To make it easier to work with a profile pipe, I made this machine to strengthen the profile pipe (15*15.20*20);
Comments 35
I also signed up. Can I have the drawing please?
Everything is great! I sign and give me the drawing please.
Cool topic! If possible, a drawing.
Cool work, I’ll join everyone who wants it, and I also need a drawing
I don’t like it with a groove, so I made a flat roller
the same thing, but combined with a profile bender. bends and presses the groove
definitely bookmarked, awesome!
Are you interested in a drawing of the machine?
Everything was done on the fly, but I’ll try to restore the picture if anything happens and I’ll send it to L/S.
If it works, send it to me, thanks in advance.
well, if you don’t mind me)))
If you don’t mind, please, me too. thank you very much in advance.
Already posted it here.
Everything was done on the fly, but I’ll try to restore the picture if anything happens and I’ll send it to L/S.
Can I do it too, or should I post it here?
Everything was done on the fly, but I’ll try to restore the picture if anything happens and I’ll send it to L/S.
Ok, I'm waiting. I'm just doing forging, I was looking for drawings and couldn't find them.
Everything was done on the fly, but I’ll try to restore the picture if anything happens and I’ll send it to L/S.
I wouldn't mind either
Everything was done on the fly, but I’ll try to restore the picture if anything happens and I’ll send it to L/S.
If it doesn’t bother me too please)
Everything was done on the fly, but I’ll try to restore the picture if anything happens and I’ll send it to L/S.
Throw it here for everyone! :-D
Everything was done on the fly, but I’ll try to restore the picture if anything happens and I’ll send it to L/S.
I would also like to get a drawing.)))
As I understand it, reinforcement means creating a groove along the pipe?
Like adding 2 more corners in opposite walls by pressing (rolling)
Well, yes, you can see it on the finished product. Apparently it’s easier to bend a pipe after this?
Like adding 2 more corners in opposite walls by pressing (rolling)
As I understand it, reinforcement means creating a groove along the pipe?
Yes, on both sides, so that when the professional pipe is bent, it does not break.
the second most needed thing after a pipe bending machine
Definitely, otherwise I’m already tired of hammering with a chisel and a hammer)))
How many blows should be made per linear meter?
It's better not to remember)))
the second most needed thing after a pipe bending machine
So this is such a machine, for further work you only need to make removable rollers on the shafts for various pipes, both profile and round.
The table is good! Already have a client for it? I didn’t understand the machine, sorry, do you roll a groove on a professional pipe? Is there a cross-sectional photo of the finished professional pipe, please enlighten me.
To watch online, click on the video ⤵
Design
The machine for strengthening the profile in its operating mechanism and design is almost in every way reminiscent of an ordinary rolling machine.
Apart from the frame and the motion drive, the main components of the machine for reinforcing a profile pipe are:
- Lower (support) shaft – 1 pc. It is leading, with its help the pipes move.
- The upper shaft is the pressing one. It deforms the profile - it presses the pipe against the lower shaft.
The supply and receiving shafts are securely mounted on a powerful base (housing); it must ensure the stability of the installation during operation. The feed mechanism ensures the rotation of the shafts around its own axis.
Special requirements are placed on the alignment of the rollers: they must be placed 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 profile pipes should not pose a danger to humans during operation. During assembly you should:
- It is very reliable to fix all moving parts. Prevent them from bouncing during operation.
- Anticipate protective flaps.
Correctly assembled homemade installations are not inferior to professional models in terms of the quality of the products produced.
Application area
To obtain a suitable configuration, profile pipes are alternately processed on profile strengthening machines, a forging block and a pipe bender.
A pipe bender allows you to bend profile pipes along a longitudinal section along a given radius. Such products are used in the installation of canopies, gazebos, and canopies.
Reinforcement is a necessary step in preparing a profile pipe for making a curl using the cold forging method. The forging block allows you to make decorative elements from pipes with a square or rectangular cross-section, curved in the most unusual way. The purchased products are distinguished by their volume, lightness, and low price.
Tools
When assembling the machine, you will need the following abilities (as well as the corresponding equipment):
Fastening by welding in some places can be replaced with threaded connections.
- drill, with a set of drills;
- wrenches of various sizes;
- level for setting the horizon line;
- caliper, tape measure.
Making a machine yourself
It doesn't always make sense to purchase a professional machine. For one-time work, simple DIY installations are more suitable. The main thing is to have drawings, carefully study the design principle and operation of the machine, select high-quality materials for the workpieces and the necessary tools for assembly.
Scheme
Schematic diagram of a machine for rolling 2 types of profile sections in section. Based on it, you can get an idea of the design and interconnection of the main components and the principle of pipe processing. In this case, the upper shaft is the driving one.
Machine diagram
Accessories
Rolling roller components must not have chips or gouges, have a decent margin of safety, and be made from certain grades of steel.
Shafts and axles are turned on a lathe. Some components can be bought in a store or removed from other mechanisms, for example:
- self-aligning rolling bearings (4 pcs.);
- stars (4 pcs.);
- chain from a bicycle, moped.
To assemble the frame (base), you will need rolled metal (channels, pipes), sheets 5-10 mm thick. The base ensures stability of the installation during operation.
Frame assembly
To strengthen the profile, it is better to make rollers (2 pieces of each type) from alloy steel; for a small amount of work, St3, St10 are also suitable. Roll blanks are subjected to hardening.
