Glossary
1 MIN READ
Vertical Rolling
A heavy fabrication process where plates are positioned and rolled perpendicular to the shop floor, preventing large, thin-walled shells from collapsing under their own weight.
Technical FAQ
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.
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.
Mass-production facilities require automated processing with minimal reliance on highly skilled operator intervention to remain competitive. A 4-roll machine uses a top and bottom roll to securely pinch the plate, while two side rolls travel up to execute the bending force. It provides total material control throughout the cycle, allows for fully CNC-automated production lines, and makes the initial squaring process simple and safe. Davi MCA and MCB 4-roll lines are the global standard for high-productivity automation, offering rapid cycle times for job shops worldwide.
Reducing the straight flat end on thick plates requires moving the bending rolls as close to the pinching point as possible. A flat gearbox features an eccentric rotation axis that avoids physical interference between hydraulic motors and the top roll cylinder shaft. It allows the side rolls to travel closer to the top roll (minimum gauge), achieving an exceptionally short flat end without compromising machine frame capacity. Davi exclusive flat gearboxes are a core component in achieving precision pre-bending on variable-axis machines.
Preventing collisions between massive workpieces and overhead supports protects your investment in capital machinery. The control system generates a high-resolution 3D simulation of the entire rolling sequence before the plate is loaded. It allows programming teams to spot potential tooling interference or material collisions offline, saving raw material and ensuring shop safety. Davi provides both on-console and offline simulation licenses for iRoll Performance and eXtreme platforms.
Large-diameter, thin-walled shells can collapse or distort under their own weight during the top half of the rolling cycle. Overhead supports are heavy-duty vertical gantries equipped with hydraulic or electric lifting heads that support the plate from above. They prevent material deformation, ensure accurate geometry tracking, and allow a single operator to manage large parts safely without an overhead crane. Davi designs fully integrated, CNC-controlled overhead supports tailored to match the maximum capacity of its rolling lines.
High operator turnover can lead to skill gaps, lower part quality, and increased risks of machine damage. The Training Academy provides structured on-site or remote training programs for operators and maintenance teams. It helps operator teams utilize the machine's CNC capabilities effectively, optimize cycle times, and perform basic troubleshooting independently. Davi provides comprehensive training as part of every new equipment installation and offers continuing education courses worldwide.