滾軋(ya)(ya)成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)機(ji)(ji)加(jia)(jia)工(gong)(gong)(gong)流(liu)程是一(yi)種、連續的(de)金(jin)屬(shu)塑性加(jia)(jia)工(gong)(gong)(gong)工(gong)(gong)(gong)藝，主要用(yong)于生(sheng)產(chan)(chan)各類定制截(jie)面(mian)的(de)型(xing)(xing)材(cai)（如C型(xing)(xing)鋼(gang)(gang)、槽鋼(gang)(gang)、軌道等），其流(liu)程可分(fen)(fen)(fen)為五個階段(duan)：**1.材(cai)料(liao)準備與(yu)(yu)上料(liao)**選(xuan)用(yong)冷(leng)軋(ya)(ya)/熱(re)軋(ya)(ya)鋼(gang)(gang)卷(juan)(juan)(juan)或(huo)鋁(lv)卷(juan)(juan)(juan)作為原料(liao)，經行車吊裝(zhuang)至(zhi)開(kai)卷(juan)(juan)(juan)機(ji)(ji)展開(kai)。材(cai)料(liao)通(tong)過矯(jiao)平機(ji)(ji)消除卷(juan)(juan)(juan)曲(qu)應力(li)后(hou)(hou)，由送(song)(song)料(liao)輥(gun)勻速送(song)(song)入成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)主機(ji)(ji)，同(tong)時進(jin)行邊(bian)緣(yuan)對中校正，確保進(jin)料(liao)直線(xian)度誤差小于0.5mm。**2.多道次(ci)漸進(jin)成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)**工(gong)(gong)(gong)序(xu)由10-30組(zu)精密軋(ya)(ya)輥(gun)分(fen)(fen)(fen)步完成(cheng)(cheng)(cheng)(cheng)。每道軋(ya)(ya)輥(gun)組(zu)按預設程序(xu)漸進(jin)改變(bian)(bian)材(cai)料(liao)截(jie)面(mian)：首(shou)道次(ci)進(jin)行初(chu)步彎曲(qu)，后(hou)(hou)續輥(gun)組(zu)逐步加(jia)(jia)深變(bian)(bian)形深度，終在(zai)(zai)2-15道次(ci)（以C型(xing)(xing)鋼(gang)(gang)為例）完成(cheng)(cheng)(cheng)(cheng)目標(biao)幾何形狀(zhuang)。關鍵(jian)道次(ci)間(jian)設有激光(guang)測距(ju)儀(yi)實時監控(kong)(kong)成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)角度，輥(gun)軋(ya)(ya)成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)機(ji)(ji)工(gong)(gong)(gong)廠，配(pei)合(he)液壓伺服(fu)系(xi)統動(dong)(dong)(dong)態調整輥(gun)間(jian)距(ju)，確保±0.1mm的(de)成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)精度。**3.在(zai)(zai)線(xian)定長切(qie)割(ge)(ge)(ge)**成(cheng)(cheng)(cheng)(cheng)型(xing)(xing)后(hou)(hou)的(de)連續型(xing)(xing)材(cai)進(jin)入飛鋸(ju)切(qie)割(ge)(ge)(ge)單元(yuan)。伺服(fu)電機(ji)(ji)驅動(dong)(dong)(dong)鋸(ju)片與(yu)(yu)型(xing)(xing)材(cai)同(tong)步運動(dong)(dong)(dong)，在(zai)(zai)300mm/min進(jin)給速度下實現(xian)(xian)動(dong)(dong)(dong)態切(qie)割(ge)(ge)(ge)，斷面(mian)垂(chui)直度誤差≤0.3°。系(xi)統配(pei)備視覺識別，可自動(dong)(dong)(dong)避開(kai)沖(chong)(chong)壓標(biao)記位置。**4.后(hou)(hou)處理與(yu)(yu)質量(liang)管(guan)控(kong)(kong)**切(qie)割(ge)(ge)(ge)后(hou)(hou)的(de)型(xing)(xing)材(cai)經自動(dong)(dong)(dong)傳送(song)(song)帶進(jin)入后(hou)(hou)處理線(xian)，依次(ci)完成(cheng)(cheng)(cheng)(cheng)去毛刺(ci)（砂帶磨削粒(li)度120目）、預沖(chong)(chong)孔（沖(chong)(chong)壓頻率(lv)45次(ci)/分(fen)(fen)(fen)鐘）等工(gong)(gong)(gong)序(xu)。