Cone Shaping Machine

With 10 years of dedication, we have become a professional manufacturer of cone rolling machines. Today, we reveal the solution to the problem of uneven ends in cone rolling machines:

The problem of uneven ends in cone rolling machines during the processing directly affects the assembly accuracy and performance of the product. This problem mainly manifests as inconsistent diameters at both ends of the workpiece, uneven end faces, or uneven taper. To effectively address this issue, targeted measures must be implemented across three key areas: equipment adjustment, process optimization, and operational control.

1, Equipment status inspection and adjustment

The mechanical precision of the equipment is a fundamental factor affecting the quality of the ends. First, check the levelness and parallelism of the roller shafts, and use a precision level to measure the relative positions of each roller shaft. If the deviation exceeds 0.1 mm/m, mechanical adjustments must be made immediately. The bearing clearance of the roller shafts also needs to be checked regularly, as excessive clearance will cause the roller shafts to shift when under load.

The degree of mold matching directly affects the end forming effect. The upper and lower rollers must be completely aligned, and a feeler gauge should be used to check the roller gap to ensure that the gap is uniform along the entire length. Molds that are severely worn should be replaced in a timely manner, especially when processing hard materials such as stainless steel, as mold wear will accelerate significantly. When installing the mold, ensure that it is securely fastened to prevent displacement during processing.

2, Process parameter optimization  

Control of the feed position is critical. The edge of the sheet material must maintain an appropriate distance from the mold edge, typically with a processing allowance of 5–10 mm. During feeding, ensure the sheet material is aligned with the mold centerline; a laser alignment device can be used for positioning assistance. For longer sheet materials, it is recommended to use an auxiliary feeding device to avoid deviations caused by manual feeding.

Pressure parameters should be adjusted in stages. During the initial pre-bending stage, use lower pressure to achieve preliminary forming of the sheet material; gradually increase pressure during the intermediate stage to complete the main deformation; maintain stable pressure during the final shaping stage to ensure the shape is set. Excessive pressure may cause material buildup at the ends, while insufficient pressure may result in severe springback. For materials of different thicknesses, the optimal pressure curve should be determined through testing.

3, Process control

The skill level of operators directly affects the quality of the ends. When feeding material, maintain a steady and consistent speed to avoid uneven material flow caused by sudden changes in speed. During processing, closely monitor the forming conditions at both ends and make minor adjustments promptly if any deviations are detected. For critical components, it is recommended to first use test pieces for parameter verification.

Subsequent processing steps are also critical. After removal, the workpiece should be placed on a dedicated cooling rack to prevent deformation caused by self-weight. For high-precision products, secondary calibration and shaping may be performed. When machining the end face, use specialized fixtures to secure the workpiece, ensuring the cutting surface is perpendicular to the axis.

Quality inspection is a critical step in ensuring product conformity. The first piece of each batch must undergo full-dimension inspection, using tools such as calipers and micrometers to measure end diameter and taper. Regular spot checks must be conducted during production, with parameters adjusted promptly upon detecting deviations. Establish comprehensive quality records to provide a basis for process improvements.

Preventive maintenance can effectively reduce the occurrence of end-related issues. Inspect the wear condition of rollers and molds weekly, and test the geometric accuracy of equipment monthly. Establish replacement cycles for critical components to avoid overuse. Keep equipment clean and promptly remove accumulated metal debris and oil residues.

The processing of special materials requires special attention. For high-strength materials, the number of processing passes should be increased appropriately to reduce the amount of deformation per pass. When processing thin-walled pipe fittings, mandrels should be used to prevent instability and deformation. For workpieces with irregular cross-sections, custom molds may be required to ensure the quality of the ends.

By systematically implementing the above measures, the issue of uneven ends on cone rollers can be effectively resolved. In practical applications, it is necessary to continuously optimize and adjust the implementation plan based on the specific characteristics of the equipment and products. Additionally, it is important to strengthen training for operators to enhance their understanding and control of process parameters. Only by seamlessly integrating equipment, process, and operator skills can high-quality conical components be produced consistently and reliably.

If you are interested in cone rolling machines, please contact us.