Do-it-yourself rollers for a profile pipe: drawing and assembly. Rollers made of profile pipes: types, principles of operation and self-assembly Drawings of a machine for rolling profile pipes

Why are rollers needed and what are they? If the design uses a profile pipe, it may be necessary to make it a semicircular or arbitrary curved shape. This is what rolling is used for. This is common practice in specialized factories.

Details about rolling

You can make the pipe take a different shape using a simple torch. This approach is often practiced, but the employee faces a number of difficulties:

• there is a need for a large lever to change the shape;
• you need emphasis and, as a result, a lot of physical strength;
• It is almost impossible to make the product even; this is due to inaccurate movements and improper distribution of effort.

To obtain best result, it is worth using rollers. With their help, a profile pipe can be easily transformed with your own hands. The photos and videos show the features of working with the tool. To familiarize yourself with the result of the tool's work, drawings are presented.

1 Type of machine is designed for radius bending of profile pipes.

Characteristics of a standard machine:

Maximum cross section pipes - 40 x40x2, 50x25x2 mm.

Minimum circle diameters:

• 30x30x2 - 650 mm,
• 40x20x2 - 650 mm,
• 40x40x2 - 1800 mm,
• 50x25x2 - 800 mm.

Drive type: manual.

Hardened rollers – all 3 pcs.

Price: 25,000 rubles.

2 Type of machine is designed for radius bending of profile pipes, round pipes and strips.

Characteristics universal machine :

The maximum pipe cross-section is 40x40x2, 50x25x2 mm.

The maximum cross-section of a round pipe is 32x2.8 mm.

Strip 40x4 mm.

Minimum diameters of a circle of profile pipes:

• 20x20x2, 25x25x2, 15x15x1.5 –560 mm
• 30x30x2 - 650 mm,
• 40x20x2 - 650 mm,
• 40x40x2 - 1800 mm,
• 50x25x2 - 800 mm.

The maximum arc diameter is unlimited.

Drive type: manual.

Hardened rollers – all 3 pcs.

Price: 30,000 rubles.

At the Customer's request, for an additional fee, the machine is equipped with a dial indicator for the production of more accurate all subsequent workpieces.

For an additional fee, the machine can be equipped with a 220-380V electric drive

2 year warranty

Contacts:

Tel: 8-919-831-25-14

Saratov region Engels

Delivery within the Russian Federation.

Industrial and home rollers

Not all modifications of this amazing tool can be used at home. How do you think a profile pipe is made? Of course, with the help of rollers. This is done as follows. The sheet of metal is rolled into a cylinder and the seam is welded. Next, the pipe is passed through rollers. Under the influence of high pressure, the desired profile is obtained.

To do the work, enormous efforts are needed, so the profile pipe is produced at special equipment. Rollers installed in factories weigh more than ten tons. How can you do this kind of work yourself?

We do it ourselves

At home you will need other rollers, not so heavy. Drawings and photos of some modifications are presented on the website. To do the job yourself, you will need a small, mobile tool. Home rollers are available mechanical and electric. Here you have to choose between saving energy and the amount of effort expended.

Electrical appliances “eat” electricity, but making a profile pipe with your own hands is much faster, it turns out like it came from a factory. Mechanical analogues are not inferior in results, but the worker has to apply force to change the shape of the workpiece. In case of electrical appliance There is one more pitfall. Its power can be so high that aluminum wiring It just can’t stand it and burns out. This is worth remembering. Electric rollers are available in different modifications, but the most popular are those with a motor power of 500 to 1500 W.

Manual devices no less in demand. You can make them yourself. To do this you will need three rollers made of durable steel. Two of them are located on the same plane. A handle for rotation is attached to one of the rollers. The third is lowered from above using a simple worm gear. The profile pipe changes shape as a result of pressing its surface during rotation. Drawings of the instrument circuit are presented here.

If you don’t plan to make products for sale, homemade rollers are what you need. It is very cheap, the device is compact, and if necessary, you can also screw in the drive - the device will be electric. In this case, it is important to calculate the power that will be required during rolling.
http://www.youtube.com/watch?v=b4NSJo-FZNY
If the pipe is not profiled, then it can be bent. To do this, a groove is cut the right size. If you plan to use an electrical appliance, then during its manufacture you should also calculate the gearbox. Thanks to optimal values gear ratio, the forces on the motor shaft are minimized.

