Benching is a technological process associated with metal processing. Many people do not know what a crimping machine is or how to use it correctly. When purchasing equipment, you need to study the characteristics and operating principle of the device.
Sealing machine
Design and principle of operation
The zig machine consists of several elements:
- lower, upper shaft;
- handle for rotating shafts (for manual machines);
- screw for adjustment;
- rollers with the help of which parts are processed;
- gears transmitting rotational force between moving shafts;
- housings made of impact-resistant materials;
- cast bed for stable holding of the machine.
Regardless of whether the installation is equipped with an electric drive or not, there are no significant changes in the design or operating process. Zigovka is carried out in several stages:
- The parts are fixed between movable rollers.
- The shafts are aligned to securely hold the workpiece.
- The operator begins to rotate the handle or starts the electric drive.
The workpiece begins to rotate behind the shaft. The depressions are formed under the pressure of the protrusions on the rollers.
Machine device
Types of rollers for zig machines
Manufacturers can change the labeling of the rollers they produce; here are the most common names.
- V - for decorating the edges of insulating boxes and pipes, rolling wire using ZB ZA;
- S - for the production of stopper ridges and stiffeners;
- SK - for making ribs of rectangular section. Wide ribs are used to fix rubber seals in the manufacture of round-section ventilation ducts;
- E, EV - the edges of the pipes are corrugated, making the diameter smaller for socket connections. Used for the manufacture of ventilation and drainage pipes and chimneys. EV rollers perform both stop rib and corrugation;
- BC - bend the edges on flat-shaped parts for flanging elements of rectangular air ducts, used in the manufacture of round-shaped plugs;
- KA - the set includes four rollers (two pairs) for connecting round pipes with further spot welding. They make connections with an overlap of 8 to 12 mm, and are used in the manufacture of small series of air ducts and chimneys;
In order for a beading machine to perform quality cuts, it must be equipped with a parallel roller clamp. The semicircular stop is an addition to the BB rollers. It is used for external flanging in round cutouts of flat parts.
Varieties
Sealing machines are classified depending on various factors. By drive type:
- Manual. Simple designs that begin to work after applying physical effort. The position of the rollers is changed manually. Manual beveling is not used for working with thick metal.
- Electrical. In terms of power, these models are considered average. The shafts rotate thanks to an electric motor. Electromechanical creasing machines are more expensive than manual ones, but they can process sheets of large thickness.
- Hydraulic. Powerful equipment. A special feature of hydraulic machines is reliable clamping of the rollers. Disadvantage - large dimensions, large mass.
A separate classification relates to the size and weight of equipment. There are compact, portable models that are easy to transport. Large-sized machines have been developed for enterprises that are suitable for mass production.
Popular hand models
The rating is based on popularity among buyers.
Prinzing SM 50
Country of origin: Germany. The manual machine can be used in the production of air ducts and drains. The model is intended for use in small-scale production. It is adapted for carrying out various zigovochnyh operations.
The machine has a durable welded body. The material of manufacture is high-strength steel. The shafts are mounted on precision bearings. The compact size of the machine allows it to be easily transported.
Specifications:
- weight – 25 kg;
- maximum metal thickness – 1.25 mm;
- overall dimensions – 570x220x440 mm.
Advantages:
- compactness;
- autonomy;
- mobility.
- deficiencies identified.
RAS 11.15
Country of origin: Germany. Powerful manual crimping machine. The body is made of high-strength sheet steel. The model is considered multifunctional and can work with all types of non-ferrous and ferrous metals.
Specifications:
- weight – 22 kg;
- maximum metal thickness – 1.25 mm;
- overall dimensions – 700x160x400 mm.
Advantages:
- mobility;
- energy independence;
- low cost;
- compactness;
- reliability;
- ease of operation and maintenance.
- deficiencies identified.
Bendmak SW-80
Country of origin: Türkiye. Powerful zigovochny machine with manual clamping of the upper roller. The equipment set includes 8 pairs of rollers, an installation key and a thrust plate. The machine can work with all types of metal.
Specifications:
- weight – 35 kg;
- maximum metal thickness – 0.8 mm;
- overall dimensions – 300x200x500 mm.
