Problem
Single-radius rollers force the strip edge through one sharp bend, creating edge strain, marking and uneven deformation that shows up as weld and roundness defects.
Cause
A single radius concentrates the bend in one place, so the strip edge is overworked at the entry of each pass and the material flows unevenly around the tube.
Solution
The ZY16 double-radius roller profile transitions the strip edge through two gentler curves, distributing bending more evenly and reducing peak edge strain. This keeps edge thickness intact and improves roundness and weld gap stability on Φ8-18mm tube, especially on thin-wall and coated strip.
Key Engineering Data
- Two-curve roller profile distributes bending more evenly.
- Reduces peak edge strain during each forming pass.
- Preserves edge thickness for a full, sound weld seam.
- Improves roundness and weld gap stability on thin strip.
| Parameter | Specification |
|---|
| Mill Model | ZY16 |
| Tube OD Range | Φ8-18 mm |
| Wall Thickness | 0.4-1.0 mm |
| Strip Width Range | 25-57 mm |
| Max Line Speed | 90 m/min |
| HF Welder Power | 100 kW Solid-State High Frequency |
| Strip Material | Hot Rolled / Cold Rolled / Galvanized Steel |
| Uncoiler | Double-Mandrel Pneumatic, 1.5-Ton Coil Capacity |
| Accumulator | 200 m/min High-Speed Cage |
| Strip Leveling | Seven-Roller Leveling Unit |
| Forming Stands | 5-Stand Rough + 3-Stand Precision |
| Roller Geometry | Double-Radius Forming Rollers |
| Roller Shafts | 42CrMo High-Strength Alloy Steel |
| Safety | Forming Stand Overload Protection |
Performance & Quality
Double-radius rollers transition the strip edge through two gentler curves, so peak edge strain drops and the material flows evenly. This keeps edge thickness intact and improves roundness, especially on thin-wall and coated strip where sharp single-radius bends cause the most defects. The smoother bend path also reduces localized contact stress on the roll surface, so the rollers run longer between regrinds while holding profile accuracy.
Application
For Φ8-18mm tube where edge integrity, surface finish and roundness matter, especially thin-wall and coated strip that cannot tolerate sharp bending.
Selection Guide
Choose double-radius tooling when you form thin-wall, galvanized or precision strip. Specify your exact OD and wall so the roller profile is machined to match.
Application Scenarios
Thin-wall and coated tube, bright-finish tube, and precision small diameter tube where surface and edge quality are key.
FAQ
Q1. What is the benefit of double-radius rollers?
They spread the bend over two gentler curves, cutting edge strain and improving roundness and surface finish.
Q2. Are they needed for all materials?
They help most on thin-wall and coated strip; heavier plain strip can use simpler profiles.
Q3. Are rollers made per size?
Yes, rollers are machined to your exact OD and wall for correct profile and gap.
Q4. Do double-radius rollers wear faster?
No, the smoother bend actually reduces localized contact stress, and the 42CrMo shafts keep alignment stable for long tooling life.
Q5. How do double-radius rollers affect speed?
By reducing edge strain and keeping the strip stable, they support higher line speed with fewer defects, so they help rather than limit throughput.
Q6. Are rollers interchangeable between sizes?
Each size uses its own machined roller profile; rollers are not interchangeable across ODs, which is why we profile them per order.
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