We are all a little Kulibina

It is human nature to create. The desire to do something on their own never leaves even the laziest people. When designing rollers, it is worth keeping safety in mind.

The advent of cellular polycarbonate for the manufacture of greenhouses has determined a new type of structure for protected ground structures - arched structures. To create a metal frame for such buildings, you need to have a machine capable of bending structural profiles along a certain curve. Homemade rollers for profile pipe designed to help in the manufacture of arches along a given radius.

Technological process profiling of long workpieces is based on pulling the part through rollers located at a certain distance from each other. To give a bend in one direction or another, the length of the length is not passed in a straight direction, one or two rollers are offset.

Pipe rolling machine

When rolling long pipes on a machine, the center of movement is shifted. Due to this displacement, a curve is formed between the rollers. One roller presses from the inside of the radial contour, and the other two form the external contour of the future product.

Drawing of a pipe bender for pulling profile pipes. All dimensions of parts required for manufacturing are indicated:

Structurally, such a device is made on a strong support made of channel. The lower rollers are located in bearings. Usually the distance between them does not change (there are versions of the machine where, by changing the location of the lower rollers, a different rolling radius is created).

The top roller is located on top. It can be moved in height. By moving the supporting part downward along the thread, significant forces can be developed. They will act on the pipe during the rolling process.

To perform rolling, additional pulling forces must be applied in the longitudinal direction. A handle is installed for this purpose. By rotating it, you can make the pipe move in one direction or another.

For self-production, you can go a different route. The walls of the device are cut out of a sheet 2...4 mm thick, where the rollers are installed.

Simplified pipe bender design:

The most difficult thing is to make the sidewalls, inside of which are located:

1. Support shafts – 2 pcs.
2. A pressure roller located on a suitable device.
3. A handle that allows you to roll a profile pipe.

Industrial machines are made with manual or electric drive. When manufacturing an electrified machine, the possibility of reverse must be provided. Then you can roll, forcing the length to move in both directions.

Making a pipe bender with your own hands

The simplest pipe bender It is relatively easy to make. Need to purchase:

• bearings No. 206;
• bearing housings;
• shafts Ø 35 mm made of hardened steel HRC 40…45 (suitable for inner size bearings);
• bicycle sprockets of the same diameter;
• bicycle pedal;
• lead screw with nut;
• channel No. 8;
• channel No. 6;
• M8 bolts with nuts;
• strip 40 mm, thickness 4 mm.

To make it you need to use:

1. Electric drill.
2. File.
3. Angle grinder with cutting and cleaning discs.
4. Welding machine.
5. Set of wrenches.

Step-by-step manufacturing of the machine

Having prepared a set of components, we begin manufacturing.

General form machine It is installed on timber 100·50 mm.

All details are displayed in a visible place. The performance of the bearings and lead screw is preliminarily checked.

Blanks are cut from channels. They are welded vertical stand, installed perpendicular to the supporting channel.

A hole is drilled for the lead screw. A nut is welded to it. Then screw in the screw. A cross member is welded on top; it will be needed to move the screw along the thread.

Bearings move along the support channel. They are pre-installed in the housings. Shafts are inserted inside. Chain sprockets are welded to one of the ends.

A bicycle pedal is welded to one support shaft. By rotating it in one direction or another, you can force the pipe to move in the desired direction.

Having manufactured the clamping mechanism, the location of all elements is checked. They try to install them according to the drawing presented earlier.

Having installed the parts in place, they are welded. Now it’s time to check the functionality of the device.

Place the pipe and roll it in both directions. There is no pressure from above yet; we are checking how easily the pipe moves.

By turning the screw, press the pressure roller down and push the pipe. Having shifted the pressure roller, the pipe is rolled. After each pass, move the roller down. Periodically remove the part and compare it with the template.

Having manufactured the machine, you can begin to manufacture greenhouses and greenhouses, which are based on profile pipes. Below are examples and information on how to make such structures.

Video: homemade pipe bender for a profile pipe.

