block.
Making a machine with your own hands
It does not always make sense to purchase a professional machine. For one-time work, the simplest do-it-yourself installations are more suitable. The main thing is to have drawings, carefully study the principle of the device and the operation of the machine, select high-quality materials for workpieces and the necessary tools for assembly.
Schematic diagram of a machine for rolling 2 types of profile sections in a section. Based on it, you can get an idea about the design and interface of the main components and the principle of pipe processing. In this case, the top shaft is the driving one.
The components of the rolling mill must not have chips, potholes, have a decent margin of safety, and be made of certain steel grades.
Shafts, axles are machined on a lathe. Some components can be bought at the store or removed from other mechanisms, for example:
- self-centering rolling bearings (4 pcs.);
- stars (4 pcs.);
- chain from a bicycle, moped.
To assemble the frame (base), you will need rolled metal (channel, pipes), sheets 5-10 mm thick. The base ensures the stability of the unit during operation.
Rollers (2 pieces of each type) to reinforce the profile are best machined from alloy steel, for a small amount of work, St3, St10 are also suitable. Roll blanks are subjected to hardening.
The rollers and axles must be many times stronger than the pipes being processed. Otherwise, the rollers will often have to be replaced with new ones. The hardness of rollers on professional installations is at least 52 HRC.
When assembling the machine, you will need the skills (as well as the appropriate equipment):
Fastening by welding in some places can be replaced by threaded connections.
- drill, with a set of drills;
- wrenches of different sizes;
- level for setting the horizon line;
- caliper, tape measure.
Construction of incoming parts
Along the edges of the rollers, special rollers are machined, which securely fix the position of the pipe during rolling.
You can get the dimensions of the rollers for profile broaching from a kit from professional installations. Drawings of rollers and axles according to the obtained dimensions are not difficult to develop on your own. Below is an example drawing.
Rolling of each profile size is carried out by rollers of the corresponding sizes. It is not easy to make a model with removable elements; for this reason, it is recommended to make rollers for strengthening the profile pipe when assembling the machine with your own hands in multi-stage. This will allow processing pipes of different sizes without reinstalling the rollers.
Both axles have the same dimensions but different lengths. On a longer axis (leading) fix the handle of the movement. Below is a drawing of the axis with a seat under the handle.
The frame is created gradually, as the rest of the parts are assembled. The individual elements of the base are interconnected by welding or large-sized bolts.
The distance between the upper and lower axle depends on the diameters of the rollers. In the absence of accurate assembly drawings, the dimensions between the axles are determined empirically:
- install rollers on the axis;
- measure the distance between the axles;
- drill holes on the side walls of the frame for the installation of bearings;
- then the axles are removed to the side, they are engaged in the installation of bearings.
The connection of the axle and rollers is carried out in several ways:
- using a dowel, about 8×8 mm in size;
- welding through pre-drilled blind blind holes made with a large diameter drill.
The second method is available if there is a machine for manual arc welding or semi-automatic welding.
Next, the axis is inserted into the bearing, which is pre-fixed in the box, pre-welded to the wall of the frame from the inside. Reliability of fastening — maximum. First of all, axles with rollers are installed in the side wall of the frame where the chain drive is supposed to be located. Then the axles are inserted into the bearings fixed on the 2nd side wall of the frame.
After installing the main elements, the frame is strengthened:
- welding seams;
- threaded connections.
The assembly of the chain mechanism in practice also occurs with the determination of dimensions in place:
- the 1st sprocket is installed on the lower axle;
- on the upper axis — the 2nd sprocket;
- try on the chain, outline the location of 2 more stars.
The rollers should rotate without difficulty with the chain tensioned. The handle is welded to the drive axle last.
For the movement feed mechanism in the form of a worm gear, you need to stock up on gears of the right size.
Special requirements are imposed on the coaxiality of the rollers: they must be located in the same vertical plane and be strictly parallel. Any misalignment will lead to uneven compression of the profile, which will significantly reduce the quality of the rolled product.
A machine made at home specifically for strengthening shaped pipes should not pose a danger to humans during operation. When assembling, you should:
- Secure all moving parts as securely as possible. Eliminate their rebound during operation.
- Provide protective shutters.
Properly assembled home-made installations are not inferior to professional models in terms of the quality of manufactured products.