Universal Section Roll Benders

The Universal Section Roll Benders include one manual model and several powered models. The most popular sizes are listed but larger units are available to provide you with the capacity you need. The benders are 3 roller type benders that can be used to bend flat bar, solid square or round, angle iron (leg in or out), round tubing, square tubing, rectangular tubing, and schedule 40 pipe. All models have hardened rolls for standard profiles included with the machine. Models RM-10 through RH-55 all have 2 rolls powered with roller spacing non-adjustable. Model R-H80 and larger has three rolls powered with adjustable spacing between the bottom two rollers (double pinch roll bender), to adjust the tightness of the bend. The larger models all have hydraulic up and down control of the top roller, and the model R-H80 and larger have hydraulic adjustment of the bottom rolls as well.

  
  

• The maximimum capacities given are the failure points for the roller shafts and should not be exceded. On the chart at the bottom of the page, the minimum internal diameters given for the certain size of material is the internal diameter of a circle bent with that material and the corresponding bender. Take the diameter by 1/2 to get the minimum radius for that size and shape of material with that bender.



• The link below takes you to our page that allows you to calculate the diameter circle you would make from bending an arch. For example: You want to know if a certain model of bender below has the capacity for your project. Check the charts and find the bender that will do the diameter and wall thickness your material has, or the closest we have. The capacities show a certain minimum circle diameter you can bend (the tightest,smallest circle possible). But I'm only bending an arch? Click on the link below and use the formula to calculate the smallest circle that your piece would produce if more than one of the pieces were put together to make a circle.



Click Here For The Calculation Formula Page



• If you are using the exact material size or smaller that is shown in the specifications for the roll bender and your minimum calculated circle diameter is larger, then you will know the bender has plenty of capacity. If the minimum circle that your piece will produce is the same size or smaller then you will know the limitations. If you are using smaller material than the maximum capacity of the bender, and your circle is smaller than the minimum the bender can do, you will be able to judge if you can still do the circles, as the machine can go as tight as you want, but below the minimum recommended circle size (i.e. doing a tighter circle than recommended), will stress the roller shafts, and this is the purpose of checking to see if the material can be bent to that size - to make sure you don't break a roller shaft.



• The standard rolls that come with the machine are segmented rollers. They can be reconfigured for the best results when bending bar stock, solid round or square, and angle iron. Retangular or square tubing may be bent with the standard rolls, but it may give you more deflection on the inside leg of the tubing than you want. To minimize this deflection, you need to purchase the correct roll set for square tubing. Round tubing normally always requires that you purchase the precise set of rollers for the size of round tubing you want to roll bend; on round there is no choice, or you will crush the round tubing using the standard rolls.


• The models with manual top roller adjustment have a scale so you can measure the movement of the top roller as it is adjusted. The units with automatic roller adjustment have a digital readout to show the distance moved of the top roller



• Features/Specifications




See all the features, specifications, and prices below. If you need additional information to order, then purchase any of the video(s) listed below for download to your computer. Click on the video order form link directly below and type in the selections you want. Videos will be e-mailed to you.

• Video No. RBNDRP1-2: Video on features of roll benders all models, running time is 3 minutes 30 seconds - Price is $10.00


Click Here To Order Any Of The Product Videos Listed Above







• Two rolls are manually powered by hand crank on back of machine


• Guide rolls are standard


• Heavy construction - special cast frame


• Shafts are hardened with special steel material, rolls are hardened and ground, gears are also milled


• Standard segmented rolls work for most configurations (tubing dies always required for round tubing)



• Model R-M10 - Price is $2345.00 plus $250.00 shipping



  




• Model R-M40 has 2 driven rolls and manual height adjustment on the top roll


• 220 volt single phase 2 hp motor powers unit, bender is direct gear driven and has variable speed control


• Comes with standard segmented rolls which are good for most materials such as square and rectangular tubing, angle iron, solid round and bar, round tubing and pipe will require die sets


• Rolls and shafts are hardened


• Guide Rolls are standard


• You can position the bending head so you can roll in either the vertical or horizontal position


• Machine is operated with easy to use foot pedal control


• Model R-M40 Roll Bender is $4245.00 plus $245.00 shipping








• Has two driven rollers, variable speed control, direct gear drive, powered by 2 hp, 220 volt, 60 hz, single phase motor


• Has manual adjustable top roll


• Guide rolls are standard


• Unit can be laid on its back so you can bend with material positioned horizontally as well as vertically


• Model R-M55 Roll Bender is $5450.00 plus $375.00 shipping








• R-H45 has 3 driven rolls and hydraulic to roll height adjustment, with programmable digital readout for top roll


• Rolls and shafts are hardened for durability


• Guide rolls are standard


• Can be used in either horizontal or vertical position


• Foot pedal control and easy to use control panel


• Model R-H45 Roll Bender - Price is $13,850.00 plus $450.00 shipping








• Has 3 driven rolls, with hydraulic height adjustment on top roll


• Programmable digital readout for top roll, mounted on top of controller with foot pedal control for forward and reverse roller control


• Segmented Roll Dies are hardened and mounted on heavy duty steel roller shafts that are hardened and ground