Arches for greenhouses and greenhouses

Different types of greenhouses are used in the practice of gardeners

Greenhouse metal frame 3·4 m:

Most often, three-meter arcs are chosen. An entrance is created at the ends. Additionally, a window is installed that can be opened while leaving the door closed. Profile pipes of 20·20 and 25·25 mm are used.

Reinforced arc of an arched greenhouse:

IN winter period the load can reach over 200 kg/m². Therefore, a curved arc inside is welded to the outer contour. Additionally, radial connections are welded. Now a more rigid circuit is working that will withstand high loads.

Stationary greenhouse “Butterfly”:

Small designs greenhouses can be made stationary and portable. They are convenient because you don’t need to go inside to work with the plants being grown. It is enough to open the doors slightly to gain access. The greenhouses are called “Butterfly” because they open in both directions. From the end, the raised doors look like butterfly wings.

Greenhouse "Breadbox":

In the beds for spring and autumn periods install portable greenhouses"Breadbox". In this design, the door opens in a similar way to how this issue is resolved in bread bins. It rises up and moves along back wall. Such devices are in enviable demand among vegetable growers.

Greenhouse "Droplet":

The desire to reduce snow load and create a durable metal frame encourages designers to create drop-shaped greenhouses. The generatrices of the walls are built along complex curves. The top is pointed, the snow rolls down without stopping on the surface.

Joining semi-arches in the “Droplet” greenhouse:

Inside, the semi-arches are connected in the center of the frame. This solution facilitates the production and delivery of products to the gardener’s plot. All that remains is to make the halves and assemble them on site.

When constructing greenhouses, designers count on the length of rolled products, as well as polycarbonate rolls. Standard length profile pipes is 6 m. You can bend them different ways. But the condition remains that there should be a distance of 3 m between the ends of the pipes.

Drawing of a radial arch for a greenhouse made of 20·20 mm profile pipe. Doorway:

The most common design is made along a radius of 1500 mm (outer profile). In it, a height of 2115 mm is reached in the center of the structure. Vertical sections are created on the sides of the generative arc; their length is 615 mm. Users will enter through a 780mm wide doorway. The opening height of 1830 mm is sufficient for the passage of people of average height.

Practice shows that such a greenhouse is in demand in most areas. There is enough space inside to accommodate beds and walkways.

Arch for a heifer 2800 mm wide:

Some people like to use a greenhouse that has a slightly smaller width (2800 mm). In it, the height in the central part is slightly higher, amounting to 2195 mm. Here the vertical sections along the edges have a height of 795 mm. The radius of the generatrix of the curve is 1400 mm (outer dimension).

The large height (2085 mm) and width (800 mm) of the doorway attracts attention. Even tall users will be able to walk inside freely without bending over when entering.

For a greenhouse 6 m long you need:

• 7 arcs, they are placed at a distance of 1 m from each other;
• for the manufacture of end elements, 33.3 m is required;
• the longitudinal elements between the arcs will total 42 m;
• To manufacture a metal frame, 20 profile pipes (6 m) will be required. The calculation was performed for a 20·20 mm profile pipe with a wall thickness of 1.5 mm. The total weight is 99 kg.

Arch for a greenhouse type “Pavilion”:

When manufacturing a “Pavilion” type structure, a reinforced arc is created. Distance between vertical supports will be 5400 mm. Profile pipes 40·60 mm (wall 2 mm) are used. Pipes of 40·40 mm are used as supports (you can also bigger size in the manufacture of carports).

Reinforcement is necessary so that such an arch can withstand a snow load in winter equal to 200...220 kg/m². They are placed at a distance of 1 m and covered cellular polycarbonate thickness 6...8 mm. For winter greenhouses, polycarbonate with a thickness of 10 mm is used.

Drawing of a small-sized greenhouse bread box:

Using a machine for rolling profile pipes, you can make for yourself and to order a wide variety of arcs for greenhouses and greenhouses.

When carrying out repairs and construction work in the private sector there is often a need to manufacture curved metal structures. They are used to create a frame for canopies, awnings, roofs of houses and gazebos. Decide this task Rollers for a profile pipe will help. These are devices that can be purchased in specialized stores or made with your own hands. Let's consider the purpose of these devices, their varieties and specifications.

