ROLL FORMING MACHINE: Cylinders and conical shapes Are being formed, no sharp bends are obviously required; instead, a gradual curve has to be formed in the metal until the ends meet. Roll forming machines have been invented to accomplish this task. The simplest method of forming these shapes is on the slip roll forming machine. Three rolls do the forming. The two front rolls are the feed rolls and can be adjusted to accommodate various thicknesses of metal. The rear roll, also adjustable, gives the section the desired curve. The top roll pivots up to permit the cylinder to be removed without danger of distortion. Grooves are machined in the two bottom rolls for the purpose of accommodating a wired edge when forming a section with this type edge or for rolling wire into a ring.

COMBINATION ROTARY MACHINE: Preparing sheet metal for a wired edge, turning a burr, beading, and crimping are probably the most difficult of sheet-metal forming operations to perform. When production dictates, large shops will have a machine for each operation. However, a COMBINATION ROTARY MACHINE with a selection of rolls will prove acceptable for most shop uses. Wiring an Edge.—The wire edge must be applied to tapered shapes after they are formed. This is accomplished by turning the edge on the rotary machine. Gradually, lower the upper roll until the groove is large enough for the wire. The edge is pressed around the wire with the rotary machine. The wire edge can be finished by hand if a rotary machine is not available. The edge is formed on the bar folder and forced into place around the wire with a setting hammer or pliers. Turning a Burr.— A BURR, in sheet-metal language, is a narrow flange turned on the circular section at the end of a cylinder. Before you cut the section, remember that additional material must be added to the basic dimensions of the object for the burr. shows how to calculate the additional material. After the rotary machine has been adjusted to turn the proper size burr, the work is placed in position and the upper roll lowered. Make one complete revolution of the piece, scoring the edge lightly. Lower the upper roll a bit more, creating more pressure, and make another turn. Continue this operation, raising the disc slightly after each turn until the burr is turned to the required angle. This procedure is also used to turn the burr on the bottom of the cylinder for a double seam. The two pieces are snapped together, the burr set down, and the seam completed.NOTE: Because turning a burr is a difficult operation, you should turn several practice pieces to develop your skill before turning the burr on the actual piece to be used.

A sheet metal object made on a brake will have corners (bends) and sides (flanges). On a forming machine, it is possible to make an object without sides. For example, you can make a circular object such as a funnel. The forming machines used in the Navy are usually located at aircraft intermediate maintenance departments (AIMDs). The two most common machines are the slip roll and the rotary. Slip-Roll Forming Sheet metal can be formed into cylindrical or conical shapes through the use of the slip-roll forming machine. Prior to using this machine, you should consult the manufacturers manual of operation. To form a cylinder in the machine, you should use the following procedures.
Adjust the front rolls so they will grip the sheet properly. Adjust the rear roll to a height that is less than enough to form the desired radius of the cylinder. Ensure that all three rolls are parallel. (The same space exists between any two rollers at each end of the rollers.) Start the sheet into the space between the two front rolls. As soon as the front rolls have gripped the sheet, raise the free end of the sheet slightly. Pass the entire sheet through the rolls. This forms part of the curve required for the cylinder. 6. Set the rear roll higher to form a shorter radius. Rolling a conical shape, Rolling a wired edge. Turn the partially formed sheet end over end, and again pass it through the rolls.
Continue turning the sheet end over end and passing it through the rolls, each time adjusting the rear roll for a new radius, until a cylindrical shape has been formed.
Remove the cylinder from the machine. The top front roll has a quick-releasing device on one end. This allows the released end of the roll to be raised and the newly formed cylinder slipped off just as you would slip a ring from your finger. Conical shapes can be formed by setting the back roll at an angle before running the sheet through it, or they can be made with the rolls parallel.

MAKE A CONE WITH THE ROLLS PARALLE: The sheet must be fed through the rolls in such a manner that the element lines (A-A’, B-B’, etc., in the illustration) pass over the rear roll in a line parallel to the roll. This involves slipping the large end of the cone through the rolls at a slightly faster rate than the rate at which the small end is being rolled through. The grooves at the ends of the rolls can be used to form circles of wire or rod. They can also be used to roll wired edges, as shown in figure. Rotary Forming The roll dies, are installed on the rotary machine to perform a specific forming operation. In the following paragraphs we will discuss their functions.

RADIAL-LINE DEVELOPMENT OF CONICAL SURFACES:  The surface of a cone is developable because a thin sheet of flexible material can be wrapped smoothly about it. The two dimensions necessary to make the development of the surface are the slant height of the cone and the circumference of its base. For a right circular cone (symmetrical about the vertical axis), the developed shape is a sector of a circle. The radius for this sector is the slant height of the cone, and the length around the perimeter of the sector is equal to the circumference of the base. The proportion of the height to the base diameter determines the size of the sector, as shown in figure 8-14, view A. The next three subjects deal with the development of a regular cone, a truncated cone, and an oblique cone. Cone geometry

REGULAR CONE: In figure 8-14, view B, the top view is divided into an equal number of divisions, in this case 12. The chordal distance between these points is used to step off the length of arc on the development. The radius for the development is seen as the slant height in the front view. If a cone is truncated at an angle to the base, the inside shape on the development no longer has a constant radius; it is an ellipse that must be plotted by establishing points of intersection. The divisions made on the top view are projected down to the base of the cone in the front view. Element lines are drawn from these points to the apex of the cone. These element lines are seen in their true length only when the viewer is looking at right angles to them. Thus the points at which they cross the truncation line must be carried across, parallel to the base, to the outside element line, which is seen in its true length. The development is first made to represent the complete surface of the cone. Element lines are drawn from the step-off points about the circumference to the center point. True-length settings for each element line are taken for the front view and marked off on the corresponding element lines in the development. An irregular curve is used to connect these points of intersection, giving the proper inside shape. Cone geometry