• Bender can be used in both horizontal and vertical position


• Comes with guide rolls standard


• Model R-H55 Roll Bender - Price is $16,885.00 plus $500.00 shipping








• All three rolls are powered, unit is a double pinch roll type bender, bottom two rolls adjust up and down to achieve the tightest bends possible, has hydraulic adjustment on the bottom rolls, and rolls are adjusted independently


• Unit comes with standard segmented dies for standard profiles (bending round tubing will require the appropriately sized round tubing die)


• Rolls are hardened and ground


• Has steel frame construction, can be used in either the vertical or horizontal position


• Brake motor equipped


• Has mobile control panel to control all functions, with digital readout showing height adjustments made to rollers


• Unit comes stanard with 3 axis mechanical guide rollers as shown


• Model R-H80 Double Pinch Roll Bender - Price is $29,450.00 plus $750.00 shipping






• DIE SETS FOR ROUND AND SQUARE TUBING ARE AVAILABLE, DIES AVAILABLE IN STEEL AND NYLON - CONTACT US FOR PRICE AND AVAILABILITY.



• Additional Bending Information


• Bending Flat And Square Bar On Edge
• The center of gravity on flat bar and square bar is in the middle of the profile, so there won't be any twisting or unusual deformation while rolling. During bending, there will be an increase in thickness and width during bending, and the respective increase and reduction may require the gap in the roll tooling to be adjusted while rolling.
• In mild steel, flat bars can normally be rolled the hard way to very small radii. The limiting factor will be the ratio of the thickness and the height. If the height of the flat bar is so great relative to the width that the bending force exceeds the material's resistance to buckling, the section will collapse, and bending will be impossible. A practical rule of thumb, is to keep the ratio of height to thickness H/T below 12. Square and flat bar should bend nicely with the standard segmented rollers, using the suggested roller configurations shown in the owners manual.


• Bending Angle Iron Leg Out


• The factory recommendation for bending angle iron is to use custom rolls made specifically for the size of angle iron being rolled, and in additon, it is recommended that the optional adjustable angle guide rollers be used instead of the standard roller tubes on the machine when bending angle iron (especially when bending angle iron leg out).


• The center of gravity of all angles is outside the material itself. Since all material bends around or in line with its center of gravity, all angles will twist when being rolled. In order to have a usable finished product, that twist must be prevented or eliminated during the bending process either by the rolls themselves or by the addition of the optional angle guide rolls. The adjustable angle guide rollers will eliminate or drastically reduce the twisting and deformation you will get when bending angle iron.


• To reduce cost you can use the standard segmented dies with the guide rolls to reduce twisting and deformation. You may also be able to just use the custom die set for each size of material, without the angle guide rolls, but the best results will be achieved by using special rolls and the guide rolls.


• Even with the use of the angle guide rolls, some deformation of the angle being rolled should be anticipated. Roll bending is an inexact science due to machine set up, operator use, and material variances in size and quality variances within the material piece (hard spots for example).


• Bending Angle Iron - Leg-In


• When rolling angle iron leg-in, the angle will twist even more than when rolling with the leg out. Since the inner leg of the angle being rolled has to undergo compression during bending, and since compression is much more difficult to accomplish thant stretching the outer leg when rolling leg-out, the minimum radius to which angle iron can be bent leg-in is somewhat larger than when bending leg-out, or about 6 times the leg height. The solution again is to use special roll tooling to reduce the deformation and in order to roll a tighter radius than would be possible with the standard rolls.


• Bending Round Tubing And Pipe


• Depending upon the wall thickness of round tubing and pipe, some deformity is unavoidable unless you first fill and cap both ends of the pipewith sand, pressurized nitrogen, resin, or other material. This level of prevention, is probably not needed by most users. The minimum bending radius for pipe or tubing depends on both the wall thickness of the section and on the amount of deformation that can be accepted.


• Bending Square And Rectangular Tubing


• Since the center of gravity of these sections is in the center of their cross-sections, there will be little or no twising during the rolling operation. Since the walls are not supported internally, the four sides may deform. To reduce this deformation to an acceptable level, the roll tooling should be designed specifically for the particular size of tubing being rolled, with special emphasis on insuring that the tooling conforms exactly to the radii of the corners of the tubing.


• Bending Beams And Channels The Easy Way


• Beams and channels when rolled the easy way (flanges in or out), act like other symetric material profiles and bend with virtually no twisting and very little deformation. The deformation, if any, would be found on the flanges of the sections, because of the extremely high surface pressure exerted on them by the top roll or the lower rolls, and some curving of the web of a channel. Special tooling can be made for beams and channels that diverts the bending force from the ends of the flanges to the web of the section. This tooling can be expensive, and us normally only necessary for high precision work.


• Bending Beams And Channels The Hard Way


• Rolling beams and channels the hard way (on the flanges) is the most difficult work to perform on an angle roll. Bending these sections requires substantial bending force. Since the flanges of the beam or channel offer the most resistance to bending, they tend to remain relatively unbent, even when the beam is forced into a radius by the rolls. The compressive stresses when combined with the bending force exerted along this line of the material, require you to control the bending forces; this is critical in order to achieve and acceptable finished product. Running the beam and channel through the machine more times and not increasing the compression force of the top roller in such large increments may be required for bending these forms without any internal support on the flanges of the channel or beam.



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