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Custom Levelers

custom-plate-leveler

High speed manufacturing, such as stamping, burning, and shearing, depends on flat material in order to increase production and prevent damage to machinery.  Consequently, many manufacturers have very strict quality requirements that they pass on to their vendors.

Flattening material is all about the difference between “elastic” and “plastic” deformation.  Material in elastic deformation will spring back to its original shape, whereas plastic deformation means the material is permanently bent.  A leveling machine’s goal is therefore to plastically bend material and bring it back to a perfectly flat shape.

A custom levelers ability to straighten material is based on the machine’s roll configuration.  Specifically, the leveler’s work roll bends material over its radius, which therefore allows the machine to flatten material – as shown in the image below:

leveling_principle

 

 

 

 

 

 

The leveler’s roll diameter, roll centers and depth of roll penetration chiefly determine the capacity of the machine.  Depending on the material thickness, width and yield strength to be processed, there are several standard types of levelers that can help.  Element can supply any of the following types of levelers to meet your requirements:

stainless_plate_leveler

 

Call us today with your leveling needs and we can help find a solution that fits your needs, and your budget.  With over 40 years of experience in flattening of metal products, we’re happy to help.

Visit our Leveler page to learn more about machines we offer for flattening of metal products.  Let’s build something!

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Custom Rolling Mills

2-high-rolling-mill_preview

Finding custom rolling mills that meets your requirements can be a frustrating task.  Although many used rolling mills are available around the world, trying to find a mill with the correct separating force and torque capacity can be hard.  Usually you will find a used mill significantly oversized for your needs, or a used mill that is way too small for your application.  That’s where Element can help!

Element specializes in many different types and styles of rolling mills, such as:

We have built rolling mills to process material all the way down to 0.0005″:

foil-mill

 

And rolling mills with up to 3,000 ton separating force:

4-high-rolling-mill

 

Let us know your rolling requirements and we can supply a solution that meets your needs and budget.  Custom rolling mills by Element make finding the right machine easy, so call us today.

To learn more about Element’s rolling products, visit our Rolling Mill page.  Let’s build something!

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Rotary Marking

rotary-stamper-tooling

Branding and quality control are the key to setting your product apart from the rest.  Our rotary marking units physically mark formed profiles with desired product or date codes to achieve just that goal.  Furthermore, these units are low-profile and easy to install in your roll forming, or tube mill line. Here are some highlights from our standard design:

  • Robust mechanical frame and bearing design
  • High quality heat treated and ground tooling
  • Easy to maintain alpha-numeric characters
  • Easy to maintain logo-etched characters

Other marking systems, such as ink jet or laser etching, struggle to perform consistently because of coolant or oil in the line.  Our rotary stamping units can overcome all of these obstacles, therefore consistently delivering desired marks.  Depending on your requirements and budget, our stamping units can be supplied with a broad range of options.  Some of our rotary stamper options include:

  • Driven roll or idler roll styles, to help feed downstream processes if needed
  • Marking frequency control
  • Automatic or manually adjustable positioning of the tooling rolls
  • Automatic or manually adjustable passline height to position tooling at desired position
  • Spare setup blocks and full complement of character tooling for spares

Here is a simple reference date-code view of what rotary stamping can achieve:

rotary-stamper-marking

 

The ability to impart stamped marks on formed profiles allow for instant product recognition at any point in the future.  Regardless of the environment that the formed product is used in, our marks will stand the test of time.  The low profile design also allows for simple retrofit and installation in an existing line.  Call Element Machinery today and we can help you set your formed product apart from the rest.

For more information about edge solutions, please visit our edging products page.  Let’s build something!

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Steel Edger for Tube & Pipe Mills

3-stand-edging-unit

Edging steel strip for a tube or pipe mill can be critical for your quality and safety needs.  Edging is a process that uses an edger (or edge conditioner) to chamfer (or fillet) sharp edges of material before going into a forming line.  Upstream slitting and shearing operations form these sharp edges, and they can cause many different quality issues in your process.  By edging the material, you may encounter some of the following benefits:

  • Produce higher quality welds in tube or pipe due to removal of burred corners, and
  • Allow for safer handling of roll form line due, due to removal of sharp edges

Steel strip come in a variety of different edges that can be difficult to identify, so here are a few standard industrial shapes for reference:

edger-profiles

 

 

 

Our edger unit shown above is an awesome example of one of our latest designs for continuous edging.  The low profile design allows for incrementally forming a shape on incoming strip to make welding and forming more consistent.

Element Machinery’s edger units can be supplied in both driven or idle configurations, and can be easily installed in an existing line.  Call us today and we can help you focus on building a better and safer manufacturing process.

 

For more information about edge solutions, please visit our edging products page.  Let’s build something!

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Steel Leveling Principles

corrective-leveling

Here is an excellent article on steel leveling:

The Fabricator – Roller Leveling 101

Element Machinery has a number of tools to help operators level material fast.  Element can supply any of the following machines to level your material:

  • Powered and Unpowered Straighteners
  • Roller Levelers
  • Plate Levelers
  • Sheet Levelers, and
  • Tension Levelers

Even more, many of our levelers include automated roll setting to make both the operator’s job easier.  As a result of this feature, your product’s level quality will be more consistent as well.  Visit our leveler products page to learn more about the machines we build.  Here is a picture of one of the largest plate levelers in the world that we built a few years ago – and we have several in production around the globe:

heavy-plate-leveler-2

Call Element today for help in finding the right leveler for your project.  Let’s build something!

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Cut-to-Length Line Designs & Options

heavy-gauge-cut-to-length

A great article highlighting cut-to-length line designs and technologies:

The Fabricator – Cutting Edge of Cut-to-Length Lines

Cut-to-length lines can come in many different styles, shapes and sizes.  Element Machinery offers a wide range of cut to length lines that can meet your needs, and most importantly your budget.  Feel free to visit our cut-to-length line products page to learn more about systems we can supply.  Here are some various styles of CTL lines we’ve supplied in the past:

  • Standard cut-to-length with stacker section
  • Flying shear systems for surface-critical materials running up to 200 FPM
  • Rotary cut off systems for high production
  • Combination slitting and cut-to-length, and
  • Traverse slitter-shears for low-profile cutoffs

In addition, there are many standard options that can be integrated in the line to meet your needs, such as:

  • Weight/count monitoring of stacked sheet
  • Thickness measurement
  • Scrap cutting and handling
  • Many other options

The art of cutting metal to length has been around a long time, and so has our machinery.  Here is an archive piece of sales literature highlighting a combination slitting/cut to length line our original company supplied way back in 1975.  Innovation and combining processes to meet a budget is what we do!

slit-cut-to-length-1975

Call Element today so we can help design a line that meets your needs and your budget.  Let’s build something!