Manual machine for profiled sheets. Do-it-yourself machine for making corrugated sheets
Making a sheet bending machine with your own hands is not so difficult, but craftsmen, both amateur home-made workers and individual entrepreneurs who live by their labor, still use it little. Meanwhile, the price of only ready-made additional roofing elements - valleys, ridges, eaves strips - and drainpipes with gutters is several times higher than the cost of the material. The same applies to paintings (roofing sheets, completely ready for laying) with double-seam edging. And that's just roofing work.
Meanwhile, many craftsmen still prefer to either buy ready-made parts, losing money, or make do with a punch the old fashioned way, losing money. potential clients – modern products Shouldn't have a dingy look. What's wrong here: economics, technology, prejudices? Or maybe just ignorance? Maybe you just need a clear drawing of a sheet bending machine that you could build yourself in a shed, and use it for a long time and successfully? Let's try to figure it out.
Among the main indicators (efficiency, productivity, simplicity of design), it is also necessary to determine durability, subject to stable performance results. At the height of the season, when the day feeds the year, there is no time to bother with repairs or adjustments, and with occasional use once a month, not every month you can do without special equipment, see below.
The minimum requirements are for a jack-of-all-trades who does roofing and tin work on a case-by-case basis when there are orders; Buying an industrial machine like this is expensive and won’t pay off. But then a homemade sheet bender must withstand at least 1200-1500 working cycles per season without deteriorating the quality of bending. Is there some more important point– corrugated sheet. More precisely, its independent production. It is worth special mention.
Qui prodest?Translated from Latin - who benefits? Producing corrugated sheets yourself, at least for yourself, is a very popular material. Let's try to figure it out.
A manual pass-through type sheet bender (see below) costs about $2000. It seems that in a day or two a ton of 0.55 galvanization worth $1000 can be converted into 250 square meters. m of corrugated sheets, which would cost $1,400 to purchase. It would seem a direct benefit; especially if you don’t wait for a sale (the market is full of offers), but put it into action yourself. Yes, but not so.
Corrugated sheeting is not rolled in one pass - the corners sometimes end up being over-tightened. Intercrystalline bonds in the metal are broken; The rough area of the bend cannot always be identified by sight or touch, but soon a crack will spread from it. Who will give an order now without a guarantee? Please correct it. For our own, of course.
You can reduce the pressure, but then the wave will be non-standard. The customer may not know the standards, but he will immediately see that the material is not the same. Put it, be as polite as everyone else, or - goodbye, I’ll turn to someone else. And I’ll tell my friends and acquaintances. Should I roll each sheet in several passes, changing the clamp or rollers? What kind of productivity and profitability are there?
A line (actually a rolling mill) for corrugated sheeting is a complex unit, see fig. Pay attention to the number and configuration of rolls. The purpose of such a system is to disperse residual stresses across the sheet so that they do not go beyond permissible limits. Therefore, the wave is formed gradually.
Such equipment costs at least $20,000 and is made in China. Stable quality of finished products is guaranteed only for specific grades of steel from a specific manufacturer. Power consumption – from 12 kW. Those. a specialized production area is needed with an appropriate limit on electricity consumption and, although one operator is sufficient for maintenance. Is there an unsatisfied demand for corrugated sheeting in your operating area (simply, in the surrounding areas available to you) that allows you to pay for it all in an acceptable time frame? And are you ready to start a very serious business with fierce competition?
Note to mastersOf course, it’s not easy to “recapture” $2000 for an individual master. Therefore, let’s try to figure out how to make a sheet bending machine yourself. Not for corrugated sheeting, but for a variety of roofing and tin work, on which you can also make a good living and raise some money to start something more serious. Non-standard little things fundamentally cannot be unified, but are always needed. And a homemade sheet bender can be a very good help here.
About purchased handbrakeTo put an end to the “company” (the article is not an advertisement) and move on to homemade products, let’s briefly look at what you can buy if you still need it. The market is clearly dominated by TAPCO and VanMark. And the domestic SKS-2, produced in Orsk, is almost unknown. In terms of price, they are all about the same; The width of our working area is 2.5 m versus 3 m for foreigners, but this is not a defect. 3 m is designed for the inch system of measures (10 feet = 3.05 m), and in metric 2.5 m is just more convenient.
But the Uralian is a passing type; you can, for example, pull gutters up to 90x90 mm. The traverse is raised/lowered using eccentrics; there is no need to turn the flywheels. Supplied with a cutting knife. User reviews are not only favorable, but enthusiastic. The general tone is “an irreplaceable hard worker.”
History repeats itself. Nikita Khrushchev spoke about similar situations live on Central Television after his trip to America (when he was there hitting the UN podium with his shoe and threatening to make everyone’s motherfucker). They say that in the States they know how to sell any obscene rubbish, but here we cannot properly serve the necessary good things.