Advantages:
- ease of operation and maintenance;
- autonomy;
- low cost;
- mobility;
- multifunctionality.
- deficiencies identified.
Keepler-Stan RM-140×1mm 00-00000222
Country of origin: Russia. The manual beading machine is equipped with needle thrust bearings. The model is intended for the manufacture of drainage, ventilation systems, thermal insulation and air ducts.
The equipment set includes three rollers for flanging, corrugating and rolling stiffeners. The design provides: longitudinal adjustment of the lower shaft, clamping of the upper roller.
Specifications:
- weight – 18 kg;
- maximum metal thickness – 1.0 mm;
- overall dimensions – 400x120x450 mm.
Advantages:
- robust design;
- reliability;
- ease of operation and maintenance;
- low cost;
- mobility;
- autonomy.
- deficiencies identified.
Selection principles
When purchasing a crimping machine you need to consider:
- dimensions of equipment, premises;
- type of drive;
- roller material;
- control system;
- number of rollers;
- thickness of metal for the manufacture of housings and moving elements.
We must not forget that there are different types of videos. They vary in shape. You need to think in advance about the purpose of using the installation and purchase a set of consumables.
Compact machine
Advantages and disadvantages
Advantages:
- mobility of hand models;
- ability to work with parts of different thicknesses;
- Ease of Management;
- low price;
- long service life;
- the ability to join metals that cannot be processed by welding.
To work with parts of large thickness, an electric or manual drive is not enough. You need to buy expensive hydraulic equipment, which takes up more space.
Manufacturers and price
There are various brands of manual, electric, and hydraulic crimping machines sold in the market. The cost depends on brand awareness, drive type, power, and performance. Manufacturers:
- JET;
- MetalMaster;
- Isitan;
- Stalex;
- Proma;
- Schulze;
- IKMN;
- STS.
The average cost of manual installations is 15,000 rubles.
The best electric machines
The rating is based on popularity among buyers.
SAHINLER IKMP 1.2
Country of origin: Türkiye. Sealing machine with 0.75 kW electric motor. The model is intended: for cutting and flaring drain pipes, corrugating them, crimping locks, applying a round seam, and other operations.
The machine frame is made of cast iron. The gear motor is equipped with an electromagnetic brake. There is a movable control pedal on the body. The model provides the ability to connect a hydraulic drive.
Specifications:
- weight – 110 kg;
- maximum metal thickness – 1.2 mm;
- overall dimensions – 560x220x500 mm.
Advantages:
- good build quality;
- reliable operation;
- high performance;
- powerful shafts;
- ease of operation;
- presence of an emergency shutdown button;
- low power consumption.
- The main disadvantage is the high cost.
Stalex RM-18E
Machines of this brand are produced in China, Poland and Russia. The model is designed for working with thin sheet metal in the production of: ventilation and thermal insulation of pipelines. It is equipped with a 1.5 kW electric motor. The main material used to manufacture the machine is high-strength steel.
The equipment set includes three sets of rollers. The machine is turned on using the length of the shafts using a special pedal. It has simple speed adjustment. Clamps allow you to avoid reconfiguring equipment when producing parts of the same type.
Specifications:
- weight – 140 kg;
- maximum metal thickness – 1.8 mm;
- overall dimensions – 820x420x1050 mm.
Advantages:
- high performance;
- ease of operation;
- reliable design.
- The main disadvantage is the high cost.
MetalMaster ETZ 18
Country of origin: Russia.
The crimping machine is equipped with a 1.5 kW electric motor. The model is intended for: flanging and forming edges, corrugation, oval and rectangular ridges, creating an L-shaped profile. It is widely used in the serial production of ventilation systems and drains. The main material used to manufacture the machine is high-strength steel. The design is equipped with a pedal for switching operating speeds. The equipment set includes all the attachments necessary for operation. The body has two compartments for storing equipment and tools.
Specifications:
- weight – 220 kg;
- maximum metal thickness – 1.8 mm;
- overall dimensions – 390x540x1140 mm.
Advantages:
- no vibration during operation;
- high performance;
- multifunctionality;
- reliability;
- good equipment.
- The main disadvantage is the high cost.