Only rolling rolling on special machine is a way to achieve a similar result. Rollers are a mechanism consisting of several metal shafts and an energy source that drives them.

Types of rollers

To give the rolled product the required shape, devices with the same mechanical part and different drives are used.

The choice of energy source depends on several factors:

• how much load will be required to bend the metal;
• how often the equipment will be used;
• under what conditions the pipe bender is planned to be used;
• own knowledge, experience in the field of design and working with iron.

Let's briefly look at the features of each type of drive.

Hydraulic

Designs of this type are the most powerful and productive. As a rule, they are used by factories and plants involved in the mass production of curved profiles. Hydraulics are difficult to self-installation, but it creates a force sufficient to bend several large-section pipes at once.

At home, constructing a hydraulic profile bender is economically justified if you plan to produce tens or hundreds of thick arched profiles.

Mechanical/lever

The products are portable and lightweight. They are easy to carry from place to place and transport in the back. Increased pressure on the drive device is achieved by increasing the length of the lever. However, only profiles with a cross-section of no more than 40×20 mm can be bent manually. These parts are suitable for building the roof of a house and yard buildings. Greenhouses covered with cellular polycarbonate are made from arched profiles.

Electrical

Usage electric motor for passing workpieces through shafts not only speeds up the process of bending pipes, but also eliminates home handyman from heavy physical labor. Performance electrical devices high with low financial costs.

Machine assembly on our own requires knowledge in the fields of mechanics, electrical engineering and kinematics. Please pay attention to safety issues.

Operating principle of rollers

Rolling a profile pipe is the process of giving it a bend of a certain radius. To achieve this, you need to place the workpiece between the rollers, which are located below and above. The workpiece is fed into the device and pressed down from above. After this, the shafts begin to rotate, moving the pipe forward and deforming it in the direction of the upper shaft.

If the degree of bending is not sufficient for the project, then the degree of pressure is increased. The product is rolled through rollers until the desired shape is achieved.

How to use rollers

This device consists of several static and moving parts:

1. The base is a strong, heavy and stable frame to which all other components and mechanisms are attached.
2. There are rollers on the frame that act as receiving and feeding devices. The transmission to the power plant is connected to the rollers.
3. A clamping device is attached to the base to regulate bending parameters. As a rule, manufacturers use a threaded clamp.
4. A guide made of metal sheet, fittings or steel profile. This part is necessary to ensure that the workpiece does not bend in the horizontal direction.

Regardless of the energy source supplied to the guide rollers, all devices operate in the same way. After turning on the equipment, the end of the profile is inserted into the hole between the rollers and moved forward. The captured workpiece passes along the shafts, where it is deformed. To reduce the radius, the clamp is tightened and the arch is run again.

Is it better to buy or make it yourself?

The products produced at the plant have one thing in common - high price. It far exceeds the purchase costs ready-made arches or order this service from professionals. With a competent approach to business homemade pipe benders superior in quality to factory analogues.

The decision about whether to make an expensive purchase or make a machine yourself should be made after studying market conditions and assessing your capabilities.

Which ones are on the market?

The economic market provides wide choose, differing in different parameters. Machines can have several rollers and even directions for simultaneous bending of several workpieces. Work zone equipped with a folding or adjustable shaft.

The drive is output to the upper and lower shafts or only to one level. Electrical and hydraulic devices provide the possibility of manual rotation with an indication of how much force is required for this.

Modern models of pipe benders are classified according to the following criteria:

• actuator;
• dimensions;
• type of metal being processed;
• profile wall thickness;
• diameter (mm) of rollers;
• maximum length of workpieces.

Almost all machines have the option of reversing the rotation of the rolling mechanism.

DIY assembly

Pipe bending rollers are a simple device. You can even make it from scrap materials left over after renovation and construction. In most cases, when deciding how to make rollers, novice craftsmen tend to choose a design mechanical type. It is easy to design and assemble using welding, which is found in every home.

The small-sized machine is easy to move around the site; there is no need to build a separate room for it.

Drawing

Before making a high-quality and functional machine for bending profiles, it is necessary to make detailed drawings, the dimensions of all parts should be drawn with high accuracy.