Designs of press brakes Drive
Bending and pressing equipment with a mechanical drive (a flywheel with a clutch and a crank or a falling load with a system of blocks, cables and levers) has high efficiency, but is still becoming a thing of the past. The mechanics give a sharp impulse (blow) at the beginning of the working stroke, and towards the end it weakens. For bending/pressing, just the opposite is needed.
The efficiency of an electric drive decreases rapidly as the size of the workpiece decreases. To form corrugated sheets on the mill described above, 12 kW is enough. To make a flange on a roof picture, you can’t get by with less than 1.5-2 kW. The fact is that external characteristic AC electric motors (except for three-phase ones with a wound rotor - complex, expensive, requiring regular maintenance) are quite tough. Due to the resistance of the bending metal, the engine does not increase the torque on the shaft, but on the contrary, the rotor slip increases and the torque decreases. And energy consumption increases.
The hydraulic drive, in theory, is ideal - the hydraulic cylinder itself automatically adjusts its force to the resistance of the part. But precision hydraulic systems are complex and expensive. Even an experienced designer would not undertake to distribute the force of, say, a car jack evenly along the entire length of a meter-long bend, nor would he be able to synchronize the work of two or more using improvised means.
The handbrake remains, and this is not so bad. If you design a sheet bender in such a way that, as in swing rowing or powerlifting, the strongest and most enduring muscles work (biceps, latissimus dorsi, thighs, calves), and the reaction (recoil) of the machine presses the feet to the floor, then the work, due to its cyclical nature, will not will be exhausting. But a skill will be developed that will give accuracy and productivity.
For example: The average person running up a flight of stairs can develop about 1 hp in 1-2 seconds. But already on the third flight, the muscles will switch from oxygen to glycogen, lactic acid will begin to be released, and fatigue will hit the body. You need to take a break to move on.
Note about sports: The rowers are lean, because the “kendyukh” makes it difficult to give a full push with the body. But for weightlifters, the “callus,” on the contrary, helps them maintain balance when jerking. But the muscle function of both is largely similar.
Schemes and purposeListogib is a rather general concept. The design of a sheet bender depends on its purpose. According to the nature of the work, you need to choose a homemade scheme, see fig.
At pos. A - a method familiar to everyone who has done at least a little plumbing. This way you can simply bend sheets up to 0.5 m wide by hand. If the bend length is no more than 200-250 mm, then the base can not be attached to the workbench, but together with the pressure beam and the part can be clamped in a vice. The bend turns out well if you press the traverse more low, as shown in the force diagram, and move it slightly forward, as if smoothing the bend. Most designs of homemade sheet bending machines are based on this principle; we'll get there yet.
Due to the elasticity of the metal, it is not possible to bend the sheet exactly 90 degrees, so spacers made from a strip of metal are used, as shown in the inset. Why are there channels on the cut and not corners? Next we will consider this issue; The seemingly simple design has significant nuances.
Pos. B shows how a press brake works. Press like a press: bed-die-punch-hydraulics-impact-ready. These are used only in industrial production with a developed labor protection system: complex, expensive, require qualified care and are extremely dangerous. A sheet that slips due to improper filling or equipment malfunction can cut off a person’s hand or head.
At pos. B – broaching (pass-through) sheet bending machine. By changing the relative position of the rolls, you can set the bending radius of the sheet. The walk-through sheet bender can be either manual or electrically driven. Those that go on general sale are usually multifunctional:
These are the kind of sheet metal benders that sell for $2000 or so. Many are equipped, or can be purchased later, with shaped rollers for corrugated sheeting, but, as has already been discussed, you cannot “drive a shaft” for sale on them. You can roll a piece if you need it now, but there is no point in buying a whole sheet.
Note: There is another interesting type of sheet bending device, but due to its high usefulness and relatively low cost, a separate section will be devoted to it.
Let's take on the sheet bending machineLet's start making our own sheet bending machine by developing the simplest specifications. And we will calculate the latter, in addition to the longevity criteria described above, based on the expenditure of muscular energy that an average-sized adult man is able to produce day after day without deterioration in health. Of course, simplicity and low cost of design are also not in last place. Also, due to its weight and dimensions, the machine must allow transportation in a passenger car and use directly at the work site. It turns out:
- The width of the bendable sheet is up to 1 m.
- The thickness of the bendable sheet is up to 0.6 mm galvanized; up to 0.7 mm aluminum and up to 1 mm copper.
- The number of operating cycles without readjustment and/or repair is at least 1200.
- Bending angle – at least 120 degrees without manual adjustment; This is necessary for folds.
- The use of special steels or non-standard workpieces is extremely undesirable.
- Welding - as little as possible; parts/assemblies lead from it, and the welds are fragile and quickly tire from alternating loads.
- Metalworking on the side (turning, milling) is also as little as possible, it costs money.
Let's face it: drawings of finished structures that meet all these requirements are not found in publicly available sources. We will try to improve one, widely known, and, in principle, very successful.
