Plate Rolls: The Manufacturer’s Buying Guide to Finding the Best Option to Improve Roll Operations (2023)

Plate Rolls: The Manufacturer’s Buying Guide to Finding the Best Option to Improve Roll Operations (1)

Posted By: Bendmak | Posted On: May 31, 2021 12:35:16 PM

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What is plate rolling and how do you select the right type and size plate roll with so many options available? Plate rolling is an incredibly essential process of metal fabrication. Since most of the products created during plate rolling are sophisticated, cutting-edge and unique, they are created using specialized equipment that is known as the plate rolling machine or the plate bending machine. In this article, we’ll take a look at what a plate roll machine is and its use in the manufacturing industry.

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What Is Plate Rolling?

Plate Rolling is a unique process whereby a sheet of steel, aluminum, stainless or other material is formed into circular or other shapes by force through a set of powered rollers. Machines consisting of 2 to 4 roll sets press, engage and form the material through force of electrically, mechanically or hydraulically driven means. It involves the rolling of flat sheet metal to create cylindrical items such as pipes, tanker trailers, buckets, and pressure vessels.

What Is a Plate Roll Machine?

A plate roll machine is a piece of equipment that is used to roll various types of sheet metal into round, semi round, round with varying radii or conical shapes (some machines specialize in rolling materials back to flat too!). The rolling machine boasts a working mechanism that allows it to bend flat sheet metal into a large arc or cylinder or even a square, an ellipse shape and a multi-section arc. Utilizing a series of precise and strong hardened rolls powered by either hydraulic or mechanical methods, the rolls are brought into a pitching position with the material desired to be shaped. Once the material is firmly held between two of the rolls, a third and sometimes fourth roll is brought into position pushing the material causing the initial bend, or what is referred to as the pre-bend. The rolls then begin to rotate pulling material through the pinched rolls and past the pushing rolls forcing an arc into the material.

What Are Plate Rollers Used For?

This process forms many common parts we see everyday such as;

  • Propane Tanks
  • “Tin” Cans
  • Fuel Tanker Trucks
  • Water Tanks
  • Piping
  • Heavy Equipment Accessories

Types of Plate Rollers

Since not all rolled metals are created equal, every project may require a specialized type of plate roll machine. Therefore, you should expect to find a vast array of plate rollers in the market. The type of equipment you choose should be based on the complexity and uniqueness of the customer's orders. Some of the standard metal rolling machines include:

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  • 2 Roll Machines (Ideal for thin, highly repetitive circular rolling such as Food Cans)
  • 3 Roll Initial Pinch (Most popular design due mostly to cost)
  • 3 Roll Double Pinch (Affordable design for heavier bending applications)
  • 3 Roll Variable Translating Geometry (Affordable Design for Variable Radii applications)
  • 4 Roll Double Pinch (The most versatile of the designs)
  • Vertical Rolls (Perfect when rolling very large Radii such as above ground fuel and water storage tanks)
  • Automated Cycle & Specialty Rolls (Spiral Duct Rolls, Corrugated Material Rolls etc.)

The two roll plate machines are designed to bend flat sheet metals with a width of up to 8-12” and 12 Gage thickness. This makes them ideal for batch production of thin cylindrical items used in household appliances such as filter canisters, food canisters and of course, tin cans.

Three roll sheet rolling machines can be further classified into asymmetrical, horizontal lower roller move type and geometric variable plate rollers. Although all tools in this category operate using different principles, they are all used to bend medium to thick plates. The three-roll sheet bending machines are commonly used not only in general fabricating but also in chemical, boiler, shipbuilding, metal structure, petroleum and machinery manufacturing industries.

The 4-roll plate bending machines are renowned for transforming flat sheet metal into spherical body, cone tube body or other shapes. Four roll plate bending machines are more productive, precise, safer, versatile, and easier to operate than the rest. Once the material is set and pinched the two rolls on either side of the pinched roll do all the work without having to remove the plate and rotate it for pre bending both ends. They can roll up to 8” thick plate steel and are most likely to be outfitted with CNC controllers for variable radii applications and complex shapes such as elliptic and polycentric workpieces. Their greatest advantage is that they can be used on a wide range of sheet metals and can also accept a high degree of automation. They can also be used to roll tube segments, ovals, rounded boxes and other shapes.