Roll patterns can be made on graph paper or on a computer. The choice depends on design skills. Based on the drawn up drawings, the need for building materials and tools. An estimate is made, equipment is selected and missing property is purchased.

Materials and tools

To assemble homemade rollers, you will need the following tools and consumables:

• welding machine;
• grinder or milling cutter with discs for metal;
• roulette;
• electric drill;
• set of screwdrivers and wrenches;
• square;
• core;
• oil level;
• hardware (angles, bolts, nuts, rivets);
• channel or I-beam;
• blanks for shafts;
• profile pipes.

When selecting material for construction, you should remember that metals and alloys for rollers must be much stronger than the steel of profile pipes.

What is included in the design

The bed is made of thick and heavy rolled steel.

The strength and weight of the base must correspond to the force applied when rolling the profiles. The assembled frame must be stable and strong so as not to swing during operation.

The clamping system is assembled in the shape of the letter “P”. On top crossbar a threaded hole is made to create clamping force. Another option is to weld the nut over the round hole. Subsequently, a bolt is inserted into it to adjust the clearance between the rollers.

The rollers themselves are equipped with rolling bearings, which are mounted on durable axles. The rollers are turned to lathe, undergo a hardening cycle in oil.

The drive is made from bicycle sprockets and a chain. The sprockets are welded to the driven and drive shafts, and then connected by a chain. A gate with sufficient leverage is welded onto the drive sprocket.

Filling with sand or water?

When the workpieces are given a strong bend, they are flattened and the cross-section geometry is disrupted. In order to prevent this, hollow profiles are filled with dense material that does not change volume under pressure.

The most simple solution is filling the blanks with sand. It is spilled with water, compacted, and then plugs are welded to the ends.

With water it is more difficult, since the plugs must be sealed. If assembly takes place in winter, then the best solution the pipes will be filled with water, closed with plastic plugs and frozen. This method is used in the manufacture of wind musical instruments.

Spring selection

Springs are used to reduce the impact of vibration from the electric motor on the rolling system. With strong vibration, workpieces may shift along the horizontal axis. The springs must be stiff to prevent the engine from rocking and at the same time reduce shaking. It is recommended to use at least 4 springs to fix the motor frame.

Cut and cook

The roller manufacturing process is carried out in the following sequence:

1. Taking measurements and applying markings in accordance with the diagrams.
2. Cutting rolled products into blanks, cleaning the field for welding.
3. Turning and hardening of shafts, installing bearings in them, attaching sprockets, securing to an axle.
4. Welding the frame with a rolling and pressing mechanism.
5. Drive installation. It can be permanent or removable.
6. Checking the functionality of the machine.

Finally, the metal is cleaned from rust, primed and painted. Moving parts are lubricated.

Process video

Watching a video of how to make rollers yourself will help novice craftsmen easily cope with this work.

Standard profile pipes of square or rectangular cross-section, due to their high bending strength and low weight, are widely used in construction. In cases of exceeding acceptable values loads that arise during strong bending, products are deformed and torn. Exclude Negative consequences allows the use of pipes with a reinforced profile.

Machine for strengthening profile pipes

Reinforcement means the formation of ribs at the corners of a square or rectangular profile during rolling on specially shaped rollers.

Pipes with a reinforced profile are characterized by high bending strength and are used to create curved structures of any degree of complexity.

The profile is strengthened using specialized equipment.

Application area

To obtain the desired configuration, profile pipes are sequentially processed on profile strengthening machines, a forging block and a pipe bender.

A pipe bender allows you to bend profile pipes along a longitudinal section along a given radius. Such products are used when installing canopies, gazebos, and canopies.

Gain – necessary stage preparing a profile pipe for making a curl using the cold forging. The forging block allows you to create decorative elements from pipes with square or rectangular cross-section, curved in the most bizarre way. The resulting products are distinguished by their volume, lightness, and low price.

Design

The machine for strengthening the profile is in many respects similar in principle of operation and design to a conventional rolling machine.

In addition to the frame and the motion drive, the main components of the machine for reinforcing a profile pipe are:

1. Lower (support) shaft – 1 pc. It is leading, with its help the pipes move.
2. The upper shaft is a pressure shaft. Deforms the profile - presses the pipe against the lower shaft.