Finishing up the cutThe design principle of this sheet bender is clearly visible in the cross-section (see the figure on the right and the list of items). Its main advantage is good ergonomics. With such a working stroke, the muscles work as they should and the feet are pressed to the floor, which will give a stable result even for an inexperienced operator. And the maximum bending angle is 135 degrees, which has a large margin for any conceivable and inconceivable elasticity of the sheet being bent.
The material of all parts is ordinary structural steel. But already here it is conditionally shown that it is better to replace the traverse from the corner with a channel of the same standard size. Why? Let's take a closer look, this is important for what follows.
The reaction (recoil) from the sheet being bent to the traverse (and the clamp, but more on that later) is uneven across the width. In the middle, where each elementary (tiny; this is a hint of differentiation and integration) section of metal is surrounded on all sides by the same metal, it is maximum. At the edges, where there is no side support, it is minimal.
The second point is that the sheet, although thin, is of finite thickness. Stresses in the workpiece will spread and be reflected on the edges. As a result, the diagrams of the load on the traverse and the clamp will take the shape of a bow with a string. On the free (distant) edges of the corner shelves, such a load will produce a tensile force, but metal does not work well in tension - it quickly gets tired of it. A DIYer who has built such a machine soon discovers that the corner in the middle is bent and the fold in the middle is swollen.
The side flanges of the channel are wedge-shaped, and it has fillets that are more developed than in the inner corner of the corner. This, firstly, smoothes out the diagram - the bow string is barely taut. Secondly, the seemingly extra side flange of the channel absorbs tensile stresses, which are converted into compression at its free edge. And the metal holds compression - wow!
The result of the calculation is impressive: if a traverse from a corner can withstand at most a couple of hundred bends, then a channel of the same width can withstand more than 1200! What is 200 bends? One or a little more roofing at best. At the height of the season, when customers are standing in line, the machine gets damaged and the work stops. And 1200 operations means the season will last. In winter, there will be time to straighten it, or replace the traverse, or, after calculating the proceeds, buy a “company” with a guarantee of service life.
Detailing
The next figure shows details with a list of positions. Here, not only do some shortcomings need to be eliminated, but some things can be further improved.
First of all, about milling the lower surface of the clamp onto a plane. It is needed for any design, and the permissible unevenness is no more than half the thickness of the sheet being bent (minimum! We will consider it equal to 0.2 mm). Otherwise, the sheet will creep (flow) under pressure - and again there will be a pot-bellied fold.
So for anyone who has ever done anything with metal, advice on smoothing the clamp with a file or grinder will only cause a grin. It needs to be sent for milling. Moreover, AFTER the welding of the entire assembly, when everything that could have happened has already happened. Otherwise, the work and payment for the router will be in vain.
Further, everything that was said above about the load on the traverse is also true for the clamp. And its most loaded part - the leading edge - is not supported by anything. It is impossible to reinforce or replace the entire assembly from a corner with a channel: the bend angle will be no more than 90 degrees.
As a result, after the same 100-200 operations, the machine will “open its mouth” (or “smile”, if you prefer white rather than black humor) and the same swollen bend. The clamp will not bend upward; in this respect it is well fortified. But the metal on the leading edge will simply flow from fatigue.
A cross-section of the clamp design, which is equal in durability to the traverse, is shown in the inset at the top right. The base is a steel strip 16x80 mm. The front edge is milled at 45 degrees, and a chamfer of at least 2.5-3 MAXIMUM thicknesses of the steel sheet being bent is removed using the same milling cutter, i.e. 1.5-2 mm. From the upward deflection, the clamp is reinforced with a six-point angle for welding. Milling, again, after all welding work.
The idea is this: if in the previous design the leading edge worked half in bending (which for metal is even worse than tension), then in the new one it works only in compression. At the same time, the general support on the edge will not allow it to leak soon.
Note: if somewhere nearby in a landfill an ancient ruined lathe– the problem of the traverse with the clamp is solved once and for all. From the frame you can cut pieces of the desired configuration, made of special steel and of excellent accuracy.
In terms of the number of working operations for manufacturing, both clamps are equivalent: cutting, drilling, welding, milling. The material consumption of the new clamp is higher than the old one; Three standard sizes of workpieces are required for both. But the durability ratio is the same as for the two types of traverses described above.
Table mountThe next point is clamps. The author of the design, of course, clearly understands the role of the stiffeners, but it seems that he lost sight of the fragility and rapid fatigue of the welds. And the working stroke of the traverse gives a variable tensile force on the clamps with lever arms of 10:1 or more. If the clamp breaks, the work is over, even if everything else remains perfectly straight. The machine will lift itself, not bend.
Why not give up clamps altogether? And then you won’t need cheeks, and welding is for both. How to do it?
- Extend the support beam laterally beyond the table.
- Select U-shaped eyes at its ends.
- Fasten to the table with bolts somewhere around M10 with shaped nuts - claws.