Rollers and axles must be many times harder than the pipes being processed. Otherwise, the rollers will have to be replaced frequently with new ones. The hardness of rollers on professional installations is at least 52 HRC.
Tools
When assembling the machine, you will need the following skills (as well as appropriate equipment):
Fastening by welding in some places can be replaced with threaded connections.
- drill, with a set of drills;
- wrenches of different sizes;
- level for setting the horizon line;
- caliper, tape measure.
Design of incoming parts
Special rollers are machined along the edges of the rollers, which reliably fix the position of the pipe during rolling.
Rollers
You can get the dimensions of the rollers for profile drawing from a kit from professional installations. It is not difficult to develop drawings of rollers and axles according to the obtained dimensions yourself. Below is an example drawing.
Roller drawing
Rolling of each profile size is carried out using rollers of appropriate sizes. Making a model with removable elements is not easy; for this reason, it is recommended to make multi-stage rollers for reinforcing the profile pipe when assembling the machine yourself. This will allow processing of pipes of different sizes without reinstalling the rollers.
Both axes have the same dimensions, but different lengths. The movement handle is attached to the longer axis (driving). Below is a drawing of an axle with a seat for the handle.
Drawing of an axle with a seat for the handle
Assembly work
The frame is created gradually as the remaining parts are assembled. The individual elements of the base are connected to each other by welding or large bolts.
Profile pipe reinforcement block drawing
I returned the drawings at your request and am posting them for everyone to see;
Functionality
Functional 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 parts;
- forging block for cool forging.
All operations are performed without readjusting equipment or changing tools. The modules allow you to make various decorative forged elements of various sizes and required shapes.
An example of a multi-purpose installation is unit with rolling crow's feet (PGL), produced in series, adapted for several operations:
- “crow’s feet” type reinforcement
- rolling out the ends of the workpiece.
After such processing, the pipe is one hundred percent ready for the production of a decorative curl on a forging block.
Drive mechanism
According to the mechanism of operation, there are different types of wired devices:
The manually driven machine has a conventional design, compactness, and is designed for small volumes of work. Only a physically developed person will be able to work on it. The metal will have to be deformed using muscle force.
An electrically driven machine for strengthening a profile pipe also takes up little space. It is powered by an electric motor, and the performance is the highest.
Hydraulically driven equipment is very bulky. Allows you to roll profile products with the highest dimensions. Created for huge volumes of work.
Drawing for a machine for strengthening a profile pipe. — DIY community on DRIVE2
I restored the drawings at your request and am posting them for everyone to see;
the second shaft needs to be made longer, under the handle
two rollers, identical
sprockets, 4 pieces, chain and bearings, everything from timing belt 406
It can be done even easier if you find and select two identical gears that will be on the shafts. And relative to them, then grind the rollers and shafts. I made it from what I had on hand. Two plates 300*300mm, I think at least 5mm thick (I had 10mm), folded them together and grabbed them to drill holes for the shafts (16mm). I didn’t draw a drawing of the holes, but I think it won’t be difficult to measure. Put the rollers on shafts and find out the distance at the centers of the shafts. The closer the rollers are to each other, the better. First, assemble the shafts onto a plate where there will be sprockets, a chain, then rollers, then a second plate. Then I put on the chain, measured where two more sprockets will be attached. When everything was adjusted (chain drive), I removed the plate from the opposite side, grabbed the rollers to the shafts( I made a hole in advance with a large drill for welding) on one side. I put the plate back on and welded the bottom and top. It seems like everything, if you missed something or it’s not clear, ask, I’ll try to explain.
It is advisable to sharpen the rollers from stronger metal, since the place that presses on the pipe rolls out.
Types of devices with rotating rollers
Rolling of a profile pipe, which results in a change in its initial configuration, can be carried out using equipment of various designs. Such devices for rolling profile pipes can differ according to the type of drive used and the main technical features. Thus, rolling rollers can have:
- manual drive (the use of such devices for rolling profile pipes requires significant physical effort);
- electronic drive;
- hydraulic drive mechanism.
Manual rolling rollers serve as a model for self-production of the machine
More ordinary (and, accordingly, cheaper) devices used to roll a profile pipe are manual profile benders. Along with their reliability and ease of use, they are distinguished by a number of significant advantages. The design of a manual profile bender consists of the following elements:
- a powerful frame that serves as a reliable foundation for the entire structure;
- rollers that perform feeding and receiving functions (these structural elements, with the help of which rolling is carried out, are connected to each other by means of a chain transmission);
- a set of clamping devices (clamps) designed to secure pipes of various sizes.
This rolling machine, which has a simple design, is also equipped with a special pipe, which acts as a guide for the bent workpiece. It should be understood that the implementation of such a machine requires significant physical effort from the performer. In addition, this device does not allow rolling with high productivity and in most cases is used for light work at home. That is why the design diagram of this machine is used to make a profile bending machine with your own hands. This profile bender, which is conventional in design, allows you to roll profile pipes efficiently and with the highest efficiency.
An electronic machine for rolling profile pipes, even manufactured independently, ensures higher productivity of the technological operation. This is explained by the fact that an electronic drive, the power of which can be quite large, is responsible for performing the main operation - pulling the professional pipe through the rollers. That’s why electronic rollers for profile pipes, which you can make yourself using drawings, are used by both small organizations or home craftsmen, and manufacturing enterprises.