The supply and receiving shafts are securely mounted on a massive base (housing); it must ensure the stability of the installation during operation. The feed mechanism ensures the rotation of the shafts around its axis.

Process technology

The amplification process on the simplest machine is performed sequentially, with two pipe installations:

• Step 1 – installing the pipe on the rollers.
• Step 2 – rolling the first 2 symmetrical sides.
• 3rd step - reinstallation of the pipe (rotate 90 0).
• Stage 4 - rental of the second 2 symmetrical sides of the profile.

Profile strengthening machine

Reinforcement of the profile is carried out on a cold forging machine equipped with rollers for squeezing the profile pipe before bending it into a curl.

Profile pipe

The rolling process depends on the wall thickness of the profile pipes and the grade of material from which they are made

Drive mechanism

According to the principle of operation there are different types wire mechanisms:

• manual;
• electric;
• hydraulic.

The manually driven machine has a simple design, compactness, and is designed for small volumes of work. Can only work on it physically developed person. The metal will have to be deformed using muscle force.

An electrically driven machine for strengthening a profile pipe also does not take up much space. It is powered by an electric motor and has high performance.

Hydraulically driven equipment is too bulky. Allows you to roll profile products with maximum dimensions. Designed for large volumes of work.

Functionality

Multifunctional stationary modules, which are equipped with:

• rollers to strengthen the profile pipe;
• rollers for rolling out the ends of blanks in the form of artistic elements;
• forging block for cold forging.

All operations are performed without readjusting equipment or changing tools. The modules make it possible to produce various decorative forged elements of different sizes and required shapes.

An example of a multi-purpose installation is a reinforcement unit with rolling crow's feet (PGL), produced commercially, adapted for several operations:

• type gain crow's feet"(squeezing, squeezing);
• rolling out the ends of the workpiece.

After this treatment, the pipe is completely ready for making a decorative curl on a forging block.

Making a machine yourself

It doesn't always make sense to purchase a professional machine. For one-time work, simple DIY installations are more suitable. The main thing is to have drawings, carefully study the principle of the design and operation of the machine, select high-quality materials for workpieces and necessary tools for assembly.

Scheme

Schematic diagram of a machine for rolling 2 types of profile sections in section. Based on it, you can get an idea of ​​the design and interconnection of the main components and the principle of pipe processing. IN in this case, the upper shaft is the driving one.

Machine diagram

Accessories

Rolling roller components should not have chips or gouges, have a decent margin of safety, and be made from certain grades of steel.

Shafts and axles are turned on a lathe. Some components can be bought in a store or removed from other mechanisms, for example:

• self-aligning rolling bearings (4 pcs.);
• stars (4 pcs.);
• chain from a bicycle, moped.

To assemble the frame (base), you will need rolled metal (channels, pipes), sheets 5-10 mm thick. The base ensures stability of the installation during operation.

Frame assembly

To strengthen the profile, it is better to make rollers (2 pieces of each type) from alloy steel; for a small amount of work, St3, St10 are also suitable. Roll blanks are subjected to hardening.

Rollers and axles must be many times harder than the pipes being processed. Otherwise, the rollers will have to be replaced frequently with new ones. The hardness of rollers on professional installations is at least 52 HRC.

Tools

When assembling the machine, you will need the following skills (as well as appropriate equipment):

• turner;
• welder;
• locksmith

Fastening by welding in some places can be replaced with threaded connections.

Required tools:

• drill, with a set of drills;
• wrenches of different sizes;
• level for setting the horizon line;
• caliper, tape measure.

Design of incoming parts

Special rollers are machined along the edges of the rollers, which reliably fix the position of the pipe during rolling.

Rollers

You can get the dimensions of the rollers for broaching the profile from the kit from professional installations. It is not difficult to develop drawings of rollers and axles according to the obtained dimensions yourself. Below is an example drawing.

Roller drawing

Rolling of each profile size is carried out using rollers of appropriate sizes. Making a model with removable elements is not easy; for this reason, it is recommended to make multi-stage rollers for reinforcing the profile pipe when assembling the machine yourself. This will allow pipe processing different sizes without reinstalling the rollers.