在(zai)(zai)線(xian)檢測站使用(yong)3D激光(guang)掃(sao)描儀(yi)全尺(chi)寸檢測，關鍵(jian)參(can)數如截(jie)面(mian)高度、彎曲(qu)半徑(jing)等實時對比CAD模型(xing)(xing)，超差0.15mm自動(dong)(dong)(dong)觸發報警停機(ji)(ji)。**5.成(cheng)(cheng)(cheng)(cheng)品處理與(yu)(yu)包裝(zhuang)**合(he)格品經靜(jing)電噴(pen)涂（膜厚60-80μm）或(huo)熱(re)浸(jin)鍍(du)鋅（鋅層重量(liang)275g/m2）后(hou)(hou)，由機(ji)(ji)械臂(bei)按5-10支/捆(kun)自動(dong)(dong)(dong)碼垛，纏繞PE保護(hu)膜（拉伸率(lv)200%）后(hou)(hou)入庫。全過程通(tong)過MES系(xi)統記錄工(gong)(gong)(gong)藝參(can)數，實現(xian)(xian)質量(liang)追溯。該流(liu)程具有每分(fen)(fen)(fen)鐘12-18米的(de)生(sheng)產(chan)(chan)效(xiao)率(lv)，材(cai)料(liao)利用(yong)率(lv)可達98.5%，特(te)別適合(he)建筑、汽(qi)車等行業的(de)批量(liang)型(xing)(xing)材(cai)制造。關鍵(jian)控(kong)(kong)制點在(zai)(zai)于軋(ya)(ya)輥(gun)的(de)漸開(kai)線(xian)型(xing)(xing)面(mian)設計和(he)道次(ci)間(jian)變(bian)(bian)形量(liang)的(de)分(fen)(fen)(fen)配(pei)，需結(jie)合(he)有限元(yuan)優化應力(li)分(fen)(fen)(fen)布，防止邊(bian)緣(yuan)褶皺或(huo)截(jie)面(mian)扭曲(qu)缺陷。

輥(gun)(gun)軋(ya)(ya)成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)機(ji)工(gong)藝(yi)(yi)解析輥(gun)(gun)軋(ya)(ya)成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)（RollForming）是一(yi)種通過多道次輥(gun)(gun)輪(lun)連續彎曲(qu)金(jin)屬帶材(cai)(cai)(cai)的(de)(de)(de)冷加(jia)工(gong)工(gong)藝(yi)(yi)，廣泛應(ying)用于建(jian)筑、汽車(che)、家電等行(xing)(xing)業的(de)(de)(de)長(chang)型(xing)(xing)(xing)(xing)(xing)材(cai)(cai)(cai)生產(chan)。其工(gong)藝(yi)(yi)在(zai)于通過精(jing)密設計的(de)(de)(de)輥(gun)(gun)輪(lun)組(zu)將金(jin)屬卷(juan)材(cai)(cai)(cai)逐步塑形為特(te)(te)定截面(mian)輪(lun)廓的(de)(de)(de)型(xing)(xing)(xing)(xing)(xing)材(cai)(cai)(cai)，具有率、高精(jing)度(du)(du)(du)和(he)低材(cai)(cai)(cai)料(liao)(liao)損(sun)耗的(de)(de)(de)特(te)(te)點。工(gong)藝(yi)(yi)流程：1.材(cai)(cai)(cai)料(liao)(liao)準備：選用鍍鋅鋼(gang)、鋁(lv)合金(jin)或不銹鋼(gang)卷(juan)材(cai)(cai)(cai)，上海輥(gun)(gun)軋(ya)(ya)成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)機(ji)，寬度(du)(du)(du)根(gen)據產(chan)品需(xu)(xu)求裁(cai)切(qie)。卷(juan)材(cai)(cai)(cai)經開(kai)卷(juan)機(ji)展開(kai)后(hou)(hou)進(jin)(jin)入矯(jiao)直輥(gun)(gun)組(zu)消除內應(ying)力。2.漸進(jin)(jin)成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)：由10-30組(zu)精(jing)密軋(ya)(ya)輥(gun)(gun)組(zu)成(cheng)(cheng)(cheng)的(de)(de)(de)連續輥(gun)(gun)系(xi)，每個輥(gun)(gun)組(zu)承擔特(te)(te)定變(bian)形工(gong)序(xu)。