The second option is holes in the legs without threads. The bolts are turned over and tightened with wing nuts. A little more expensive, but more convenient to use.
Cross-beam fasteningHere the question arises: how to attach the traverse, since the cheeks are no longer there? And they are not needed. Firstly, the design is non-removable, and the traverse will have to be changed once a year. Secondly, remember, we need an accuracy of about 0.1 mm, otherwise the fold will swell. How soon will the pin break a simple “hole” in the cheek by a large amount? The question is rhetorical. And at the same time I apologize to my fellow engineers: I, of course, know that someone has a hole somewhere, and in metalworking there is a hole.
But how then to attach the traverse? Butterfly door hinges; lower right inset in Fig. They do not require insertion (they were designed specifically for metal doors), and two of these hinges hold the door armored against a burst of Kalash or F-1 grenades. It takes six healthy men to put one on.
As for accuracy, most butterfly loops easily pass the “choke” test. If you quickly separate the loop, you can hear a smacking sound from the air replacing the vacuum formed when the pin was pulled out. That is, the fit of the parts is very tight, but they rotate easily.
The butterflies are secured with countersunk screws. If you put it on a red lead, the traverse will stand indestructible. Opening angle – 160 degrees. Probably, the inventor of butterfly hinges once made a homemade sheet bender. It's a joke.
AssemblyFinally, in front of you is an assembled sheet bending machine:
Just one remark can be made here. Perhaps the author of the design had flywheel nuts lying around somewhere in his stash, that’s why he installed them. In fact, the clamp will only have to be raised by 2-3 mm to place the next sheet. Well, by 30 mm, if you need to remove a picture with a fold already molded on the other side. Do you remember the M10 thread pitch? That is, you don’t need to turn the flywheels for a long time, like a gun when aiming. Wing nuts or even ordinary ones with welded collars are enough.
Note: after welding the knobs, it is necessary to drive the threads “completely” - holding the nut in a vice, and using the first and then the second tap, or a single-pass machine tap. The welding makes the thread look so bad that oh...
Video: example of a finished homemade sheet bender Zig machine
A Zig machine is, of course, not a robot in the form of a screaming Hitler with an outstretched hand. A creasing machine (see figure) or a zigging machine is a device for creasing, or zigging. And zigovka is the pulling out of flanges or special potholes - zigs - on sheet metal blanks. Have you seen the rigid edges on buckets and basins? These are zigs. The actual machines are also often called zigovkas for short.
Sealing machines, as follows from the definition, also belong to the category of sheet-bending equipment, only special ones. They can be electric or manual. The latter are desktop stationary (in the figure) or portable (mobile), with a clamp. You can carry these with you in your tool bag.
Zigmashina – indispensable assistant in tin and roofing works. You can zig not only round shell blanks, but also sheets. Try using the best manual sheet bender to make a bend for the already mentioned double fold. This kind of zigging is achieved in one pass; with some skill - right on the roof. What else can be achieved by zigging using standard pairs of rollers can be seen in the following figure. Letter designations are standard; they correspond to the type of operation performed. The bevel machine costs three to five times, or even ten times less than a factory manual sheet bender.
Let's summarize - which sheet bending machine is best for whom:
- For an amateur DIYer - bending with improvised means, as described, or homemade by hand, if you have a supply of scrap metal and a desire to tinker.
- For a general-purpose craftsman on the job, who from time to time receives orders for sheet metal or roofing, a homemade manual one like the one described plus, if there is some excess funds, a zig machine.
- A roofer or tinsmith - a professional who has a stable flow of orders - a branded manual one with a zig machine.
Your own machine for corrugated sheeting will help you not only make good material, for example, for suburban construction, but also to start profitable business, however, for this you need to know many nuances.
Such a device is quite easy to make at home with your own hands, if you understand the principle of its operation.
Considering that almost no construction site today can be completed without this material, it is widely used in everyday life, and if you make your own machine, you can make goods for sale.
Corrugated sheeting is an extremely popular coating today. It is used as a picket fence, material for walls and roofs, and cladding material.
Moreover, such sheets are characterized by relatively low cost and ease of installation.
However, it is worth understanding that corrugated sheeting has strict operational requirements that must be taken into account, especially if you make the material yourself on a homemade machine.
There are several types of corrugated sheets, in the manufacture of which various raw materials are used. For example, metal corrugated sheeting is very popular.
It is made from steel using cold method rental
For structures that will be used outdoors, for example, for a picket fence, you can make sheets coated with an additional protective coating - enamel, polymers, fiber.
Each type of raw material gives its own sheet thickness.
In the case of steel, we can get high-quality corrugated sheets, which can also be galvanized to increase strength and resistance to aggressive environments.
If you make sheets without any coating at all, the material will wear out faster. Therefore, we can say that not only the machine itself, but also the raw materials play a big role.
It is better to assemble a rolling machine for corrugated sheets in indoors, where there is a smooth concrete floor.