Both axes have the same dimensions, but different lengths. The movement handle is attached to the longer axis (driving). Below is a drawing of the c axis seat under the handle.

Drawing of an axle with a seat for the handle

Assembly work

The frame is created gradually as the remaining parts are assembled. The individual elements of the base are connected to each other by welding or large bolts.

The distance between the upper and lower axle depends on the diameters of the rollers. In the absence of precise assembly drawings, the dimensions between the axes are determined experimentally:

• install the rollers on the axle;
• measure the distance between the axes;
• drill holes on the side walls of the frame for installing bearings;
• then the axles are put aside and the bearings are installed.

The connection between the axle and the rollers is carried out in several ways:

• using a key, about 8x8 mm in size;
• welding through pre-drilled countersunk blind holes made with a large-diameter drill.

The second method is available if you have a machine for manual electric arc or semi-automatic welding.

Next, the axle is inserted into a bearing, which is pre-fixed in an axle box, pre-welded to the wall of the frame with inside. Reliability of fastening is maximum. First of all, the axles with rollers are installed in that side wall frame where the chain drive is supposed to be located. Then the axles are inserted into bearings mounted on the 2nd side wall of the frame.

After installing the main elements, the frame is strengthened:

• welding seams;
• threaded connections.

The assembly of the chain mechanism in practice also occurs with the determination of dimensions on site:

• install the 1st sprocket on the lower axle;
• on the upper axis - 2nd sprocket;
• try on the chain, mark the location of 2 more sprockets.

Chain mechanism assembly

The rollers should rotate without difficulty when the chain is tensioned. The handle is welded to the drive axle last.

Chain mechanism

For the motion feed mechanism in the form of a worm gear, it is necessary to stock up on gears of the required size.

Motion feed mechanism

Special requirements are placed on the alignment of the rollers: they must be located in one vertical plane and be strictly parallel. Any misalignment will lead to uneven compression of the profile, which will significantly reduce the quality of the rolled product.

A machine made at home specifically for strengthening profile pipes should not pose a danger to humans during operation. During assembly you should:

1. Fix all moving parts as reliably as possible. Prevent them from bouncing during operation.
2. Provide protective flaps.

Properly assembled homemade installations They are not inferior to professional models in terms of the quality of their products.

Profile pipe is an element of many building structures and frames. Used in the construction of industrial and residential buildings. The main characteristic that distinguishes it from other types of pipes is the non-round shape of the cut. A profile pipe is produced from a sheet, welded and bent lengthwise in in the required form. If necessary, you can make rollers for a profile pipe with your own hands - you will find drawings and explanations in this article.

Manufacturing of profile pipes using the rolling method

Assortment of profile pipes

In factory conditions, two methods are used for the production of profile pipes from sheet metal:

• hot method, in which straight-seam round pipe heats up;
• cold method, in which rollers for a profile pipe are rolled over unheated metal.

The basis for production is carbon, low-alloy, less often stainless steel. Modern factory equipment will make it possible to obtain a profile with high precision of seams and bends, since the process is controlled through data transfer from a computer and receiving it from sensors that take readings with an accuracy of thousandths of a millimeter. Homemade rollers for profile pipes cannot provide such detail, but they cope with the task of producing elements for home construction and household work. This technique is used to produce consumable elements for fences and canopies, greenhouses and technical buildings, gutters and cable ducts. It is not recommended to make a profile pipe for large-scale buildings at home. Factory equipment makes it possible to subject each manufactured element to test tests and check both the quality of the seam and the accuracy of profile calibration. The absence of such equipment does not give the master the opportunity to guarantee the quality of a homemade product.

Assembly of a machine for profile production

Application of curved profile pipes

A do-it-yourself rolling machine for a profile pipe looks similar to a design for bending pipes. It consists of the following elements:

• supporting frame;
• roller system;
• pressing mold:
• stop and levers for activating the rolling mechanism.

In fact, these are two different mechanisms and only the frame can be similar. All structural elements are assembled from durable elements and welded: any defects and negligence can result in work injury. The machine itself is firmly fixed to the surface.

Almost impossible to provide required pressure manually: it is advisable to equip the press for creating a profile pipe with an electric drive.