前(qian)段(duan)輥(gun)(gun)組(zu)完成(cheng)(cheng)(cheng)初(chu)步彎曲(qu)，中(zhong)段(duan)進(jin)(jin)行(xing)(xing)角(jiao)度(du)(du)(du)修正，末(mo)段(duan)實(shi)現終定型(xing)(xing)(xing)(xing)(xing)。輥(gun)(gun)隙精(jing)度(du)(du)(du)控(kong)制(zhi)在(zai)±0.02mm，成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)速度(du)(du)(du)可達30-120m/min。3.在(zai)線(xian)檢測：配備激光(guang)測距儀(yi)實(shi)時監測截面(mian)尺寸，反饋系(xi)統自動(dong)調整輥(gun)(gun)壓(ya)參數。4.定長(chang)切(qie)斷(duan)：采用液壓(ya)剪(jian)或飛(fei)鋸進(jin)(jin)行(xing)(xing)動(dong)態切(qie)割，精(jing)度(du)(du)(du)達±1mm，特(te)(te)殊產(chan)品可同(tong)步沖孔(kong)。5.后(hou)(hou)處理：根(gen)據需(xu)(xu)求進(jin)(jin)行(xing)(xing)噴漆、覆膜(mo)或時效處理。技術(shu)(shu)優勢：-材(cai)(cai)(cai)料(liao)(liao)利(li)用率超(chao)95%，較(jiao)傳統沖壓(ya)工(gong)藝(yi)(yi)節(jie)能(neng)40%-可生產(chan)復(fu)雜截面(mian)（C型(xing)(xing)(xing)(xing)(xing)、Z型(xing)(xing)(xing)(xing)(xing)、多腔結構）-冷加(jia)工(gong)保持(chi)材(cai)(cai)(cai)料(liao)(liao)力學(xue)性(xing)能(neng)，輥(gun)(gun)軋(ya)(ya)成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)機(ji)生產(chan)廠家，表面(mian)質(zhi)量優良(liang)-集成(cheng)(cheng)(cheng)CNC系(xi)統實(shi)現快速換(huan)模，換(huan)型(xing)(xing)(xing)(xing)(xing)時間縮短至2小(xiao)時典型(xing)(xing)(xing)(xing)(xing)應(ying)用：建(jian)筑領域(yu)（幕墻龍(long)骨、鋼(gang)襯），汽車(che)加(jia)強(qiang)梁，光(guang)伏支架，冰箱冷柜邊(bian)框等。現代輥(gun)(gun)軋(ya)(ya)線(xian)已實(shi)現全(quan)自動(dong)化生產(chan)，配合機(ji)器(qi)人(ren)碼垛系(xi)統，單線(xian)年(nian)產(chan)能(neng)可達5萬噸。該工(gong)藝(yi)(yi)特(te)(te)別適合大(da)批量標(biao)準化產(chan)品，但對(dui)異型(xing)(xing)(xing)(xing)(xing)件開(kai)發(fa)需(xu)(xu)要投入高精(jing)度(du)(du)(du)模具（成(cheng)(cheng)(cheng)本約5-30萬元）。隨著伺服直驅技術(shu)(shu)和(he)數字(zi)孿(luan)生技術(shu)(shu)的(de)(de)(de)應(ying)用，輥(gun)(gun)軋(ya)(ya)成(cheng)(cheng)(cheng)型(xing)(xing)(xing)(xing)(xing)正朝(chao)著柔性(xing)化、智(zhi)能(neng)化方向發(fa)展。

輥彎成型(xing)機(ji)(ji)(ji)定(ding)制(zhi)流(liu)程(cheng)及(ji)關(guan)鍵(jian)要(yao)(yao)素解(jie)析(xi)輥彎成型(xing)機(ji)(ji)(ji)作(zuo)為(wei)金屬板(ban)材(cai)(cai)加(jia)(jia)工(gong)的(de)(de)設(she)備，其定(ding)制(zhi)需(xu)(xu)(xu)遵循(xun)系(xi)統(tong)化流(liu)程(cheng)以滿足個性化生(sheng)產需(xu)(xu)(xu)求：一(yi)、需(xu)(xu)(xu)求分析(xi)階段客(ke)戶需(xu)(xu)(xu)明(ming)確加(jia)(jia)工(gong)材(cai)(cai)料參(can)數(shu)（材(cai)(cai)質、厚度(du)(du)、屈(qu)服(fu)強度(du)(du)）、目(mu)標(biao)產品(pin)規格（截面(mian)形狀、尺(chi)寸公差）、生(sheng)產節(jie)拍要(yao)(yao)求及(ji)自動(dong)(dong)化程(cheng)度(du)(du)。