Spiral rolling machines: how do they work?
Today, making spirals is no longer something that only artisans with years of experience and attention to detail can accomplish. As proven by metal fabricators in many different industries, like power plants, petrochemical manufacturing plants, food manufacturers, and manufacturers of industrial heating and cooling products, the right tool can produce spirals consistently and accurately.
This is especially interesting because, in many cases, the fabricator must meet precise specifications so that the final product is not only visually acceptable but also conforms to the original design intent. Indeed, since spirals are used in complex mechanisms, their final manufacturing must meet specified tolerances, or the final product will not perform as expected.
Multiple passes are not acceptable during spiral rolling; therefore, clients require power and precision in their chosen equipment, a must to accomplish the needed capacity and tolerances in one single pass.
Furthermore, spiral rolling is compounded by the fact that customers will need to bend a variety of profiles, each with its unique mechanical properties and characteristics. Even the same sort of profile can have a wide range of parameters, affecting the spiral’s rolling diameter and pitch as it is produced.
Spiral manufacturing made easy
Since spiral rolling is a manufacturing activity used in several industries, a wide range of customized solutions has been developed by specialized fabricators, all based on the requirements of each manufacturing department or the individual needs of the customer. However, whatever the needs that may arise from a particular industry or customer, there are some common requirements shared by all manufacturers involved in spiral rolling. Such requirements require specific technical know-how specific to profile benders.
- Power and precision: it’s crucial to ensure that operators can roll the section to the desired diameter in one pass (power) while maintaining the tightest tolerances (accuracy). In a single heat exchanger, two sizes of spirals are frequently encountered, one smaller encircled by a larger one or two spirals of the same diameter and pitch inserted one inside the other. As a result, adherence to tolerances becomes a need.
- Versatility: spirals can be made using a variety of profiles, each with its unique mechanical properties and characteristics. Even the same profile might have a wide range of dimensions, not only in terms of the profile itself but also in terms of the rolling diameter and spiral pitch. As a result, operators require a piece of versatile equipment that allows them to do a wide range of tasks while maintaining the highest level of precision possible.
- Accuracy: each material reacts to stresses differently, necessitating greater sensitivity in the bending machine movements, which must react variably depending on the material being processed and its spring-back rate. In this regard, sophisticated hydraulics is extremely beneficial to the operator, as it allows for proper fine-tuning and the creation of a homogeneous spiral.
Faccin Group’s extensive range of solutions
Faccin Group produces a wide selection of profile bending machines that are technologically innovative, precise, and dependable, ensuring high quality and efficiency. Faccin and ROUNDO, two of the Faccin Group’s brands, design, manufacture, and supply tailored fittings that make the spiral manufacturing process easier. The Faccin Group’s product portfolio includes high-performance models like the Faccin RCMI and Taurus series, as well as the Roundo R series and all of its readily available special solutions.
The main features of the group’s spiral rolling solutions include:
- overhead supports for diameter setting and pitch adjustment;
- horizontal support table;
- spiral lifting and insertion systems;
- special tools for multiple spiral rolling;
- lifting and rotating the basement;
- hydraulic machine tiling system.
All these features enable operators to roll the section to the desired diameter (power) and to achieve the tightest tolerances (accuracy) in only one pass.