The machine can be equipped with an electric drive later, the main thing is to take this into account at the beginning and develop a fairly strong design
But, naturally, the hydraulic profile bending machine has the highest power, which is quite difficult to make with your own hands. Devices of this type, created for rolling profile pipes, are used to a greater extent in industrial enterprises, where such a technological operation must be carried out with the highest productivity.
Do-it-yourself rollers for profile pipes, drawings and videos
For high-quality implementation of the construction process, it is necessary to have a complete list of tools. When working with pipes, you cannot do without a pipe bender - a special device with which a profile pipe can be given a correctly curved shape. But professional equipment costs money, so let’s look at how you can make rollers with your own hands.
Based on the design features and the source of the force used to bend the pipes, the tool can be divided into the following types:
- Electrically driven. This device for changing the shape of pipes is almost completely automated and does not require human power to carry out the work process. It allows, in the shortest possible period of time, to give a large number of elements the desired shapes.
- On hydraulics. The presence of an installed press with a hydraulic drive allows you to bend a pipe of any diameter - the force of the device is very high. But due to their huge dimensions and the inability to be moved from place to place, they are inferior to mobile models.
- Manual. Such rollers are small in size, which simplifies transportation, but their operation requires a person to have a certain force necessary to bend the profile pipe.
The first two types are largely manufactured in factories or relevant enterprises, so we will focus on manual rollers, the possibility of making them yourself is quite real.
Pipe bender
How do they work?
To bend a profile pipe, you need:
- Place the pipe on the feed rollers of the device.
- Press the pipe against either of the two rollers, increasing the pressing force until the element begins to bend at the desired angle.
- Turn on the transmission mechanism. The pipe will begin to pass through the device and a uniform bend will be obtained along its entire length.
If the desired result is not obtained the first time, the operation is repeated, but with a changed clamping force.
Making a pipe bender with your own hands
Self-production is a process that is quite feasible at home, but requires the performer to have some skills in carrying out mechanical work. It is equally important to choose the correct drawing, according to which all parts of the future mechanism will be manufactured in exact accordance.
Depending on which drawing is selected, the mechanism may have the following elements:
- Support frame.
- Rollers. In most cases there are 3 of them: 2 bypass and 1 clamp.
- Bearings.
- Drive unit.
- Guide rings.
- Stopper (needed to fix a certain level of bending).
- Rod for feeding the pressure roller.
- The base must withstand heavy loads - to make it yourself, use a channel, or better yet, a tubular frame.
- The part that will be responsible for supplying the force for bending is made of a U-shaped frame. A nut is welded into its top. In this case, a threaded clamp is used. A bolt of suitable diameter is screwed into the stud and a round metal heel is welded to its end.
- To make a feed mechanism, you need to find a chain from a motorcycle or bicycle. 2 sprockets are welded onto the rollers: 1 for the deforming one and 1 for the driven one. The chain is tensioned and checked. Only after making sure that the rollers with a tensioned chain rotate without difficulty is the handle welded.
- The rollers must have a high level of strength, which will allow them not to be affected by the profile pipe (you need to bend the pipes, and not vice versa). They can be made from ordinary steel, which must be hardened after turning.
- To fasten the rollers, roller bearings are used, which are installed on the frames (located on the cups).
Note. The design can be improved with a hydraulic jack. It is installed under the bed. This will allow the bending force to be transferred via incoming pressure to the upper feed rollers.
Should I buy a machine or make it myself?
It makes no sense to compare homemade mechanisms with purchased ones. But, if you do the work correctly when making it yourself, a good drawing is chosen and there is no need to use a pipe bender every day - it is better to do without unnecessary expenses (especially if you take into account the cost of devices for such purposes).
Before starting work, determine the degree of expected load on the device and consider the possibility of manufacturing it using an electric drive. You also need to take into account that the more functional the pipe bender is, the less opportunities there will be for its transportation - as the functions increase, the weight also increases.
Choose clear drawings and carry out the work in full accordance with them. Then the mechanism, made by yourself, will perform high-quality bends and will last for many years.
Drawings of a pipe bender for a profile pipe updated: November 25, 2017 by: kranch0 Loading. Read on topic
Standard profile pipes of square or rectangular cross-section, due to their high bending strength and low weight, are widely used in construction. In cases where the permissible load values are exceeded, which occur during strong bending, the products become deformed and break. The use of pipes with a reinforced profile allows you to eliminate negative consequences.
Rollers for profile pipes: making manual profile bending with your own hands
Making rollers for a profile pipe with your own hands, using drawings and knowledge of the operating mechanism of this useful device, is completely possible. Using such a device, which has the highest versatility, you can independently produce bent structures of any degree of difficulty from corrugated pipes.
Rolling profile pipes for a canopy on a homemade machine
The main working parts of the rollers, which exert a mechanical effect on the processed profile pipe, are rotating rollers, the number of which can vary from 3 to 5 pieces. It is in the gap between the rolls that plastic deformation of the corrugated pipe occurs.
