Faccin Group: choosing the right rolling technology

Plate rolling machines are among the most versatile solutions in the metal-forming industry. They can be used to roll metal cans and cones to manufacture parts and components in a large variety of sectors, which allows maximizing ROI to the fabricating shop easily. Choosing the right partner is vital for a successful operation: machines must be manufactured with top-of-the-range materials and components, since special attention to the machine structure is a key element. This will not only prevent malfunctions, but also reduce the minimum machine downtime. Faccin Group’s plate rolling machines have an average life span of more than 25 years with proper use and maintenance.

Plate Rolling Equipment: an insight
The company’s plate rolls can be equipped with two, three, or four-bending rolls. Pyramid-type machines, with three or four rolls, are divided into two separate categories for cost and performance: the first one with planetary guides and the second one with linear guides. Faccin Group’s planetary guides are appreciated for their lower cost, while linear guides are preferred because they guarantee a shorter distance between the bending rolls and therefore higher rolling precision. 

4-roll plate bending machines, with linear or planetary guides, guarantee greater productivity and are easier to use, as well as being the only ones that are effectively automated with CNCs. They are the ideal solution for mass production, high volumes, and repetitive process in an automatic cycle. Fast and precise, they are usually used to produce wind towers, truck tanks, HVAC components, etc.

3-roll machines are instead preferred for their versatility and flexibility and are divided into two categories: 3-roll pyramidal plate rolls (linear or planetary guides), and 3-roll plate rolls with variable geometry. These machines are the ideal solution for versatile and flexible production, including cone manufacturing. They are commonly used to manufacture pressure vessels, heat exchangers, pipelines, etc.

Last are the 2-roll plate bending rolls, suitable for large series production of thin-sheet metal products (<0.2’’ / <5 mm).




Technical features
As with any other metal bending machine, the most important technical feature is the distance between the bending points, which translates into accuracy. In a press brake, it is the “V width”, while in a plate bending roll is the distance between the rolls. In short, the closer the lateral rolls approach to the machine's central axis, the more precise the rolling will be. Let’s take the press brake as an example: rolling accuracy means concentrating the bending force on a small portion of sheet metal to obtain a pre-bending with minimal flat or to optimize the final calibration quality in a longitudinally welded area. 

This feature makes the 3-roll variable geometry machine the preferred choice for those fabricators who demand rolling versatility with maximum use of the bending force, precision in pre-bending, and calibration.




Force management
In a plate roll, like in any other metal-forming machine, the bending capacity is directly proportional to the available force. The force required to achieve the bending momentum that forms the steel plate depends directly on the distance (minimum and maximum) between the lateral rolls. In practice, the larger the distance between the rolls, the smaller the force they exert - because the leverage effect will be higher at the expense of circularity tolerances. On the contrary, machines that have rolls positioned closer together require larger hydraulic cylinders and structures in order to achieve the same bending capabilities. Although this results in higher bending accuracy, it also requires a greater investment. When evaluating whether to invest more in a machine with tighter geometry (closer rolls) and higher tonnage, you must consider the following factors:

• amount of material to be cut at the edge not properly rolled in the pre-bending phase;
• time spent to calibrate the circularity of the shell;
• quality of the final product.

Greater quality and reliability are guaranteed by a machine that provides the maximum expected force by using the hydraulic circuit with medium-low pressures.

Control systems
Workforce, consistency, productivity needs point to CNC. There are many reasons to choose a CNC plate bending roll: they provide consistent leading and trailing edges and accuracy, facilitate varying degrees of automation, and allow simple development of irregular shapes. However, the most important reason is that they augment the skills of the new workforce. CNC capabilities help increase productivity. Faccin Group’s latest Siemens CNC is an invaluable must-have integration. All the company's CNCs can be powered with a special function called RSM (Remote Service Management), which is securely connected to the FACCIN Cloud Service. The RSM is a system that ensures the machines can be reached via IP connection for different purposes, such as software updates and diagnostic, as well as monitoring of the machine functions. This also used for collection and transmission of production data for the implementation of all the functions necessary to ensure compliance with Industry 4.0 standards, and creation and transmission to the Cloud Database of the physical operating data of the machinery for parameter analysis and development of predictive diagnostics. Furthermore, a web portal allows evaluating the performance and settings of the machine.

Reviewing, these are the main features to consider when acquiring a plate rolling machine:

• machine construction;
• machine power;
• possibility of adding tech-based accessories such as support devices, feeding tables, plate alignment systems, etc;
• control systems;
• reliable partner with an expert team to support the process.




The Group
Faccin Group has been one of the world’s leading manufacturers of metal-forming machines since the '60s. Thanks to its three leading brands - FACCIN, BOLDRINI, and ROUNDO – the Group offers all the technologies available on today’s market for plate rolling equipment. 

The company makes use of all its experience and technology to provide energy-efficient and innovative Industry 4.0 products and services, which result in exceptional value to help its customers succeed. Let the corporate team assist you with your new or existing metal forming project by reviewing your application and engineering, providing a higher productivity and ROI solution. Contact Faccin Group through the references on the side.