In this case, the temperature in the room also plays a big role: it must be heated, without sudden changes. We choose a temperature not lower than 4 degrees.
If you plan to constantly produce such material, then it is better to immediately prepare rooms for storing rolls, dry and warm.
Varieties of design and principle of operationTo make a device such as a machine with your own hands, you need to understand the operating principle of industrial models.
This approach will help compensate for many shortcomings by replacing parts with more affordable ones.
Any corrugated sheet is produced by cold rolling smooth sheet raw materials through special nozzles and shafts.
The end result is a corrugated sheet of a given shape, which can be used as a picket fence, a fence, or a wall.
Even at home, a machine for the production of corrugated sheets requires the purchase of high-quality raw materials. It is bought in rolls for ease of use.
Such rolls still need to be unrolled, and here everything depends on the thickness of the raw material.
If you initially aim to make subtle modifications to the corrugated sheeting, then there should be no problems - the sheets can be straightened by hand.
But if you need to produce fairly thick products, then you can’t do without a bending machine.
The machine for corrugated sheeting can be made in two types: manual and automated.
The first one has a simpler principle of operation, it is easy to do it yourself and the cost of the design will be more affordable.
However, here the feed and adjustment of the shaft is carried out independently using its own force.
It is almost impossible to construct an automatic device at home on your own. This is economically unprofitable and also extremely difficult.
It is noteworthy that difficulties arise in final stages rental
The fact is that the rolls have a decent length, so in order to get finished products that can immediately be used as a picket fence or fence, you also need to provide a method for cutting the sheets.
Special guillotines can help here. These scissors are made of very well sharpened steel and are also equipped with protective boxes and mechanisms for safe operation.
The best option would be to buy ready-made blades, since they follow the shape of the finished sheet.
Also, a manual machine for the production of corrugated sheets, like an automated one, can be designed using both simultaneous and sequential profiling technology.
In the first case, corrugation is produced simultaneously on both sides of the sheet. In the second, you need to run the sheet twice on both sides.
Of course, you can make corrugation on only one surface, but such sheets are not suitable for all purposes.
For example, for a home picket fence it is better to make two sides.
There are also machines that work with the hot rolling method.
But they are not used at home, since it is initially necessary to heat the steel and pour it into a mold that practically melts.
Ready-made sheets are suitable for a picket fence, but are unlikely to be used as cladding or for building walls.
Step-by-step instructions for assembling the machine at homeThe main difference between corrugated sheets and other metal sheets is the trapezoidal corrugation. It seems that it is impossible to make such material at home, but this is not so.
It is quite possible to make a machine for making corrugated sheets made by yourself using a sheet metal folding machine.
However, it is worth understanding that a home device will not always be able to help in the manufacture of products that are too thick.
Thus, the maximum thickness of galvanized steel that can be bent should not exceed 5 millimeters.
With such a device you can make not only sheets for picket fences, but also ridges, cornice strips, and so on.
First of all, the frame of the machine is assembled. It is small in size and does not require complete closure of the walls.
It will be enough to make good supports and secure them to the concrete floor with screws. Next, you need to prepare a table on which the sheet will be served.
Usually its length should be at least a couple of times greater than the expected length of the product, because there should still be room to receive the finished sheet. The table can be made from aluminum plywood.
The main thing here is to make a special bar that will allow you to secure the roll or raw material. It is pulled tightly to the table using bolts. The hand lever is secured in the same way.
It is needed to move sheets across the table and adjust the feed angle. For greater reliability, this design can be equipped with a control spring.
It is worth understanding that some parts need to be purchased ready-made. For example, rolling shafts. It is impossible to make them at home from available materials.
But you can order them - today this is not a problem, and the cost for a home workshop will be very low.
They are fixed to the frame and brought to the lever. The shafts should be secured using brackets made from pieces of metal corners.
With this procedure, it is necessary to carry out preliminary assembly. The first running-in of corrugated sheets is also carried out on it. All bolts are not tightened full force, and the sheets are served extremely carefully.
It is necessary to be guided by the fact that during operation the shelf of the corner and the shelf of the frame must be on the same plane.
If you manage to attach corrugated sheets the required form, then all parts can be secured. However, do not forget about safety precautions.
This is especially true if guillotines are installed.
The work should be done extremely carefully, without haste, even if you are an experienced craftsman, since there is increased chance injuries.
The mechanism of operation of the device is quite simple, which is why it is possible to make such a machine at home. First we place the sheet of metal on the table. It is fixed using paws or a bar.
You can also cover corrugated sheets with different compositions, but for this you need to equip a special table.
At all stages you must wear protective clothing, gloves, and use safety glasses.
However, it is worth noting that when starting to work in this area of business, you need to take into account the level of competition in each specific region. This is due to the fact that the production of corrugated sheets is available not only to large factories, if any, but also small companies those with the necessary funds, and even individual entrepreneurs.