Do-it-yourself rollers for a profile pipe: drawing and assembly instructions
Often in the household, during all kinds of repair work, it is necessary to bend a piece of pipe in a special way, and in this case you need to think about how to make rollers for a profile pipe with your own hands. Naturally, the easiest way is to buy professional rollers at a hardware store, but not everyone has the extra money for this device.
You can make the pipe material take the desired shape using a conventional torch. This method is often practiced, but the master faces some difficulties:
- it is almost impossible to get the product even, this is explained by improper distribution of forces and inaccuracy of movements;
- emphasis is required and, as a result, a lot of physical strength;
- it becomes necessary to have a large lever to change the shape.
To get a high-quality result, you need to use rollers. With their help, you can easily transform a profile pipe with your own hands.
Conventional rollers are a structure that has a special lever that drives several steel shafts, passing through which the metal pipe receives the required curved shape. To make rollers with your own hands at home, you need to have the necessary drawings on hand and thoroughly know the principle of the device. Homemade rollers for bending profile pipes will have good performance and decent quality if the assembly technique is strictly followed.
Types of rollers and operating features
The most popular are manually driven rollers. This universal device most often has a relatively light weight and compact dimensions. The master should have no questions about placing them in his home workshop.
Homemade devices for rolling pipes
In fact, you cannot do without such a device as a device for rolling corrugated pipes in those situations when you decide to do repairs on your own, during which you will have to deal with bent pipes. To do this, you can purchase a serial device for a similar purpose or use a homemade profile bender, the design of which is not extremely complex. It also makes sense to ask the question of how to make a profile bender for the reason that serial models are quite expensive, so their acquisition (especially if they are required only for home repairs) is not always targeted.
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Approximate dimensions of homemade rollers
In order to perfectly make homemade rollers, you can study theoretical information, watch a video on this topic, but the main thing is to follow the advice of those who have already achieved good results in solving this issue. Naturally, to make your own roller, you need to have not only the proper knowledge, but also certain abilities to produce and use various technical devices.
Homemade rollers can even be made from scrap materials, which are practically always available in any garage or home workshop. With all this, the efficiency of such rollers, if they are made taking into account all the tips, will not be much lower than that of commercially produced models.
How to make a profile bender yourself
To make a roll forming machine with your own hands, you need to follow the following sequence of actions.
- First, a base or frame is made, why you can use pipes of huge diameter or iron channels.
- Strict attention should be paid to the manufacture of the vertical support of the machine, the material for which can be a U-shaped profile. It is in the highest part of such a support, which must be distinguished by the highest reliability, that a pipe-deforming unit - a roller mechanism - is installed. To install a vertical support, the lower part of which is firmly fixed under the frame, you will need a clamp of the appropriate size. With this method of attaching the vertical support, the deformation force exerted on the bent profile pipe will be moderately distributed over the two feed rollers.
- To rotate the feed rollers, they use a chain drive, which can be assembled using a chain and sprockets from an old bike. The sprockets, which in terms of their geometric characteristics must strictly correspond to the features of the chain used, are fixed on the feed and driven shafts. When installing a chain feed mechanism for your homemade machine, you should ensure good chain tension and only then proceed to fix the feed mechanism handle. Naturally, the drive mechanism of your machine for rolling corrugated pipes should ensure easy rotation of the feed and driven shafts.
- The homemade rollers themselves, which will exert pressure on the bent profile pipe and thereby take the main load during operation of the machine, are best made from steel that has undergone the hardening function.
The entire production process of a manual profile bender is carefully depicted in the photo below.
In order for a self-made rolling machine for profile pipes to have the highest versatility and be used for processing products of various sizes, its design must provide for the possibility of performing circular adjustments. This fundamental function allows you to change the size of the gap between the work rolls. To make your homemade rollers even more multifunctional, you can provide in their design the possibility of performing angular or, as it is also called, axial adjustment.
Homemade devices for bending profiled pipes, made according to universal schemes, can be modernized in the future, if the need arises. For example, they can be equipped with an electronic drive or installed on a larger number of work rolls.
The design of the machine can be simpler if you use a hydraulic jack, as shown in the video below.
How to make a block for rolling and reinforcing a profile pipe
In this review, the master will share his experience in producing blocks for decorative rolling, as well as reinforcing corrugated pipes.
To produce the machine, the following materials will be required:
- iron plates;
- bearings;
- round pipe ;
- hairpins;
- bolts with nuts;
- steel washers.
First of all, the author cuts off two rectangular metal plates, and uses a paper template to make markings - using a punch, he marks the places for drilling holes.
It is necessary to drill holes with a diameter of 12 mm along the edges of the cut blanks, and with a diameter of 38 mm in the center.
Main stages of work
In the next step, the author cuts four pieces of round pipe. We make bearing cages from them.
We weld the races to the metal plates, and then press the bearings into them.
Next, we need the car's crankshaft toothed pulleys. We weld nuts to them.
We prepare the remaining parts and begin assembling the structure.
We put gears on the prepared studs, and then - homemade rolling rollers with washers. We fix the stud with nuts.
Finally, we tighten the metal plates together using pins with a diameter of 12 mm. We make and attach the handle.
Details on how to make a block for rolling and reinforcing a profile pipe can be seen in the video below. This idea belongs to the author of the YouTube channel Welder DIY.
How to make rollers for a profile pipe?
The advent of cellular polycarbonate for the manufacture of greenhouses determined a new type of structure for protected ground structures - arched structures. To create a metal frame for such buildings, you need to have a machine capable of bending structural profiles along a certain curve.