How to Identify the Right Plate Rolling Machine

Choosing the right type of plate roll is the first step. As there are various types available and at various prices When it comes to choosing a plate roll, alongside choosing the correct type it’s imperative that you get the correct size. If the size of the plate roll doesn’t match your application you’re going to waste your money unnecessarily. Getting the right type and size for the job should be a priority. To determine what size of plate roll you’re going to need or benefit from the most you’ll need to consider the types of applications, the material you will be rolling mostly and the operator skill level you have to work with.

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Choose the type of plate roll that will perform your work the fastest with the least amount of intervention involved. As 2-Roll machines are dedicated to one specific type of application they are not well suited for the job shop. In most job shops and plate production facilities we see a large variety of initial pinch, pyramid style 3-Roll and 4-Roll machines. For simple round sections an initial pinch or 3 Roll Double Pinch Design can be selected, however for more complex geometry a Variable Translating Geometry or 4-Roll machine with CNC Controls should be used. Of these selections the choice can be made easily as follows:

    • 3 Roll Initial Pinch
      • Pros: Cheapest Design, simple to operate with small sheets with limited thicknesses
      • Cons: Material must be rotated to pre-bend each end manually causing labor intensive operation
    • 3 Roll Double Pinch
      • Pros: Cheapest Design for Heavier plate Bending Applications
      • Cons: Material Slippage during forming possible. Difficult Angle of Material approach
    • 3 Roll Variable Translating Geometry
      • Pros: Cheapest Design for rolling with variable Radii (Rounds-to-flat-to-round)
      • Cons: Material Slippage is likely without skilled operation
    • 4 Roll Double Pinch (The most versatile of the designs)
      • Pros: Easiest to operate from small to larger sizes. Material does not need to be removed for pre bending operation. Easily can be automated with CNC controls
      • Cons: Price

How to Select the Plate Roll Size for Your Application

Once you have selected the correct type of plate roll for your application, it’s imperative that you get the correct size. If the size of the plate roll doesn’t match your application and material you’re going to waste your money unnecessarily. Getting the right type AND size for the job should be a priority. To determine what size of plate roll you’re going to need or benefit from the most you’ll need to consider the material types, thicknesses and yield strength you are intending to use it for.

Also noted, you should consider that a machine designed to form 1” (25MM) Grade 50 steel plate will not perform well attempting to roll 16GA material as the rolls are simply too large. Conversely, a machine designed to run ¼” (6MM) X 4’ (1250MM) material cannot roll the 1” (25MM) material or any material at all wider than 4’. The critical factors you need to consider in selecting the right sized plate roll are:

    • Bending Length: The overall rolling capacity is determined by the physical length of the rolls. When purchasing a plate roll make sure you are sizing the roll length for the maximum width of material you will be rolling, understanding that the longer the rolls the larger the roll diameter has to be in order to maintain strength under rolling pressure. The adverse reflection of that is the larger the diameter you will need to be rolling.
    • Minimum Diameter: The minimum diameter is the smallest diameter you desire to roll your material into. Use the factors 1.5X the top roll diameter for easy, no problem, rolling in one pass to achieve this goal. 1.3X the top roll diameter can be achieved with multiple passes or material at a shorter length than the full width capacity of the pallet roll. 1.1X the diameter of the top roll is also achievable in softer materials less then the full width of the rolls AND utilizing a multipass technique.
    • Bending Capacity: Bending Capacity on a plate roll is the capacity at full width the machine is capable of. Rated in mild steel, a ¼” X 10’ plate roll is capable of bending ¼” thick mild steel in a 10’ width to 1.5X the top roll diameter in a single pass but be careful as it may not be able to pre-bend that same material.
    • Pre-Bending Capacity: Pre-Bend is the initial bend a plate roll operator must make before actually rolling the material. The process involves pinching the material firmly between two of the rolls and then using the side or lateral roll to force the material into an initial bend before rolling commences.This process must be repeated on each end of the plate being rolled to avoid large flattened sections at the mating ends of the cylinder. Pre-Bend capacity is always less than that of the rated bending capacity so it is important to ensure the rolling system you are looking at can properly pre-bend the material you are working with.
    • Yield Strength: The yield strength is the strength of the material you are rolling, or better put, the strength of resistance to bending that the material has. The harder the material the higher the yield strength and the larger/stronger the plate roll must be to roll the material. Yield points vary greatly from Aluminum to Stainless and other materials in between. Make sure you know the Yield strength of your material as plate rolls are all offered on a mild steel (30,000 PSI) yield strength rating but can be sized in accordance with your needs.