As for the material itself, corrugated sheeting is actively used in construction or repair work, be it the construction of a roof, or cladding the walls of garages, utility rooms, warehouses, most often non-residential premises. The material is well suited for the rapid construction of fences and all kinds of fencing, canopies and other structures.
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This line consists of three main components and includes:
- Unwinding center
- Table including roller blade
- Rolling mill
Organization of mini production of corrugated sheets.
Corrugated sheeting, depending on the purpose of its use, comes in different types.
The main ones are: roofing and wall, load-bearing corrugated sheeting or in the form of a sandwich panel. The average width of corrugated sheet rolls varies between 980-1850 mm, the length may vary depending on the purpose of use.
If there is one in your area large factories Those involved in the production of this building material, be prepared for the fact that you will have to spend a certain and often considerable amount of money to attract your own customers in a highly competitive environment.
In addition, in the presence of serious competition, at first you should not hope for a full profit, since often beginning entrepreneurs have to lower the price for own products to conquer a certain niche in the building materials market.
Things will be much easier if there is not a single plant producing corrugated sheets at a great distance from your production.
Another positive point is the developed metallurgical production, which will allow you to purchase the necessary materials at affordable price, which does not include a surcharge for long-distance transportation.
When drawing up a business plan, also take into account the quality and types of products produced by competing companies, promotions and special offers they organize.
In addition, it is worth paying attention to the characteristics of the region in which you are going to sell corrugated sheets. How much demand it will have can be predicted by taking into account, for example, the number of private houses in cities and beyond, buildings under construction, etc.
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Business practice.
Statistics show that one of the most popular sizes of corrugated sheets are 1.5 m, 1.8 or 2 meters. Popular colors remain galvanized, wine red, chocolate, and moss green. As for thickness, most often it is about 0.5 mm.
As some private entrepreneurs note, in order for the business of manufacturing and selling corrugated sheets to generate significant income, it is necessary to sell at least 100 per day square meters, which, given the presence of regular customers, is not so much.
It should be taken into account that the sale of building materials is largely a seasonal activity. Most often, orders for the purchase of corrugated sheets are received from April to November, since in cold times construction and renovation work are suspended.
It will be a good help if you can find a corrugated sheet production line at an affordable price and fairly cheap materials. This will allow you to save money and spend it, for example, on wages workers or electricity payments.
Experience in marketing corrugated sheet products.
A few more tips. IN winter time, as already said, construction material for sale, to put it mildly, it doesn’t matter. To improve this matter a little, you can offer customers more profitable terms. For example, good discounts for goods and various promotions and offers to purchase corrugated sheets in installments or, for example, take out on credit.
At the same time, it is advisable to limit the validity of discounts to a time frame, in particular, before the arrival of warming and the start of the main sales season. As some entrepreneurs note, the method is quite effective, and you can get a good profit even during a period of reduced product sales.
Also, regardless of the time of year, do not forget about advertising your products. High-quality and well-constructed advertising will allow you to significantly increase the number of your regular customers.
Once the business starts making money good profit You can also think about investing money in additional equipment, which, in turn, will help establish production and increase the number of products produced.
Business development prospects.
A promising direction to develop the business for the production of corrugated sheets there will be production garages pencil cases, warehouses and of course fences. Additionally, for this area it will be necessary to purchase welding equipment and hire installers.
Production of corrugated sheets using manual equipment.
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Corrugated sheets have been actively used in construction and in many other areas for several decades. This reliable material, the production of which requires a special machine for the production of corrugated sheets, is used as the main element of enclosing structures, it covers the roofs of building structures, cladding walls, and also solves a whole list of other problems associated with both capital and private construction.
The production of profiled sheets can be carried out using both mechanized and manual equipment, which, if desired, can be made with your own hands. Knowing all the nuances of such production, you can organize a profitable business for the production of profiled sheets that are in demand on the market or with minimal costs produce such material for their own needs.
Properties of corrugated sheetsCorrugated sheeting, which is on modern market presented in several main varieties and can be made from various materials. However, the main raw material for the production of corrugated sheets is cold-rolled sheet steel, on the surface of which a thin layer of zinc is applied. To give a steel sheet the required configuration, a rolling method is used, which can be done in a hot or cold state. The production of corrugated sheets, in which the steel sheet is preliminarily subjected to significant heating, is carried out only by large metallurgical plants. At home or on a small scale manufacturing enterprise Corrugated sheets are produced by cold rolling.
Depending on the conditions of further use and the loads that the corrugated sheet will experience, steel of various thicknesses can be used for its manufacture. Instead of a zinc coating, a layer of paint or other material can be applied to the surface of the corrugated sheet, which can provide reliable protection of the metal sheet from negative influences external environment. Considering the fact that structures made from corrugated sheets are used primarily outdoors, the presence of a coating that protects them from intense wear due to corrosion makes it possible to provide such material with the required durability.