Homemade rollers for profile pipes are designed to help in the manufacture of arches along a given radius. The technological process of profiling long workpieces is based on pulling the part through rollers located at a certain distance from each other. To give a bend in one direction or another, the length of the length is not passed in a straight direction, one or two rollers are offset.
Recommendations
Special requirements are placed on the alignment 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 profile pipes should not pose a danger to humans during operation. During assembly you should:
- Fix all moving parts as reliably as possible. Prevent them from bouncing during operation.
- Provide protective flaps.
Properly assembled home-made installations are not inferior to professional models in terms of the quality of their products.
Functionality
Multifunctional stationary modules, 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 or changing tools. The modules make it possible to produce various decorative forged elements of different sizes and required shapes.
An example of a multi-purpose installation is unit with rolling crow's feet (PGL), produced commercially, adapted for several operations:
- “crow’s feet” type reinforcement
- rolling out the ends of the workpiece.
After this treatment, the pipe is completely ready for making a decorative curl on a forging block.
Application area
To obtain the desired configuration, profile pipes are sequentially processed on profile strengthening machines, a forging block and a pipe bender.
A pipe bender allows you to bend profile pipes along a longitudinal section along a given radius. Such products are used when installing canopies, gazebos, and canopies.
Reinforcement is a necessary stage in preparing a profile pipe for making a curl using the cold forging method. The forging block allows you to create decorative elements from pipes with a square or rectangular cross-section, curved in the most bizarre way. The resulting products are distinguished by their volume, lightness, and low price.
Accessories
Rolling roller components must not have chips or gouges, have a decent margin of safety, and be made from certain grades of steel.
- self-aligning rolling bearings (4 pcs.);
- stars (4 pcs.);
- chain from a bicycle, moped.
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To assemble the frame (base), you will need rolled metal (channels, pipes), sheets 5-10 mm thick. The base ensures stability of the installation during operation.
To strengthen the profile, it is better to make rollers (2 pieces of each type) from alloy steel; for a small amount of work, St3, St10 are also suitable. Roll blanks are subjected to hardening.
Rollers and axles must be many times harder than the pipes being processed. Otherwise, the rollers will have to be replaced frequently with new ones. The hardness of rollers on professional installations is at least 52 HRC.
Process technology
The amplification process on the simplest machine is performed sequentially, with two pipe installations:
- Step 1 – installing the pipe on the rollers.
- Step 2 – rolling the first 2 symmetrical sides.
- 3rd step - reinstall the pipe (rotate 900).
- Stage 4 - rental of the second 2 symmetrical sides of the profile.
Reinforcement of the profile is carried out on a cold forging machine equipped with rollers for compressing the profile pipe before bending it into a curl.
The rolling process depends on the wall thickness of the profile pipes and the grade of material from which they are made
Application area
To obtain the desired configuration, profile pipes are sequentially processed on profile strengthening machines, a forging block and a pipe bender.
A pipe bender allows you to bend profile pipes along a longitudinal section along a given radius. Such products are used when installing canopies, gazebos, and canopies.
Reinforcement is a necessary stage in preparing a profile pipe for making a curl using the cold forging method. The forging block allows you to create decorative elements from pipes with a square or rectangular cross-section, curved in the most bizarre way. The resulting products are distinguished by their volume, lightness, and low price.
Assembly work
The frame is created gradually as the remaining parts are assembled. The individual elements of the base are connected to each other by welding or large bolts.
The distance between the upper and lower axle depends on the diameters of the rollers. In the absence of precise assembly drawings, the dimensions between the axes are determined experimentally:
- install the rollers on the axle;
- measure the distance between the axes;
- drill holes on the side walls of the frame for installing bearings;
- then the axles are put aside and the bearings are installed.
The connection between the axle and the rollers is carried out in several ways:
- using a key, about 8x8 mm in size;
- welding through pre-drilled countersunk blind holes made with a large-diameter drill.
The second method is available if you have a machine for manual electric arc or semi-automatic welding.
Next, the axle is inserted into the bearing, which is pre-fixed in the axle box, which is pre-welded to the wall of the frame from the inside. Reliability of fastening is maximum. First of all, the 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 bearings mounted on the 2nd side wall of the frame.
NEW profile pipe rental unit. Cold forging reinforcement of professional pipes
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 on site:
- install the 1st sprocket on the lower axle;
- on the upper axis - 2nd sprocket;
- try on the chain, mark the location of 2 more sprockets.
Chain mechanism assembly
The rollers should rotate without difficulty when the chain is tensioned. The handle is welded to the drive axle last.
Chain mechanism
For the motion feed mechanism in the form of a worm gear, it is necessary to stock up on gears of the required size.
Motion feed mechanism
Drive mechanism
According to the principle of operation, there are different types of wire mechanisms:
- manual;
- electric;
- hydraulic.
The manually driven machine has a simple design, compactness, and is designed for small volumes of work. Only a physically developed person can work on it. The metal will have to be deformed using muscle force.
An electrically driven machine for strengthening a profile pipe also does not take up much space. It is powered by an electric motor and has high performance.
Hydraulically driven equipment is too bulky. Allows you to roll profile products with maximum dimensions. Designed for large volumes of work.
