The principle of operation and drawing of the machine for strengthening the profile pipe

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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.

Application area

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.

Design

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:

  1. Low­er (sup­port) shaft — 1 pc. It is lead­ing, with its help the pipes move.
  2. 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.

Process technology

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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 strength­en­ing machine

Pro­file rein­force­ment is per­formed on a cold forg­ing machine equipped with rollers for squeez­ing the pro­file pipe before bend­ing it into a curl.

pro­file pipe

The rolling process depends on the wall thick­ness of the pro­file pipes and the grade of the mate­r­i­al from which they are made.

Drive mechanism

Accord­ing to the prin­ci­ple of oper­a­tion, there are dif­fer­ent types of wire mech­a­nisms:

  • man­u­al;
  • elec­tric;
  • hydraulic.

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.

Functionality

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

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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.

Scheme

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.

Machine dia­gram

Accessories

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.

Frame assem­bly

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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.

Tools

When assem­bling the machine, you will need the skills (as well as the appro­pri­ate equip­ment):

  • turn­er;
  • welder;
  • lock­smith.

Fas­ten­ing by weld­ing in some places can be replaced by thread­ed con­nec­tions.

Required tools:

  • 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.

rollers

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.

Roll draw­ing

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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.

Draw­ing of an axis with a seat under the han­dle

Assembly work

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 8x8 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.
Chain assem­bly

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The rollers should rotate with­out dif­fi­cul­ty with the chain ten­sioned. The han­dle is weld­ed to the dri­ve axle last.

chain mech­a­nism

For the move­ment feed mech­a­nism in the form of a worm gear, you need to stock up on gears of the right size.

Move­ment feed mech­a­nism

Recommendations

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:

  1. Secure all mov­ing parts as secure­ly as pos­si­ble. Elim­i­nate their rebound dur­ing oper­a­tion.
  2. Pro­vide pro­tec­tive shut­ters.

Prop­er­ly assem­bled home-made instal­la­tions are not infe­ri­or to pro­fes­sion­al mod­els in terms of the qual­i­ty of man­u­fac­tured prod­ucts.

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