TRUNCATED CONE: The development of a frustum of a cone is the development of a full cone less the development of the part removed, as shown in figure 8-15. Note that, at all times, the radius setting, either R1 or R2, is a slant height, a distance taken on the surface of the cones. When the top of a cone is truncated at an angle to the base, the top surface will not be seen as a true circle. This shape must be plotted by established points of intersection. True radius settings for each element line are taken from the front view and marked off on the corresponding element line in the top view. These points are connected with an irregular curve to give the correct oval shape for the top surface. If the development of the sloping top surface is required, an auxiliary view of this surface shows its true shape.

OBLIQUE CONE: An oblique cone is generally developed by the triangulation method. Look at figure 8-16 as you read this explanation. The base of the cone is divided into an equal number of divisions, and elements 0-1, 0-2, and so on are drawn in the top view, projected down, and drawn in the front view. The true lengths of the elements are not shown in either the top or front view, but would be equal in length to the hypotenuse of a right triangle, having one leg equal in length to the projected element in the top view and the other leg equal to the height of the projected element in the front view. When it is necessary to find the true length of a number of edges, or elements, then a true-length diagram is drawn adjacent to the front view. This prevents the front view from being cluttered with lines. Since the development of the oblique cone will be symmetrical, the starting line will be element 0-7. The development is constructed as follows: With 0 as center and the radius equal to the true length of element 0-6, draw an arc. With 7 as center and the radius equal to distance 6-7 in the top view, draw a second arc intersecting the first at point 6. Draw element 0-6 on the development. With 0 as center and the radius equal to the true length of element 0-5, draw an arc. With 6 as center and the radius equal to distance 5-6 in the top view, draw a second arc intersecting the fast point 5. Draw element 0-5 on the development. This is repeated until all the element lines are located on the development view. This development does not show a seam allowance.

DEVELOPMENT OF TRANSITION PIECES: Transition pieces are usually made to connect two different forms, such as round pipes to square pipes. These transition pieces will usually fit the definition of a nondevelopable surface that must be developed by approximation. This is done by assuming the surface to be made from a series of triangular surfaces laid side-by-side to form the development. This form of development is known as triangulation.

SQUARE TO ROUND: The transition piece shown in figure 8-18 is used to connect round and square pipes. It can be seen from both the development and the pictorial drawings that the transition piece is made of four isosceles triangles, whose bases connect with the square duct, and four parts of an oblique cone having the circle as the base and the corners of the square pipe as the vertices. To make the development, a true-length diagram is drawn first. When the true length of line 1A is known, the four equal isosceles triangles can be developed After the triangle G-2-3 has been developed, the partial developments of the oblique cone are added until points D and K have been located Next the isosceles triangles D-1-2 and K-3-4 are added, then the partial cones, and, last, half of the isosceles triangle is placed at each side of the development.

RECTANGULAR TO ROUND: The transition piece shown in figure 8-19 is constructed in the same manner as the one previously developed except that all the elements are of different lengths. To avoid confusion, four true-length diagrams are drawn and the true-length lines are clearly labeled.

PARALLEL JOINTS: The development of the transition piece shown in figure connecting two circular pipes is similar to the development of an oblique cone except that the cone is truncated The apex of the cone, 0, is located by drawing the two given pipe diameters in their proper position and extending the radial lines 1-11 and 7-71 to intersect at point 0. Fit the development is made to represent the complete development of the cone, and then the top portion is removed. Radius settings for distances 0-21 and 0-31 on the development are taken from the true-length diagram.

OBLIQUE JOINTS: When the joints between view is required to find the true length of the chords the pipe and transition piece are not perpendicular to between the end points of the elements. The the pipe axis (fig. 8-21), then a transition piece should development is then constructed in the same way as the be developed. Since the top and bottom of the development used to connect two circular pipes with transition piece will be elliptical, a partial auxiliary parallel joints.

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אד-אם סחר מייצגת בישראל חברות אשר להן ניסיון רב בייצור מכונות לעיבוד פח וכיפוף צנרת חברתנו הוקמה ב-1970 ומנוהלת בידי מר מוטי פרי-מור, צברנו ניסיון רב בהקמת מפעלי מתכת ובשיווק מכונות לתעשיית המתכת, התמחותנו המיוחדת הינה בכל תהליכי כיפוף ועיבוד צנרת, פיתוחים בלעדיים שלנו בענף הצנרת מיושמים בתעשיות השונות בארץ ובחו"ל בשבח רב. באתרינו תמצאו מידע רב על תחום התמחותנו ועל ייחודנו המקצועי בתחום הפח והצנרת. אנו משוכנעים כי ההשקעות שלכם מחייבות הבנה וידע טכני מעמיק לדרישותיכם הן של יצרני המכונות והן של נציגיהם. נסיוננו עתיר השנים עומד לשרותכם !.
לרשותכם האתר למכונות משומשות לעיבוד פח וצנרת, באתר תמצאו הזדמנות עסקית נאותה להוזלת עלויות המיכון במפעלכם.

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