Friday, September 13, 2013

The advantages of cutting gable ends with an inline miter shear while rollforming your metal building panels.

Cutting gable ends in the field can be time consuming, increase the risk of damage and creates unnecessary waste.

The following video shows our Hayes International Post Cut panel rollforming machine with an integrated miter shear. This line was configured as a post cut with the ability to produce short straight and mitered cut sheets.  The operator is able to enter their cut list into the Beck SII control, or download the list from the office, then run the building pack with gable ends being processed inline.  When a miter is cut, opposite comers of the building are produced. With the stacking system,  each corner of the building is stacked separately, eliminating the need to sort panels on the job site.  With a 4 on 12 pitch, 1 linear foot of steel is saved per miter cut.
These post cut shears can be designed for pitch specific cuts to produce a good quality cut.  This pivoting shear is rafted, so when running other pitches it is easily removed and a different pitch shear is mounted.

Integrating gable cutting into your roll forming operation can save steel, installation time in the field and require less material handling. If you would like more information on gable shears or products from The Bradbury Group, contact us by clicking the button below or go to our download page for literature and technical information.
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Monday, June 24, 2013

It looks Flat, but does it stay Flat? Adjusting Precision Hydraulic Roller Levelers

A precision roller leveler will produce flat sheets from coiled steel.  If the leveler is not adjusted properly, stress can be induced in the material causing bow in the end product.

Bradbury edrive precision roller leveler

Hand cutting strips with plasma for burn test

The picture (right) shows a burn test on .250" X 72" hot rolled steel X 46 KSI yield. With all of the back ups flat, the leveler was producing flat sheets. However, after the burn test was preformed, the strips showed upbow on outer edges.

After burn test before leveler adjustments
Close up view of edge bow

The leveler was 96" wide so the #1 and #7 backups were outside the material stripwidth.

Adjustments made

Lowering the #1 and #7 entry backups improved the bow, but did not eliminate the problem. 

The next adjustment was to lower the exit #1 and #7 backups which resulted in a flat sheet in all directions and produced good laser material.

This proved that the machine is under an even load where material is being worked. The cylinders that do not have material over them and are not lowered away will put upward pressure on the edges of the coil causing stress to be induced in the coil.

Steel strips after adjustments made on the leveler
Outside strips of leveled material after cut

The Solution

The operator must know where the material is in the leveler and lower the entry and exit backups that are outside of the strip width.  

To make this adjustment easier, new Bradbury Leveler Controls will display where the material is running on the control screen allowing the operator to make adjustments right from the console.

Material position in leveler is now designated by green numbered backups

Leveled steel sheets
Do you have questions about your leveler or coil processing line? Give us a call at +1-620-345-6394 or contact us by clicking the button below or visit our download page for more technical information.

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