Scope of application of profile pipes
Profile pipes in the retail chain are sold in sections 6 m long
Profiled pipe made from thin sheets has a number of irreplaceable properties:
- the presence of a rectangular or square cross-section provides a fairly high resistance to bending influences;
- against torsion, this type of section works quite successfully;
- with a small mass, the spatial structure is able to withstand significant static and dynamic loads;
- such blanks are easy to cut to a given size;
- the material is easily welded with all types of welding;
- blanks from corrugated pipes are delivered to the installation site, and then relatively quickly and easily assembled into the finished product;
- used as a metal frame, it is subsequently sheathed with finishing materials.
An original bench that uses pipes bent into two different radii
Industrial enterprises and craftsmen in their workshops make a wide variety of products from profile pipes. Protected ground structures are the most represented. Greenhouses and greenhouses are created according to different schemes:
- with a gable roof. Such designs have a traditional look. They form two slopes for dumping snow and rain moisture. Such greenhouses are quite spacious, the walls are vertical;
- arched type. To create such a product, you must first create arches. Rollers and special bending equipment are used here. With minimal costs of metal and cellular polycarbonate, a significant area of insulated soil is achieved. Such structures are made according to pre-created drawings;
- “drop” is a special type of greenhouse. It has a peaked roof, on which snow practically does not linger in winter. High space is used for growing tall plants. Even quite large trees and grapes are placed here;
- “Pavilion” is another interesting type of greenhouse. A semicircular roof is used with vertical walls. Such structures make it possible to create not only greenhouses for summer growing vegetables, they are used even in severe frosts. The temperature inside remains summer, and heat-loving plants grow.
A “butterfly” greenhouse allows you to approach plants from two sides. In hot weather, the walls rise. In cold weather they are lowered. The cold will not reach the plants
Country furniture made of profile pipes. Metal can be used to make elegant designs
Budget tables and benches made from profile pipes are in high demand among the population
Outside the city, as well as in parks and places of public recreation, you can happily sit down on a comfortable rocking chair
In summer it's nice to be in the shower. The booth was also made from a profile pipe
An inexpensive and comfortable gazebo is in demand almost everywhere. They are placed in dachas, they find a place in the local architecture. A small roof will provide protection from the sun and rain
Light bar stools are laconic and quite comfortable. They can be placed in a bar, or at home.
Related article: is it possible to bend a profile pipe without a pipe bender?
Operating principle and drawing of a machine for strengthening a profile pipe
Standard profile pipes of square or rectangular cross-section, due to their high bending strength and low weight, are widely used in construction. In cases where the permissible load values are exceeded, which occur during strong bending, the products become deformed and break. The use of pipes with a reinforced profile allows you to eliminate negative consequences.
Process technology
The amplification process on the simplest machine is performed sequentially, with two pipe installations:
- Step 1 – installing the pipe on the rollers.
- Step 2 – rolling the first 2 symmetrical sides.
- 3rd step - reinstallation of the pipe (rotate 90 0).
- Stage 4 - rental of the second 2 symmetrical sides of the profile.
Profile strengthening machine
Reinforcement of the profile is carried out on a cold forging machine equipped with rollers for compressing the profile pipe before bending it into a curl.
Profile pipe
Profile pipe reinforcement block, answers to questions, another drawing
The rolling process depends on the wall thickness of the profile pipes and the grade of material from which they are made
Accessories
Rolling roller components must not have chips or gouges, have a decent margin of safety, and be made from certain grades of steel.
- self-aligning rolling bearings (4 pcs.);
- stars (4 pcs.);
- chain from a bicycle, moped.
To assemble the frame (base), you will need rolled metal (channels, pipes), sheets 5-10 mm thick. The base ensures stability of the installation during operation.
Frame assembly
Block rolling and strengthening pipe profile without turning
To strengthen the profile, it is better to make rollers (2 pieces of each type) from alloy steel; for a small amount of work, St3, St10 are also suitable. Roll blanks are subjected to hardening.
Rollers and axles must be many times harder than the pipes being processed. Otherwise, the rollers will have to be replaced frequently with new ones. The hardness of rollers on professional installations is at least 52 HRC.
Design
The machine for strengthening the profile is in many respects similar in principle of operation and design to a conventional rolling machine.
In addition to the frame and the motion drive, the main components of the machine for reinforcing a profile pipe are:
- Lower (support) shaft – 1 pc. It is leading, with its help the pipes move.
- The upper shaft is a pressure shaft. Deforms the profile - presses the pipe against the lower shaft.
The supply and receiving shafts are securely mounted on a massive base (housing); it must ensure the stability of the installation during operation. The feed mechanism ensures the rotation of the shafts around its axis.
Disadvantages of profile pipes and solutions
With all the advantages of profile pipes, they also have a disadvantage. Manufacturers try to use materials of small thickness. Therefore, when designing long products, it is necessary to lay larger workpieces. The lightness of appearance is lost.
But homemade structures are quite often made from a rather thin initial blank. To strengthen the profile pipe from deflection, additional ribs are added to it. The result is increased rigidity.
The issue can be resolved by tapping with a hammer on one of the sides, crushing the edge. You can approach the issue more rationally: make a device that will slightly change the shape of the pipe profile.