The conditions in which it is operated also affect the quality of the finished product. Thus, it is advisable to install both a manual machine used for the production of corrugated sheeting and an automated line for the production of such material in a dry and heated room in which sudden changes are not observed temperature regime. The conditions in which the raw materials for the production of profiled sheets - sheet steel rolls - are stored also play a role. The room in which such storage is carried out must also be dry and heated.
Types of equipment for the production of corrugated sheetsAny equipment for the production of corrugated sheets operates according to a standard scheme. To give it the required configuration, a flat steel sheet is driven through a system of rollers equipped with a machine used for the production of corrugated sheets. As a result of this technological operation, the flat steel sheet is deformed, acquiring the required geometric shape.
As mentioned above, the main raw material from which profiled sheets are made is sheet steel supplied from manufacturing plants in rolls. If the steel sheet rolled into such a roll has a small thickness, then unfolding it will not be a big problem: this can even be done manually. The situation is completely different if it is necessary to use sheet steel of considerable thickness for the profiled sheet. In this case, the machine used for the production of profiled sheets needs to be equipped with an additional device that will be responsible for bending sheet metal of considerable thickness.
Depending on the required performance, it can be equipped with a manual or mechanized drive. Of course, the manual machine for the production of corrugated sheets has a simpler design. Meanwhile, when deciding to use such equipment, you should keep in mind that working on a manual machine for the production of profiled sheets requires significant physical effort, so using such a device for the production of profiled sheets of significant thickness is problematic.
Meanwhile, manufacturing at home a machine equipped with a mechanized drive for the production of corrugated sheets is also associated with certain difficulties. The fact is that such equipment for corrugated sheeting must have a device that ensures cutting of profiled sheets into products of a certain length. To perform this technological operation, ordinary guillotine shears are not suitable, since this requires devices whose working bodies in their shape completely correspond to the configuration of the profiled steel sheet.
There are two technologies that can be used to produce corrugated sheets using specialized equipment. The first of them is called simultaneous profiling and involves immediately deforming both sides of the steel sheet used to make the profiled sheet. Machines for the production of corrugated sheets, operating on the principle of sequential profiling, separately deform each side of the steel sheet.
The greatest efficiency in the production of corrugated sheets is a specialized line for the production of corrugated sheets, the structure of which already contains all the necessary equipment. Production line structureTo provide High Quality production line for the production of corrugated sheets must be equipped with the following mechanisms and devices.
- In such a line, a mechanism is required that ensures the fixation of rolls of sheet steel, as well as their unwinding. Manufacturing of steel sheets in industrial scale involves the use of sheet metal rolls as raw materials, the weight of which can reach up to ten tons. It is almost impossible to manipulate such rolls without the use of special devices.
- A special device allows you to automatically regulate the degree of sagging of the workpiece between the unwinding mechanism and the receiving part of the machine. The corrugated sheet production line generally processes sheet metal with high speed, which simply does not allow you to adjust the sagging of the workpieces manually.
- To provide high performance and the required quality of manufactured products, professional equipment for the production of metal profiles they are equipped with several groups of work rolls. These groups of rolls, called stands, perform various functions as part of an automated line for the production of profiled sheets. Typically, these stands, consisting of varying numbers of work rolls, are used to load sheet metal into the processing area of the equipment, to carry out work operations and unload finished product from the machine.
- The production line has a drive mechanism that must be powerful enough to ensure high productivity. technological operations related to the production of profiled sheets by rolling.
- The cutting device that is equipped with professional equipment for the production of corrugated sheets must ensure high-quality cutting of the finished product, without the formation of burrs and bends on its edges. The presence of such defects significantly reduces the cost of the finished product.
- A machine for the production of corrugated sheets on an industrial scale must also be equipped with a compartment in which finished products are stored.
The production line for the production of corrugated sheets can be controlled by automated system or a simpler device that is not able to provide the required level of automation technological process. Meanwhile, even operators with a low level of qualifications can use a machine for corrugated sheeting, controlled by a simpler device.
How to make a machine for the production of profiled sheetsYou can make a machine for making sheets, the profile of which has a trapezoidal configuration, with your own hands. However, it should be borne in mind that such equipment will have limited technical capabilities and can be used for processing workpieces made of sheet metal of small thickness. Such a homemade machine can be used not only for the production of corrugated sheets, but also for the production of elements of roofing structures - ridges, eaves strips, etc.
The basis of such a machine, the manufacturing details of which can be seen in the video, is a frame installed on a concrete base and fixed to it using anchor bolts. A work table is mounted on such a frame, the length of which must exceed the length of the workpieces being processed. Desktop homemade machine, intended for the production of corrugated sheets, is used both for feeding the workpiece into the processing zone and for removing the finished product.
To securely fix the sheet metal roll on the machine frame, a special strip is used, which is fixed using a bolted connection. The mechanical impact on the processed sheet metal, from which the profiled sheet is formed, is carried out by means of a manual lever mounted on the equipment frame. With the help of such a lever, the design of which can be additionally equipped with a pressure spring, not only the supply of steel sheets to the processing zone is carried out, but also the angle of their supply is adjusted.
