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The Φ100mm Manual Leveling Machine is a specialized piece of equipment designed for the precise leveling of medium-to-heavy-gauge sheet metal. Leveraging the unique advantages of its large-diameter work rolls, it overcomes the limitations of traditional leveling machines—such as their inability to handle thick sheets effectively and their lack of precision—while balancing ease of operation with processing stability. It is widely suitable for sheet metal straightening needs in various industries, including hardware manufacturing, mechanical manufacturing, and steel structure processing, making it a cost-effective choice for small and medium-sized enterprises seeking precise sheet metal processing.
This machine can straighten sheets ranging from 3.0 mm to 20.0 mm in thickness, with a straightening width of 200 mm to 2100 mm (customizable upon request). It is compatible with various metal sheets, including carbon steel, stainless steel, aluminum, and copper. Whether performing routine straightening of cold-rolled or hot-rolled sheets or precise correction of slightly deformed sheets, it delivers high-efficiency results. The drive system employs a motor-and-gearbox linkage design, ensuring smooth transmission, ample power, and low operating noise. It is capable of continuous, long-term operation, making it well-suited for batch production requirements.
Width of standard series | 200 | 400 | 600 | 1000 | 1300 | 1600 | 1900 | 2100 |
|---|---|---|---|---|---|---|---|---|
Diameter of leveling roller | 100 | 100 | 100 | 100 | 100 | 100 | 100 | 100 |
Number of leveling rollers | 19 | 19 | 19 | 19 | 19 | 19 | 19 | 19 |
The shortest workpiece length for flattening Lmin (mm) | Lmin=160 | Lmin=160 | Lmin=160 | Lmin=160 | Lmin=160 | Lmin=160 | Lmin=160 | Lmin=160 |
Nominal thickness of leveling material T (mm) | 3.0-12.0 | 3.0-12.0 | 3.0-12.0 | 3.0-12.0 | 3.0-12.0 | 3.0-12.0 | 3.0-12.0 | 3.0-12.0 |
Maximum thickness of flattening material Tmax (mm) | Tmax=20 | Tmax=20 | Tmax=20 | Tmax=20 | Tmax=20 | Tmax=20 | Tmax=20 | Tmax=20 |
Leveling accuracy | The parameters are calculated according to the material Q235/yield strength 235MPa, and the length and width are detected within 1m | |||||||
0.1-0.15mm | 0.1-0.15mm | 0.1-0.15mm | 0.1-0.15mm | 0.1-0.15mm | 0.1-0.15mm | 0.1-0.15mm | 0.1-0.15mm | |
Straightening line speed (m/min) | Speed adjustable at 1-10m/min | |||||||
voltage | AC three-phase 380V | |||||||
Optional Accessories | 1. Automatic loading/unloading manipulators/palletizing robots | 3. Number of leveling rolls | 5. Uncoiler – Laser cutting and blanking line | |||||
2. Infeed/outfeed roller conveyor: Powered/non-powered | 4. Uncoiler – Hydraulic/mechanical cutting line | |||||||
Customized requirements | Customer customization requirements are acceptable | |||||||
The equipment is designed based on the theory of elastic-plastic deformation of metallic materials and the “Bauschinger effect.” After entering the leveling machine, the sheet passes between the upper and lower rows of staggered rollers; each time it passes through a pair of rollers, it undergoes a reverse bend. The opening of the first pair of rollers at the inlet is the widest, applying a greater bending force to the sheet, causing the outer fibers of the material to enter the plastic deformation zone first; As the sheet progresses toward the exit, the roll gaps narrow pair by pair, and the bending amplitude decreases. The residual stresses within the sheet are released layer by layer through continuous tension-compression cycles; ultimately, at the exit section, the sheet is discharged smoothly in a state of near-zero curvature, achieving the leveling objective.
The core advantage of this process lies in “small deformation, multiple passes”—the bending amount per pass is controlled within a range that does not damage the material. By gradually eliminating the original deformation through cumulative, repeated deformation rather than a single, forceful flattening, the process avoids material hardening and surface damage caused by over-processing.
The frame employs a monolithic welded box-type steel structure. Post-welding annealing thoroughly eliminates internal welding stresses, ensuring that the frame’s elastic deformation under maximum load remains within permissible limits, thereby providing a more reliable rigid foundation for straightening accuracy.
The work rolls are made of 9Cr2Mo cold-rolled roll steel or Cr12MoV die steel. They undergo a composite processing sequence including tempering, medium-frequency quenching, cryogenic treatment, precision grinding, and micro-arc oxidation. The roll surface hardness reaches HRC 58–63, with a surface roughness of ≤0.4 μm and a hardened layer depth of 3–5 mm. The high-hardness, high-finish roll surfaces effectively prevent roll marks and scratches when processing medium-to-thick stainless steel sheets, high-strength steel sheets, and other materials, and can be reground and reused multiple times.
A double row of closely spaced support rolls is positioned beneath the 100mm-diameter work rolls. Each work roll is flanked by two rows of support rolls arranged in a staggered pattern along its length. Contact pressure is pre-tensioned via an integrated wedge-type adjustment mechanism, effectively suppressing the elastic deflection of large-diameter work rolls under heavy loads and ensuring that leveling pressure is uniformly distributed across the entire width.
The motor drives all lower rolls synchronously via a hard-tooth-surface reducer and a distribution gearbox, while the upper rolls rotate passively. Additionally, a manual friction clutch-type auxiliary push device is installed at the inlet end, which can work in conjunction with the upper roll’s power to feed the material, preventing thick plates from slipping. Gears are made of 18CrNiMo7-6 steel, which undergoes carburizing and quenching followed by high-intensity shot peening. With a precision grade of IT6, the system ensures smooth transmission and high load-bearing