The following was noticed:
- if you roll a square from above and below, you can additionally create reinforcement ribs;
- bending strength increases by 20...30%, which allows the use of smaller format pipes of one or even two standard sizes.
As a result, the master saves material and creates a lighter and more interesting design.
Manufacturing of rolling rollers
In this case, we will do without using a milling machine and lathe - the method is available to every craftsman. We will use hex nuts M30 and M27 as a basis.
Please note: nuts must be used from KAMAZ, but not ordinary construction ones - they will not cope with their task. The M30 nut was taken from the jet rod, and the M27 nut from the stepladder.
All dimensions of parts and drawings of shafts and other structural elements will be presented by the author in the video.
First of all, we make a homemade roller for rolling 15x15 mm square corrugated pipe.
We take an M30 nut, grind a semicircular chamfer from the end, and then mark a line from the edge of the nut with a marking tool at a distance of 8.2 mm. We cut this nut according to the marked markings.
We cut out a template from paper, apply it to each face of the nut, and trace it with a pencil or marker.
Next, we grind the nut along the markings using an angle grinder and a flap wheel.
READ How to remove glass sealant from a body
Now we need an M20 nut. We grind the edges with a flap wheel and press it inside the rolling roller so that the edges of the nut protrude the same distance on each side.
In a similar way, we make other rollers for rolling profile pipes with our own hands, but you will need to take into account the standard dimensions indicated in the drawing.
For example, to make a roller for rolling a 20x20 mm profile, we use an M27 nut and cut the roller not 8 mm wide, as in the previous case, but already 11 mm wide.
There is one caveat - the M20 nuts that are pressed inside the roller are 15 mm wide, so they will have to be increased. Or you can use an extended M20 nut and cut a piece of the desired size from it.
You can watch the detailed process of making homemade rollers for rolling (rolling) a square corrugated pipe with your own hands in the video. The author of the YouTube channel Welder DIY shared his experience.
Manual machine for decorative rolling of professional pipes
In this article we will tell you in detail how to make two devices for processing (cold forging) a square corrugated pipe. The first option is a mini machine, the second is a manual jig.
The machine is of greatest interest to home craftsmen.
There are a variety of designs - we will look at one of the simplest. We will describe in detail below how to roll a corrugated pipe with your own hands for cold forging.
The drive of the rolling machine can be used in different ways - you can roll the profile manually, or you can install an electric motor. At home, a machine with a manual mechanical drive is quite sufficient.
For synchronous rotation of the shafts (lower and upper), we will use gears that are installed on each of the shafts. The drive shaft is the one located on top.
Shafts for rolling corrugated pipes can be made composite - from several elements or solid - from steel round timber of suitable diameter (but this will require a lathe or, at least, a familiar turner).
Manufacturing of the block body
Materials that will be required to make the body of a homemade reinforcement block for a profile pipe:
- metal plate;
- round steel pipe ;
- bearings (size - 6304);
- threaded rod;
- rollers for rental;
- gears from a car crankshaft.
To assemble the body of the machine block to reinforce the profile pipe, using a grinder or plasma cutter you will need to cut a metal plate 10-12 mm thick.
After this, we drill two holes in it with a diameter of 38 mm (for this you can use a metal crown).
We cut two rings from a metal round pipe and weld them to the plate. These will be the bearing races. Using the same principle, we make another such plate with clips.
We take four 6304 bearings and press them into the cages. If possible, it is better to press it in a bench vice. If you hit it with a hammer, you can damage the bearings.
Next we need two gears from the crankshaft. Hex nuts must be welded to the gears on both sides. We screw the gears onto the shaft (in this case, an M20 threaded rod is used).
The nuts on the gears must be welded to the stud. To do this, use an angle grinder to make a cut in the nuts to the thread of the stud, and then carefully weld them.
To assemble a homemade machine, you will also need special rollers for decorative rolling (used for cold forging of profile pipes) - we will tell you how to make them below. We put them on threaded rods. We install steel washers between the rollers.
Additionally, we cut off four metal strips - they will be used during assembly (to connect the side walls).
The step-by-step process of manufacturing the block body with all the explanations can be seen in the video below.
Functionality
Having small dimensions and weight, a homemade machine allows you to perform many operations on processing profile pipes.
As a result, we get not just a reinforced profile, but also a decorative element.
Using a rolling machine, the manufacture of which we discussed in detail above, you can create different patterns on the surface of the corrugated pipe - “pigtail” and “wave”.
A reinforced profile pipe after one- or two-sided rolling is capable of withstanding increased bending loads, due to which it can be used in the manufacture of various bent decorative metal structures.
In a home workshop, the use of a homemade mini rolling machine to strengthen a profile pipe is completely justified, and a do-it-yourself design is much more profitable than a factory-made machine.
You can use a variety of rollers (rollers), depending on what kind of pattern you require. Eccentrics are used to roll out (flatten) the ends of the profile pipe.
Recommendations
Special requirements are placed on the alignment 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 profile pipes should not pose a danger to humans during operation. During assembly you should:
- Fix all moving parts as reliably as possible. Prevent them from bouncing during operation.
- Provide protective flaps.
Properly assembled home-made installations are not inferior to professional models in terms of the quality of their products.
When carrying out repair and construction work in the private sector, there is often a need to manufacture curved metal structures. They are used to create a frame for canopies, awnings, roofs of houses and gazebos. Rollers for profile pipes will help solve this problem. These are devices that can be purchased in specialized stores or made with your own hands. Let's consider the purpose of these devices, their varieties and specifications.