At self-production using a manual machine for corrugated sheeting, it should be borne in mind that it will not be possible to completely make such equipment with your own hands: some elements of its design will have to be ordered from metalworking specialists. Such elements, in particular, are rolling shafts, with the help of which the required profile of the workpiece is formed.
The production of reliable, lightweight and inexpensive corrugated sheets used in the construction industry today is carried out using special manual and automatic equipment.
1Corrugated sheeting is a universal modern material for the construction of low-rise buildings, wall cladding, roofing and other construction tasks, made from galvanized cold-rolled steel sheet. To give such rolled products the required shape, only two methods are used - hot and cold rolled. Both of these operations involve passing flat sheets of steel through special rollers.
Due to its characteristics, hot-rolled technology is available exclusively at large metallurgical plants.
But cold rolling of steel blanks for the purpose of obtaining from them can be performed in semi-professional and even amateur conditions. The main thing here is to choose the right equipment and learn how to use it correctly.
The cold rolling production technology consists of two procedures following each other. First, the workpiece is passed through rollers, and then the resulting corrugated sheet is cut into specified geometric sections. The shape of the rollers determines, as you yourself understand, the shape of the finished product.
The simplest manual machine for making profiled sheets is capable of “giving” us products of only one shape. In cases where an automated line for the production of corrugated sheets is used, it, as a rule, makes it possible to produce products of different assortments and shapes. This variety is achieved due to the fact that automated equipment makes it possible to change the settings of the rollers.
2Manufacturing is possible using three main types of installations:
- manual machine;
- mobile (mobile) type equipment with partial automation of work operations;
Any person can use a basic machine for the production of profiled sheets, provided that he is ready to make quite serious physical efforts to process steel sheets. Small-thick workpieces are usually rolled on manual machines. The quality of the resulting products is at a low level. In most cases, such a machine is used to produce profiled sheets for fencing and fences.
Manual equipment does not have to be purchased ready-made. There are a huge number of detailed drawings and diagrams on the Internet, following which you can independently make a simple bending machine. Let us note once again that there is no point in using it to produce truly high-quality profiled sheets. You simply won't succeed.
Partially automated equipment for the production of corrugated sheets allows us to produce much more professional products. Such units are equipped with an electric drive, they have a relatively light weight, which allows them to be transported and used directly on those sites where low-rise construction is carried out, the construction of storage facilities for agricultural products and warehouses, hangars, fences, and so on.
Semi automatic equipment In terms of the efficiency of its work and the quality of the profiled products produced, it is in no way inferior to fully automated lines. Moreover, it is mobile, which in some cases is of great importance.
A stationary automatic line is a whole complex of units. Depending on the specific configuration, it may include the following settings:
- directly rolling mill with rollers of several sizes;
- device for cutting profiled sheets;
- equipment for applying to finished products polymer coating.
Also, automated lines sometimes include a unit for loading operations. It is clear that such complexes have high cost. But their productivity is many times greater than the capabilities of manual and semi-automatic machines. It makes sense to invest in automatic equipment when you plan to work long and fruitfully in the field of manufacturing and selling profiled sheets with various geometric parameters.
3Experts say that in the minimum configuration automated equipment To produce high-quality profiled sheets, the following mechanisms and devices must be present:
The corrugated sheet production line is controlled by special system. It can be relatively simple or truly complex. A simple control system does not provide high level automation of the production process, but people with low qualifications can work with it. But a complex equipment control system increases the efficiency of the line. True, not everyone will be able to understand such a system; to use it, it is necessary to attract specialists with a large amount of technical knowledge.
4Harvesting in the production of profiled sheet products on automatic lines directly depends on the number of rollers for rolling. They are arranged in pairs above each other. There is a small gap between individual pairs of rollers. The steel sheet from which the corrugated sheet is made is slightly less than the specified gap in thickness (and sometimes these indicators are the same).
The initial workpiece is passed through rolling shafts, and similar procedure is carried out several times in a row, since it is usually impossible to achieve the required sheet shape in one pass. In one pass, the workpiece is bent between the rollers by a certain amount. At the same time, minimal pressure is exerted on it, which ensures perfect result final deformation.
It is important not to “overdo it” with the number of pairs of rolling shafts. If you pass the workpiece through too many of them, there is a possibility that the zinc coating of the steel sheet will be destroyed. In addition, the quality of profiled sheets is influenced by the quality of the steel alloys from which the rolling shafts are made and the level of cleanliness of their processing.
Experts advise purchasing equipment from foreign manufacturers (for example, Finnish) or domestic production lines, and never pay attention to units for the production of profiled sheets Chinese companies. And one last thing. If possible, it is better to buy new rather than used lines for the production of corrugated sheets, since the technical capabilities of the latter are usually at a very low level due to their wear and tear.
