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How Abraservice Conquered the Challenges of Bending High-Strength, Abrasion-Resistant Steels

Overcoming Aerospace Fabrication Bottlenecks: How Plate Rolling Replaces Bump Forming for Isogrid and Orthogrid Rocket Panels

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Machines

Engineering

Automation

Plate Rolls

4 Rolls

3 Rolls

Angle Rolls

Wind Energy Solutions

Other

Control Systems

Measuring Systems

Explore all industries

Agriculture Aircraft & Helicopters Architectural Works Automotive Food Industries

HVAC Jobshop & Metal Structures Mining & Earth Moving Oil & Gas and Nuclear Pharmaceutical

Pipe Mills & Hydropower Process Industry (Chemical, Paper, Beverage, etc.) Railway Roller Coasters Shipbuilding

Space Storage Tanks Tank Trailers Wind Energy

Beyond standards, challenge our engineering.

When standard is not enough, we design the exception.

Explore all service

OPERATIONAL SUPPORT

Performance solutions

Explore all Resources

How Abraservice Conquered the Challenges of Bending High-Strength, Abrasion-Resistant Steels

Overcoming Aerospace Fabrication Bottlenecks: How Plate Rolling Replaces Bump Forming for Isogrid and Orthogrid Rocket Panels

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Glossary

1 MIN READ

Cone Bending

Q: What is the main difference between plate rolling and angle rolling?

Metal fabricators often need to diversify their production from flat sheets to structural profiles, which requires choosing the right technology to adapt to varying market demands. While plate rolling utilizes wide cylinders to form flat sheet metal into cylinders or cones, angle rolling utilizes specialized, narrower driven shafts to bend structural shapes like beams, pipes, channels, or angles. This clear distinction helps job shops select the exact machinery needed to maximize shop versatility, expand their service portfolio, and capture new commercial opportunities. Davi builds dedicated lines for both applications, engineering systems that handle plates up to 400 mm (15.75 inches) thick and structural sections like beams up to 1,200 mm (47.24 inches) in height.

Q: Why does a flat end occur during the plate rolling process?

Eliminating material waste and avoiding secondary cutting operations is a primary goal for high-productivity job shops looking to protect their margins. A flat end is the straight, unbent section left at the leading and trailing edges of a plate because the material cannot physically reach the exact tangent contact point between the machine rolls. Minimizing this straight section directly reduces material scrap and eliminates the time-consuming process of pre-bending plates on a separate press brake, thereby accelerating overall floor cycle times. Utilizing Davi all-rolls-drive technology ensures the plate can be positioned precisely at the tangent point to achieve the shortest flat end possible without compromising safety.

Q: What is pre-bending and why is it critical?

Fabricators working on high-precision applications like pressure vessels must ensure perfect roundness from the absolute edge of the plate to comply with strict safety codes. Pre-bending is the preliminary manufacturing step where the leading and trailing edges of a sheet are bent to the target radius before continuous rolling begins. Executing this properly minimizes the flat end, ensures structural integrity at the subsequent weld seam, and reduces the need for manual grinding or expensive re-rolling calibration. Davi 4-roll and variable-axis 3-roll machines are engineered to execute high-tonnage pre-bending safely and accurately in a single automated cycle.

Q: What is a pendular shaft-mounted gearbox arrangement?

Cone rolling requires heavy roll tilting, which can introduce damaging torsional stress into rigid drive mounts. A pendular arrangement provides a swingable, flexible connection between the drive gearboxes and the machine frame. It permits free deflection of the rolls under extreme loads and allows for stress-free roll tilting up to 100 mm (3.94 inches) every 3 meters (9.84 feet) of roll length. Davi utilizes this configuration to ensure long-term bearing reliability and high tilting capacity for complex cone forming.

Q: How does Progressive Bumping Mode assist in cone bending?

Forming heavy, steep-angled cones on a standard rolling machine can cause material slippage and uneven layouts. Progressive Bumping Mode steps the plate through incremental roll adjustments, forming the cone shape in precise, sequential stages. It ensures high geometric accuracy on thick-walled tapered sections and reduces the risk of material slippage or twisting. The Davi MAV series utilizes three fully tilting rolls to deliver reliable performance during continuous cone rolling.