Find the Best New & Used Plate Rollers At BendmakUSA

At BendmakUSA our staff and network of partner distributors are experts at helping you select the right plate roll for your needs and budget. We understand the challenges of fabricators and work hard to ensure you make the right choice in not only a machine type and size, but in your machine tool supplier partner as well. Connect with us to learn more about Plate Rolls and the equipment available from BendmakUSA.

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Plate Rolls: The Manufacturer’s Buying Guide to Finding the Best Option to Improve Roll Operations (2)


What is plate rolling process? ›

Steel plate rolling involves passing a piece of steel plate through one or more pairs of rollers in order to reduce the overall thickness of the material. This process also ensures that the workpiece thickness is unchanging throughout.

What is metal plate rolling? ›

What Is Plate Rolling? Plate Rolling is a unique process whereby a sheet of steel, aluminum, stainless or other material is formed into circular or other shapes by force through a set of powered rollers.

What is a rolling machine used for? ›

A rolling machine is a piece of manufacturing equipment that contains two or more rollers through which raw metal is fed. The purpose of rolling machines is to compress raw metal into a thinner and more uniform shape, which is essential when producing sheet metal.

What is roll forming in manufacturing? ›

Roll forming is a continuous process which converts sheet metal into an engineered shape using consecutive sets of mated rolls, each of which makes only incremental changes in the form. The sum of these small changes in form is a complex profile.

What are the defects in rolled plates? ›

What are common sheet metal rolling defects?
  • Impurities.
  • Edge cracks.
  • Alligator cracks.
  • Wavy edges.
  • Zipper cracks.
  • Center buckling.

What is the correct use in the metal rollers? ›

Metal rollers are used to form rounded sections out of flat metal stock and sheet metal. The final forms can take the shape of hoops, cylinders and cones or combinations of any of these forms. Metal rollers range in size from small bench-mounted manual crank models to large motorized units.

How do you use a sheet metal roller? ›

Follow the below-listed steps to ensure safe and precise rolling without any material damage.
  1. Adjust the tension using the front knobs.
  2. Adjust the radius using the back knobs.
  3. Place the sheet metal to be formed between the rollers.
  4. Rotate the handle gently.
  5. The flat sheet metal is now rolled to your specifications.
17 Aug 2018

Which rolling machine is used for bending thick heavy plates? ›

Initial Pinch Plate Roll ASI

Thanks to asymmetric geometry in moving rolls, ASI delivers a superior level of rolling. Durable construction for maximum safety, self-supporting frame for placement on any surface. ASI is ideal to bend plates of thickness between 1 and 9 mm and width between 1000 and 3000 mm (40” – 120”).

How does rolling affect material properties? ›

It had be concluded so far that in hot rolling, increase in height of roll grooves which was a function of its expansion, caused by the process parameters, resulted in increase in thickness of rolled stock, which affected the mechanical properties of the rolled samples such as ultimate tensile strength, yield strength, ...