例如(ru)建(jian)筑(zhu)行(xing)業需(xu)(xu)(xu)加(jia)(jia)工(gong)0.5-3mm鍍鋅板(ban)，汽車(che)行(xing)業則涉(she)及(ji)高(gao)強度(du)(du)鋼(gang)加(jia)(jia)工(gong)，不同行(xing)業對設(she)備剛性、精(jing)(jing)度(du)(du)要(yao)(yao)求差異顯著。二、方案(an)(an)設(she)計(ji)環節(jie)1.輥系(xi)配(pei)(pei)置(zhi)(zhi)(zhi)：根據產品(pin)展開圖設(she)計(ji)輥輪(lun)組數(shu)（通(tong)(tong)常12-25組），每組輥輪(lun)需(xu)(xu)(xu)進(jin)(jin)行(xing)三維建(jian)模(mo)(mo)驗證成型(xing)軌跡2.動(dong)(dong)力系(xi)統(tong)：計(ji)算總功(gong)率需(xu)(xu)(xu)求（常規機(ji)(ji)(ji)型(xing)30-75kW），選擇伺服(fu)電機(ji)(ji)(ji)或(huo)變(bian)頻驅動(dong)(dong)方案(an)(an)3.機(ji)(ji)(ji)架(jia)結(jie)構：采用(yong)(yong)(yong)整體(ti)焊接框(kuang)架(jia)（常用(yong)(yong)(yong)Q235B鋼(gang)材(cai)(cai)），重型(xing)設(she)備需(xu)(xu)(xu)配(pei)(pei)置(zhi)(zhi)(zhi)地腳螺栓安裝(zhuang)位三、生(sheng)產制(zhi)造要(yao)(yao)點部件采用(yong)(yong)(yong)數(shu)控(kong)加(jia)(jia)工(gong)中心(xin)加(jia)(jia)工(gong)，輥輪(lun)表面(mian)進(jin)(jin)行(xing)HRC58-62高(gao)頻淬火處理。電氣(qi)系(xi)統(tong)配(pei)(pei)置(zhi)(zhi)(zhi)PLC（西門(men)子(zi)/三菱）控(kong)制(zhi)模(mo)(mo)塊(kuai)，配(pei)(pei)合HMI人機(ji)(ji)(ji)界面(mian)實(shi)現(xian)參(can)數(shu)存(cun)儲功(gong)能(neng)。機(ji)(ji)(ji)型(xing)可(ke)集(ji)成激光測距儀(yi)實(shi)時(shi)監測成型(xing)精(jing)(jing)度(du)(du)（±0.1mm）。四、測試(shi)(shi)驗收(shou)(shou)標(biao)準空載測試(shi)(shi)需(xu)(xu)(xu)滿足噪音≤75dB(A)，輥軋成型(xing)機(ji)(ji)(ji)生(sheng)產廠家，負載測試(shi)(shi)連(lian)續運行(xing)8小時(shi)溫升不超過45℃。驗收(shou)(shou)時(shi)應使用(yong)(yong)(yong)實(shi)際材(cai)(cai)料進(jin)(jin)行(xing)試(shi)(shi)生(sheng)產，驗證產品(pin)直線(xian)度(du)(du)（≤1.5mm/m）、回彈控(kong)制(zhi)等關(guan)鍵(jian)指(zhi)標(biao)。五(wu)、增值服(fu)務配(pei)(pei)置(zhi)(zhi)(zhi)可(ke)選配(pei)(pei)自動(dong)(dong)上(shang)料機(ji)(ji)(ji)（載重2-5T）、在線(xian)沖孔單元（定(ding)位精(jing)(jing)度(du)(du)±0.2mm）或(huo)視覺(jue)檢測系(xi)統(tong)。維護方面(mian)建(jian)議配(pei)(pei)置(zhi)(zhi)(zhi)遠(yuan)程(cheng)診斷(duan)模(mo)(mo)塊(kuai)，關(guan)鍵(jian)軸承(cheng)位設(she)置(zhi)(zhi)(zhi)智能(neng)潤滑裝(zhuang)置(zhi)(zhi)(zhi)。定(ding)制(zhi)周(zhou)期通(tong)(tong)常為(wei)45-90個工(gong)作(zuo)日，建(jian)議選擇具(ju)備10組以上(shang)成功(gong)案(an)(an)例的(de)(de)廠家合作(zuo)。設(she)備交付時(shi)應包(bao)含(han)3D成型(xing)動(dong)(dong)畫(hua)、工(gong)具(ju)包(bao)及(ji)易損件清單，確保后續維保便利性。通(tong)(tong)過的(de)(de)定(ding)制(zhi)化設(she)計(ji)，可(ke)使設(she)備投資(zi)回報周(zhou)期縮短至(zhi)18-24個月。