Why is the roller leveler so powerful?

Sheet metal processing companies face huge challenges: they must ensure high product quality and timely delivery while also offering competitive service prices to the market. Therefore, it is imperative to optimize the entire process chain from sheet metal parts to finished parts or components. Roller levelers produce flat and stress-free sheet metal parts in seconds. How can you use this state-of-the-art leveling method to optimize your processes?

In sheet metal processing companies, traditional leveling methods such as hammers and flames, plate rolling machines or leveling presses are no longer effective in reducing residual stresses in the material. These residual stresses in the material can have serious adverse effects in the subsequent processing of the sheet metal parts. They are released by punching or laser cutting, causing sheet metal parts to bend and deform, resulting in time-consuming rework, endangering the entire subsequent process chain and increasing production costs. Therefore, a high degree of automation in sheet metal processing is inseparable from precise leveling processes. Using roller levelers to eliminate stresses in the material The principle of roller leveling is simple and ingenious: the arrangement of the leveling rollers allows the sheet metal parts to be bent several times in a row and alternately. The degree of bending is relatively large at the beginning, and the whole process is very similar to a decaying sine curve. After the leveling, the sheet metal is flat and almost all stresses are eliminated. Therefore, no annoying surprises will occur during the subsequent processing. The number of leveling rollers depends on the thickness of the material. A basic rule is: the more alternating bending is carried out in the roller leveler and the smaller the diameter of the leveling rollers, the less residual stress there will be after the sheet metal is processed and the better the leveling effect. When selecting a roller leveler, make sure that the leveling rollers are sufficiently supported to prevent them from buckling.

Roller levelers are suitable for almost all common metal materials, such as ordinary steel, stainless steel, aluminum or copper. If you do not know the characteristics of the material you are using, you can determine whether your material is suitable for roller leveling by trial processing. In principle, any metal that can be bent can be leveled, which is also suitable for the processing of hard and high-strength sheet metal. However, processing these materials requires small-diameter leveling rollers and high forces to form them. The sheet metal processing market requires high quality, and if the material has defects from the beginning, it will hinder the operation of highly automated production processes. This increases production costs and limits the competitiveness of sheet metal processing companies. The use of roller levelers can effectively reduce rework and scrap rates. For example, sheet metal parts produced by laser processing plants are deformed after stamping, which is not conducive to subsequent processing with process safety. After roller leveling, sheet metal parts can be welded quickly and accurately, with very little need for expensive rework. Reduce working hours by 90% per year

The data shows that by using roller levelers, you can produce more sheet metal parts with stable quality. Improved processing efficiency means reduced production costs, as shown in the case of a large supplier to a construction equipment manufacturer: Using traditional leveling methods, such as leveling presses, it takes an average of 20 minutes for a worker to process each workpiece. Leveling by hammering and flame heating can take up to an hour even for experienced technicians. In contrast, roller levelers can complete the leveling of large-size workpieces in less than a minute. Overall, the use of roller levelers can reduce the total man-hours for processing 60,000 workpieces per year to about 1,000 hours, which is only one-tenth of the time used by traditional leveling methods. With the reduction of labor costs and the significant increase in production capacity, coupled with the most critical improvement of subsequent processes, the company’s annual cost savings potential can reach several million yuan. Sheet metal processing companies will step onto a new level in leveling technology. The use of roller levelers is becoming more and more common in the industry. In addition to lower process costs, it can also significantly save man-hours and production resources, creating space for winning new customers and new orders.