Assembling a machine for strengthening a profile pipe
After the rollers and other parts have been made, you can begin assembling the homemade device. Let's look at the main stages of work to be done.
Metal plates with bearing cages act as the side walls of the housing.
We insert shafts into them (M20 threaded rods) with gears and rollers mounted on them for rolling out (reinforcing) the profile. Fix with nuts.
Before inserting the studs with rollers into the second side wall, we put eccentrics on them, and weld nuts to them.
Shafts with installed eccentrics
We weld two metal strips on the bottom and top of the side walls.
To fix block in a vice, it is necessary to weld a piece of metal angle or profile pipe to the bottom of the side walls.
At the last stage, all that remains is to clean the welds and paint the homemade product. You will also need to make and install a handle to rotate the drive shaft.
You can see the step-by-step process of assembling a cold forging machine in the video below.
Design of a homemade rolling machine
To roll a profile pipe, you need to make a simple device that will implement the following ideas:
- the pipe moves between guide bearings installed with a small gap (0.2...0.4 mm);
- Profiling rollers will press on it from above and below. When pushing the workpiece between them, the upper and lower edges will collapse. The side edges will not change.
Rolling machine for profiling pipes 20·20 mm: 1 – stand; 2 – body-cover; 3 – rolling roller; 4 – bearing
Between the upper and lower housing-covers 2, bearings 4 are located on special axes. The distance is chosen so that with a small gap the profile pipe can pass between them.
Rolling is carried out by two rollers 3 mounted on special stands 1. They are welded to the housings so that the rollers crush the pipe by 2.0...2.5 mm on each side.
The body-cover is made of a 6 mm thick plate
The roller must be made of high-strength structural steel. 65G spring steel can be used
There is no need to use expensive material to make the stand. Regular quality steel will do
The design provides for the use of a handle to rotate the roller. Similar handles are used on washing machines produced in the eighties and nineties of the last century. They can be found at metal depots and scrap metal collection sites.
A simple device for strengthening a profile pipe
Let's consider another option for a homemade design, which is perfect for a home workshop (for performing a small amount of work).
Materials that will be required to make this device:
- metal plate 50 mm wide;
- round pipe (steel);
- bearings - size 6201;
- hardware - bolts, nuts, washers.
Required parts for assembly
We cut two plates 50 mm wide (metal thickness - at least 5 mm). The length of the first plate is 130 mm, the second is 160 mm.
It is necessary to drill holes with a diameter of 12 mm in the metal plates to install bearings. The distance between the centers of the holes should be 43 mm.
We cut two round pipes and weld them along the edges of one of the metal plates.
Using washers, you can adjust the distance between the walls of the device body - for rolling square pipes of different sizes.
For example, if you need to strengthen a 15x15 mm profile, then we use two washers 3 mm thick. We add to them the thickness of the bearing (10 mm) and get the distance between the walls - 16 mm.
We assemble the device (we use bolts and nuts to secure the bearings), and we can get to work. Making such a design takes a minimum of time.
We drive the end of the profile pipe between the rolling rollers (bearings). After this, we fix the edge of the profile in a bench vice and roll it manually - in short jerks or translational movements.
For details on how to assemble such a device with your own hands, and how to then use it to roll a professional pipe, see the video below.
Sources:
https://iobogrev.ru/blok-usilenija-profilnoj-truby-chertezh https://met-all.org/oborudovanie/prochee/valtsy-dlya-profilnoj-truby-svoimi-rukami-chertezhi-video.html https: //rukinekryuki.ru/2020/10/02/kak-sdelat-blok-prokata-i-usileniya-profilnoj-truby/ https://aomur.ru/stanki-i-instrumenty/kak-sdelat-valtsy-dlya- profilnoj-truby.html https://znatoktepla.ru/truby/printsip-raboty-i-chertezh-stanka-dlya-usileniya-profilnoj-truby.html https://sdelairukami.ru/ruchnoj-stanok-dlya-dekorativnogo- prokata-proftruby/
Drawing for a machine for strengthening a profile pipe. — Community “Do It Yourself” on DRIVE2
I restored the drawings at your request and am posting them for everyone to see;
the second shaft needs to be made longer, under the handle
two rollers, identical
sprockets, 4 pieces, chain and bearings, everything from timing belt 406
It can be done even easier if you find and select two identical gears that will be on the shafts. And relative to them, then grind the rollers and shafts. I made it from what I had on hand. Two plates 300*300mm, I think at least 5mm thick (I had 10mm), folded them together and grabbed them to drill holes for the shafts (16mm). I didn’t draw a drawing of the holes, but I think it won’t be difficult to measure. Put the rollers on shafts and find out the distance at the centers of the shafts. The closer the rollers are to each other, the better. First, assemble the shafts onto a plate where there will be sprockets, a chain, then rollers, then a second plate. Then I put on the chain, measured where two more sprockets will be attached. When everything was adjusted (chain drive), I removed the plate from the opposite side, grabbed the rollers to the shafts( I made a hole in advance with a large drill for welding) on one side. I put the plate back on and welded the bottom and top. It seems like everything, if you missed something or it’s not clear, ask, I’ll try to explain.