In the profile shaping machine O round shape the main thing is a press that twists a sheet of metal. Such pressure only gives robust design: The pipe must be held motionless throughout the welding period. To simplify the work, the metal is heated and then rolled. After welding, the round pipe is checked for the quality of the connection: an insufficiently smooth and clean seam will separate when rolling of the profile pipe from a round shape to a rectangular or square one begins.

Workpiece processing process

The finished straight-seam pipe is rolled hot or cold. At home, it is difficult to organize hot rolling, so the process is often carried out on already cooled metal.

The pipe is placed under a press of rollers, forming the required shape.

Rolling is carried out gradually with a decrease in the distance between the upper and lower rollers. Sudden pressure will cause internal folds in the metal, which will affect the strength of the knees. The last rolling reaches the planned diameter and cut contour.

The pipe is checked for cracks and metal deformation in the bend area after each rolling. Zone special attention– the seam area, it is the most vulnerable.

After processing with rollers, the pipe is calcined: this measure eliminates the stress of the metal layers and increases the strength of the structure as a whole.

Bending of profile pipes

Craftsmen rarely decide to independently manufacture a profile pipe, preferring to purchase ready material factory production. The profile pipe is an inexpensive consumable element, so bending is necessary with my own hands No. A machine for bending profile pipes with your own hands is a more popular equipment, since the element is sold in direct form, and ordering bending according to your own drawings is an expensive service. A curved or rounded profile is used for construction and construction decorative elements as more aesthetic. Frames and cornices, greenhouse arches and gate arches can be made with your own hands. The simplest rollers for bending a profile pipe are assembled in a few hours. They will not provide industrial volumes and accuracy, but production costs individual elements will be cut.

Bending quality requirements

The simplest way bending of profile pipes - glow and pressure. In this way you can even create sharp corner, but you shouldn’t count on the accuracy and strength of the knot. Folds on inner surface knees and cracks on the outside are guaranteed. Bending without defects is achieved only by gradually rolling the pipe on rollers and calculating the minimum diameter. The maximum bend angle is not standardized, the minimum is limited by safety requirements. A standard factory machine for bending profile pipes sets minimum diameters rounded bend, you can focus on the same indicators when creating homemade machine:

• pipes 20x20x2, 25x25x2, 15x15x1.5 - 56 cm;
• pipes 30x30x2 – 65 cm
• pipes 40x20x2 - 65 cm;
• pipes 40x40x2 – 180 cm;
• pipes 50x25x2 - 80 cm.

Machine drawings for home use

The simplest deformable structure can be assembled right in the yard or technical room, securing all the elements on a thick shield or directly on the fence. Elementary models will help out if you need to bend several pipes into a single shape, for example, to install the upper arches of a greenhouse. Regardless of the selected bend diameter and the size of the pipe itself, you will need:

1. A frame that follows the contour of the required arch. It is cut from a single piece of wood or assembled from a series of planks. The pipe will bend according to this stencil.
2. Support on one side of the frame. The gap between the stop and the stencil is made corresponding to the diameter of the pipe being processed. A smaller one will make it difficult to install the element into the device, a larger one will not secure the knee firmly.
3. A block with which the pipe is manually pressed against the template.

Working with such a pipe bender is difficult: all efforts will have to be done manually. But the design will ensure accuracy when bending: it is possible to make several elements with an identical angle of deformation on it.

The pipe bender for permanent use is assembled on a durable U-shaped frame. The following elements are required in his system:

• two rotating shafts mounted on a rail, along which the profile will pass during rolling;
• an extrusion shaft located above them, which presses the profile during rolling;
• a clamp or jack that provides pressure;
• a chain with which the set of rollers will move.

To assemble rollers for a profile pipe with your own hands, you will need a welding machine and skills engineering work. Inaccuracies in calculating the diameter of the functional shafts will make the device inoperable.

Video: working with a manual profile bender

Assembling a bending device with your own hands is a complex, time-consuming and expensive process. Against the background of moderate prices for equipment, it is worth thinking about the rationality of the purchase. Perhaps, to bend several elements, it is more profitable to contact a workshop, but for permanent job purchase a factory model with a quality guarantee.