Modern cold bending forming machines widely utilize Computer-Aided Design (CAD) and professional simulation software, such as COPRA, for precise simulation and optimization of irregular, complex, and large profiles in the cold bending industry.
The design must ensure accurate calculation of the neutral layer in the deformation zone, accurate material calculation within the deformation zone, and good symmetry in roller machining. The non-deformable area should be kept as free from pressure as possible, and the gaps between the upper and lower rollers should be consistent during assembly. Before material is engaged, a guide bevel should be set according to the previous rolling condition to ensure smooth material sliding within the roller before stable pressure is applied.
Bending and twisting problems during production are mainly caused by unbalanced forces. The design must adhere to the principle of balanced force distribution. For example, the design should follow the principle of average force distribution across all passes, ensuring even force distribution on all rollers and balanced wear, which helps extend the service life of the rollers.
Roller machining accuracy is crucial. Therefore, a special tool is used for inspection under a projector at 20x magnification. To improve processing accuracy and adapt to different sheet materials, modern equipment employs precision adjustment mechanisms. For example, an "eccentric gap adjustment mechanism" allows for fine-tuning of the gap between the upper and lower rollers, preventing sheet material conveying deviation. Simultaneously, it adjusts the lateral spacing of adjacent rollers to match the sheet material thickness and required pressure, preventing deformation and improving equipment applicability.
The main drive uses roller tapered bearings to ensure the radial runout of the spindle is within 0.04mm, preventing lateral movement of the spindle. Furthermore, post-forming processing must be considered during manufacturing. For instance, integrated gantry frames, feeding assemblies, and stacking assemblies enable automatic guidance, cutting, and stacking of profiles, resolving quality damage issues that may occur during manual handling and enhancing the automation level of the production line and the protection of finished products.