Why rolling process it is important in steel industry? ›

The main purpose of rolling is to decrease the thickness of the metal. Steel, magnesium, aluminum, copper, and their alloys are the materials commonly rolled. As a result of the friction between the rolls and the metal surface, the metal is subjected to high compressive stresses.

How many types of rolling equipment are there? ›

In the past two articles we briefly outlined rolling mills, and also expounded on three different types. In this article, we will finish the series outlining the differences between a four-high rolling mill, cluster rolling mill, continuous mill and a planetary rolling mill.

What are the applications for roll forming? ›

Common Roll Forming Applications/Products
  • Door and window hardware.
  • Metal fencing.
  • Computer casings and components.
  • Metal furniture components.
  • Rain gutters and house siding.
  • Desk drawer slides.
  • Steel support framing.
  • Metal tubing.
27 Mar 2019

What products are made by roll forming? ›

Examples of common roll formed products include: angle irons, aluminum angles, steel angles, metal channels, metal trim, metal wall panels and metal rings. Roll formed products may also be custom made for specialty applications, like bus industry seat tracks.

What are the roll forming mistakes? ›

Bowing, Camber, Twist

Metal imperfections are common and can create problems during the roll forming process. They can even occur during the roll forming process. Using tension-leveled steel or aluminum coil helps.

What causes defect in rolling? ›

This defect occurs due to the self-equilibrating residual stresses that result from the rolling process. During center buckling, fibers at the center of the metal piece are longer than those at the edges. In an event where hot or cold mills have too much crown, mills roll out at the center.

What can cause an over roll defect? ›

Over-Roll / Overlap

Generally caused by slow travel speed and wrong torch angle.

What are the 4 steps for a roller application? ›

A huge thank you to my super awesome model, Katie!
  1. Step 1: Section the Hair. Part the hair in the front where you'd like to wear it, then section the hair across the head from ear to ear. ...
  2. Step 2: Get to Rollin' Take sub-sections that are as wide as your roller. ...
  3. Step 3: Let Cool and Remove. ...
  4. Step 4: Enjoy!

What tools are used during a roller set? ›

Best Tools for Long Lasting Roller Sets
  • Setting lotion/mousse: While some ladies skip a setting product altogether, a good-quality setting product helps hold your style in place. ...
  • Magnetic rollers: These smooth rollers usually have vent holes scattered across the surface, in order to speed up the drying process.
25 Aug 2021

How does a sheet roller work? ›

Sheet metal is usually placed by hand between the rollers, which turn together to pull the sheet through. As it passes between the rollers, the sheet curves to a diameter limited by the size of the rollers. The action that draws in a metal sheet can also draw in a hand.

What is pre bending in plate rolling? ›

Pre-bending refers to the process of holding sheet metal firmly between multiple rolls and pushing it in order to create the initial bend.

Which type of rolling is most suitable for production of very thin strip in hard materials? ›

Flexible rolling, a novel forming method for the production of strips with longitudinal thickness variation, has been rapidly developed and gradually used on a large industrial scale, such as automotive, construction, and energy industries.

Which type of rolling mill is used for hard metals? ›

Cluster Rolling Mills

They're basically a specialized type of four-high rolling mill that allows you to add some larger and smaller work rolls of sheet metal during the rolling process. Thanks to their strength, they're often used for hard metals like titanium alloys.

How many types of rolling mills are used in rolling operation? ›

Based on this classification rolling mills are basically of two types. They are namely (i) hot rolling mill (ii) cold rolling mill. In the hot rolling mill, rolling is done above the recrystallization temperature of the metal.

Which is the most important property used in the rolling process? ›

It is essential that in a metal rolling process the level of friction between the rolls and work material is controlled, use of lubricants can help with this. During a metal rolling operation, the geometric shape of the work is changed but its volume remains essentially the same.

Which parameters are important during the rolling process? ›

Strain rate, flow stress, heat of deformation, roll force and coefficient of heat transfer are all controlled by rolling speed directly. Therefore, rolling speed can be considered as one of the important parameters for rolling [9].