ACL LX-15
Country of origin: China. The model is intended for: corrugating, flanging, cutting and other simple beading operations with various types of non-ferrous and ferrous metal. The machine is equipped with an electric motor with a power of 0.75 kW.
The design is equipped with a convenient clamping handle. The main material of the machine is high-strength steel. The model has a switch for left and right rotation of the rollers. There is a single foot pedal.
Specifications:
- weight – 140 kg;
- maximum metal thickness – 1.5 mm;
- overall dimensions – 700x400x950 mm.
Advantages:
- reliable, well-thought-out design;
- high performance;
- ease of operation.
- The main disadvantage is the high cost.
SAY-MAK SKMP 1.2
Country of origin: Türkiye. The model is intended for: flanging, beading, corrugating various types of non-ferrous and ferrous metals. Electric motor power – 0.75 kW. The material used to manufacture the machine is high-strength steel.
The electric motor is started using a foot pedal. With its help, you can set the left and right direction of rotation. Increased operational safety is ensured by an emergency stop button. The equipment set includes all the attachments necessary for operation.
Specifications:
- weight – 110 kg;
- maximum metal thickness – 1.2 mm;
- overall dimensions – 950x450x1350 mm.
Advantages:
- high-quality assembly;
- increased security;
- high performance.
- The main disadvantage is the high cost.
DIY making
If you wish, you can assemble a manual zig machine with your own hands. To do this, it is enough to find a drawing, prepare materials, tools, and perform the work.
Sealing machine
Preparation
Before you start assembling a manual zigging machine, you need to prepare tools and consumables:
- drill with metal drills;
- a small grinder with discs;
- welding machine;
- two shafts;
- gears for transmitting force between shafts;
- metal corners, profiles, sheets for the manufacture of beds, frames, housings;
- fasteners;
- handle for rotating moving parts.
- screw for adjusting, pressing the shafts.
Assembly steps
When assembling equipment, you need to consider the following nuances:
- The lower shaft must be stationary, the upper one must move within a range of at least 12 mm.
- Side stops should be installed to prevent the shafts from moving to the side when working with workpieces.
- To transmit force, gears are used, which should not be less than 60 mm in diameter.
- Secure the shafts so that they can be changed during operation of the equipment.
- Welding equipment is used for the manufacture of frames, housings, and beds.
- To make the case, it is enough to use metal sheets with a thickness of no more than 5 mm.
The handle can be made from handles from any old machine. If commercial rollers are not suitable for the finished unit, you will have to create them yourself. For this you will need a lathe.
Electromechanical zig machines are more difficult to manufacture. To do this, you need an electric motor with a speed controller, a belt drive, and a control panel.
Questions and answers
What products can be made on crimping machines?
Buckets, deflectors, and funnels can be produced using crimping equipment. The machines allow you to roll thrust ridges, corrugate metal blanks, make drainage elbows, etc.
Are there any differences in the operating principle of manual and electric seaming machines?
There are no fundamental differences in the operation of manual and electrical equipment.
What machines can handle metal with a thickness of 3-4 mm?
Metal of this thickness can only be processed on electric or hydraulic industrial crimping machines.
What does roller overhang affect?
Regardless of the type of equipment drive, roller overhang affects its technical capabilities.
What type of crimping machines is best to use for roofing work?
In roofing work, it is better to use manual zig machines. They can be lifted directly onto the roof.
Exploitation
For home-made or purchased models of staking machines, there are a number of operating rules:
- Check the integrity of the rollers, gears, and the location of the shafts before starting work.
- Turn the handle several times without the workpiece to eliminate defects.
- Keep your hands as far away from the treatment area as possible. Do not wear long sleeves.
- Do not attempt to connect parts of large thickness. Excessive effort will lead to material damage and equipment failure.
- Do not overload the electric motor.
- Lubricate moving parts with machine oil at least twice a month.
- Check the accuracy of the workpiece alignment between the rollers.
Metal beading is a simple process that anyone can do.
Metal creasing machines are used to carry out various technological processes. With their help, you can connect metal pipes and increase the strength of individual parts. You can make a homemade hand loom for your home.
