Cylinders - The Forming Process
Custom cylinders are made through a process that begins by putting a flat sheet of material into the laser and programming it to cut rectangles out of various materials to specific sizes. If the cylinder has any customizations or features including custom holes, windows or other shapes, these are cut out in the laser, as well. The laser is able to cut through a variety of materials including steel, stainless steel, aluminum, copper, and other metals.
After the blanks are precisely cut, they are put through the rollers, where they are rolled into their required diameter. Prior to welding the seam, welds are tabbed, preventing ‘blow through’ on the cylinder’s ends, while ensuring a very strong and durable weld, fit for a lifetime of use. They are then sealed with a seam weld from the TIG automated welding system. After the weld is completed, it is planished, a process that ensures the weld is nearly flush with the cylinder, increasing its strength and durability yet again. Finally, the tabs are cut off, leaving smooth ends to the cylinder.
Once the forming process is complete, adding customizable features is an option, whether that be ribbed or custom formed ends, fittings, side holes, or flanges. Common configurations include no flanges, a single or double flange, custom cutout windows or doors, and custom steps and ribs.
What occurs during the forming process?
The rollers push the blank through at a specific angle, depending on the material type, thickness, size of the blank, and required final diameter of the cylinder.
Three-roll bending machines typically prebend the leading cylinder end, run the blank through to bend the trailing end, and then reverses the rollers direction to roll the rest of the cylinder body. This process is efficient, but cannot roll the entire cylinder as quickly as a rolling machine equipped with four rollers.
Four-Roll bending machines are able to process the cylinder faster, as they have the ability to preroll the leading edge, and run the rest of the cylinder body through, finishing with rolling the trailing end, all without changing direction. The fourth roller to provides a constant pinch on the material, keeping the sheet in place and preventing it from slipping.
Typical rolled and welded applications and products
Spools
Spools are used for connecting valves, tubes, or pipes to each other, using flanges equipped with bolt holes. Spools are extremely durable because of the extra support created by the flange. Spools can provide secure and leak-proof joints which allows for modification or eat access, that otherwise would not be possible.
Spray Dryers
Spray dryers are used to turn liquids into powders or granules in a single step. This is a common process in the food, pharmaceutical, and chemical industries because of its high efficiency, consistency, and adaptability.
HVAC
Typical HVAC equipment consists of cylinders with or without flanges. Fan blade and motor housings are a very popular use for these products. They allow for easy disassembly and reassembly, making it convenient for maintenance, repairs, or modifications.
Gravimetric Feeders
Also known as loss-in-weight feeders, gravimetric feeders are self-calibrating feeder systems that doses based on weight and speed. They offer precise flow control by automatically adjusting the material being dispensed, allowing the system to maintain a consistent feed rate. Volumetric feeders are similar, but dispense based on volume, rather than weight.