Why does rolling increase hardness? ›

They found that the cold rolling increases the hardness and strength due to increasing of dislocation density and grain refinement. They also found that dislocation density increased with increasing stacking fault probability. Lim et al.

What is the principle and mechanism of rolling? ›

Working principle of the rolling process:

The metal is compressed by the rollers while simultaneously shifting it forward due to the friction at the roller interfaces. As soon as the workpiece passes through rollers, the operation is fully done.

What are the two types of roller arrangement? ›

As per the requirement of the process and arrangement of the rolls, the rolling mill rolls can be divided into the following categories:
  • Two High Rolling Mills. ...
  • Three High Rolling Mills. ...
  • Four High Rolling Mills. ...
  • Tandem Rolling Mills. ...
  • Cluster Rolling Mills.
24 Dec 2018

What are the rolling machines called? ›

A plate rolling machine is a machine that will rolldifferent kinds of metal sheet into a round or conical shape. It can be also called a “roll bending machine”, “plate bending machine” or “rolling machine”. ...

What are the roller machines called? ›

A construction roller is also known as a road roller, compaction roller, or steam roller. Although these machines are not powered by steam anymore, they used to be and in some cases, the name stuck.

What is rolling process and its types? ›

There are two types of processes. One is Hot rolled and another is Cold Rolled. If the strip is rolled after heating the strip above the re-crystallization temperature then it is termed as Hot rolled and if that done in room temperature then it is termed as the Cold rolled.

What is steel rolling process? ›

Steel undergoes the process of rolling to reduce the thickness of the metal as well as make it uniform. In this process, steel is placed between two rolls where the thickness is altered by manipulating the length direction of the steel rather than the width direction.

What is tube rolling process? ›

As suggested by its name, tube rolling is a manufacturing process used to roll material into tubes and other tubular components. It involves first wrapping the material around a mold and then heat curing it to hold the shape. Afterward, the mold is removed, leaving behind a molded hollow component.

What is the casting and rolling process? ›

The process used is called Rolling whereby the cast metal goes through a series of heavy metal rollers that slowing decrease the initial larger cast of metal into the required thickness.

What are the different types of rolling? ›

What are the Different Types of Rolling Mill Rolls?
  • Two High Rolling Mills. It consists of two rollers, which rotate in the opposite direction for the desired movement of the workpiece. ...
  • Three High Rolling Mills. ...
  • Four High Rolling Mills. ...
  • Tandem Rolling Mills. ...
  • Cluster Rolling Mills.
24 Dec 2018

Why is rolling process important? ›

The main purpose of rolling is to decrease the thickness of the metal. Steel, magnesium, aluminum, copper, and their alloys are the materials commonly rolled. As a result of the friction between the rolls and the metal surface, the metal is subjected to high compressive stresses.

What are the three 3 main steel making processes? ›

Of the three major steelmaking processes—basic oxygen, open hearth, and electric arc—the first two, with few exceptions, use liquid blast-furnace iron and scrap as raw material and the latter uses a solid charge of scrap and DRI.

Why is it called tube rolling? ›

What Is Tube Rolling? Simply put, tube rolling is the process of trying out a variety of different tubes in the same socket in an amplifier in order to find the one that sounds best to you. The name comes from the circular rolling motion used to slide the tube's connection pins out from their sockets in the amp.

What is rolling in engineering materials? ›

Rolling is the most widely used deformation process. It consists of passing metal between two rollers, which exert compressive stresses, reducing the metal thickness. Where simple shapes are to be made in large quantity, rolling is the most economical process.

Which characteristic of material is used in rolling process? ›

Lubrication is used in the roll forming process to reduce friction between the rolls and metal to prevent tool wear. Friction is a necessary part of the rolling process and an important part of shifting the metal forward between the rollers.

What are the 3 ways of casting? ›

Mainly there are 3 Different Types of Casting processes. They are Die casting, Investment casting, and Sand casting. Each of them provides its own unique fabrication benefits. The casting manufacturing method is the process of pouring molten metal materials into a mold.


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