How to choose the right zig machine
Equipment is selected according to several main parameters:
- Purpose. For roofing workshops and crews, hand-held machines, inexpensive electromechanical models, and universal machines with replaceable drives are suitable. Zig machines do an excellent job with metal up to 1 mm, are mobile, and easy to use.
- For mass production and the manufacture of large-sized products, for example, air ducts, more powerful equipment is needed.
- Permissible thickness of rolled products. Industrial creasing machines are capable of applying relief, cutting, and flanging rolled products up to 4 mm or more. The maximum metal thickness for low-power electromechanical and manual equipment is 0.8-2.5 mm.
- Roller offset and center distance. The characteristic determines the processing width. The larger the reach, the wider the workpieces and parts can be processed.
- Supply voltage of electromechanical machines. Most stationary models are equipped with a 380 V motor and require an electrical connection. They also produce machines for small workshops with single-phase 220 V electric motors.
When choosing machines, they also take into account the dimensions, the presence of a reverse function, hydraulic clamping, and other parameters.
Types of creasing machines
According to the type of drive, manual ones
,
electric
crimping machines.
Manual creasing machine
Non-drive models can handle rolled products up to 1.25 mm thick. The machines are lightweight, easy to rearrange and transport, and do not require connection to an electrical outlet. The equipment can be installed in small workshops and on construction sites. Zigmachines of this type are used in piece production of small batches of products.
The main advantages of manual seaming machines:
- Mobility.
- Easy to use.
- Light weight and dimensions.
The machines do not consume electricity, do not require installation on concrete and fixation to the floor. In a number of models, installation of an electric drive is allowed. Such machines are universal, they allow you to reduce the time required to perform similar operations and are used in both small-scale and piece production.
Electromechanical machines. The equipment is driven by a three- or single-phase motor. To regulate the shaft rotation speed, a gearbox or frequency converter is used.
Variable frequency drive machines are more expensive. The advantages of such models include low energy consumption and the lack of regular maintenance of the gearbox.
The main advantages of electromechanical zigmachines:
- High performance.
- Ability to process rolled metal up to 2; 2.5; 3 mm.
- Relatively small size and weight.
Machines with a reversible drive significantly reduce the processing time of stainless steel or thick rolled products. To extrude a ring or lock in 2 passes, you do not need to rearrange the workpiece; just switch the rollers to reverse rotation.
The design of a number of models of electric drive machines involves dismantling the power unit and installing a handle. If necessary, such equipment can be easily converted into manual machines and used on non-electrified construction sites.
To process rolled metal 2.5-4 mm, powerful machines with hydraulic clamping are used.
Sigma machines have high productivity. Processing of sheets or parts made of hard steel grades and thick rolled products is carried out in one pass. The equipment is used in the serial production of tanks, chimneys and other structures.
Areas of application for creasing equipment
Equipment designed to perform beading, even though the name of such a technological operation is familiar mainly to metalworking specialists, is actively used in various fields of activity. Sealing machines are practically indispensable for the manufacture of elements of roofing structures, in particular, for the formation of their edges.
Examples of drainage elements made on a crimping machine
It should be noted that in the construction industry, bending machines have found very wide application. Using such machines, in particular, the following elements of building structures and communication systems are made from sheet metal: parts of drainage and air duct systems, insulation for heating mains, etc. In the construction industry, manual staking equipment is predominantly used, since it is characterized by its small dimensions and insignificant weight, does not require an electrical supply for its operation and can be used almost anywhere.
The creasing machine can also be used to reliably connect cylindrical workpieces made of thin sheet metal together. Rollers for equipping a zig machine of this type, when a cylindrical workpiece passes through them, form locks on it, with the help of which the two parts are connected.
Rolling the lock on the air duct elbow
When making connections using locks, unlike welding, there is no thermal effect on the metal parts, which eliminates the possibility of their warping. In addition, such a machine, which you can also make yourself, does not require any additional consumables for its use.
To expand the functionality of a staking machine, including a manual one, it can be equipped with additional working parts. Machines equipped in this way can be used not only as creasing equipment, but also as bending and profiling equipment. Modern creasing machines for industrial use are often equipped with automated control systems, which increases their productivity and accuracy of technological operations performed with their help.
Special attachments allow you to make folds for connecting thin-walled pipes
