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Equipment Differences
Difference between a Flattener, Straightener,
and Leveler
Flattener
Design characteristics:
Work rolls supported by bearings on the ends of the rolls only
Normally fewer number or rolls (4 to 7)
Relatively large diameter rolls
Typically capable of 10% to 20% of material in yield
Operational characteristics:
Only capable of removing coil set and maybe reduce some cross bow
Typically used for heavier gage materials
When working the material hard a flattener can actually induce edge wave
Straightener
Design characteristics:
Work rolls are supported by backup bearings along the full face
Normally a larger number of rolls (10 to 20+)
Close roll spacing with smaller diameter rolls
Typically capable of 50% to 70% of material in yield
Normally designed for narrow strip (less than 36") but can be designed for wider strip
In general a much more precision machine than a flattener
Operational characteristics:
Removes coil set and cross bow and maybe some edge wave and center buckle
Typically used for lighter gage materials but can be designed for heavy gage
Rolls stay straight no matter how hard you work the material (within the machine
design limits)
Shape Correction Leveler
Design characteristics:
Work rolls are supported by backup bearings along the full face of the work rolls
Backup bearing rails either top or bottom can be adjusted up and down individually to
bow or bend the work rolls
Normally a larger number of rolls (10 to 20+)
Close roll spacing with smaller diameter rolls
Typically capable of 50% to 80% of material in yield
Normally designed for wider strip (greater than 36")
In general a much more precision Machine
Operational characteristics:
Removes coil set, cross bow, edge wave, center buckle, and combinations
Machines have been built for all gage materials but more common for .015" to .250"
Requires operator expertise to set up and operate properly
How bending the work rolls can correct strip shape
By bending the work rolls you can selectively work some zones of the strip (from edge
to edge) more than other zones causing elongation. The basic principle is to elongate
the short zones to match the length of the long zones.
Elongation occurs due to working the material and differential path length thru the
leveler.
Typical roll bending to eliminate center buckle. The short edges are worked harder
than the long center.
Typical roll bending to eliminate edge wave. The short center is worked harder than
the long edges.
Tension Leveler
Design characteristics:
Work rolls are supported by backup bearings along the full face of the work rolls top
and bottom to keep them straight. Normally intermediate rolls are used also
Spread center distance between rolls with fewer number of work rolls, typically five
Bridle sections before and after leveler section to pull very high strip tension through
leveler. All material is stretched beyond yield point
Leveler section is normally very long with the bridles, takes a lot of space
Very expensive equipment and high operating cost due to the very high tension
requirements
In general a much more precision machine
Operational characteristics:
Removes coil set, cross bow, edge wave, center buckle, combinations of defects, and
internal stress. Can also remove some camber as well
Typically built for light gage material only
Normally does not require much operator expertise to run
Working metal strips through rolls
What happens when Metal Strip is worked through Rolls? To correct shape we need to
know the physical properties of the material.
Thickness
Width
Yield strength - Stress or force it takes to permanently deform the material
Modulus of elasticity - Ratio of strain (material deformation) to stress (force on the
material)
Shape defect - Type of defect and severity
When material is wrapped around a roll or bent into a curve the outer portion is
stretched and the inner portion is compressed.
When the strip is under little or no tension the effective bend radius of the material is
not necessarily determined by the roll diameter. The bend radius is actually
determined by the roll centers and penetration of the work rolls, basically a 3 point arc.
Coil Set
Top side is longer than the bottom side in line with the length of the strip. Easy to
correct.
Cross Bow
Top or bottom side is longer than the other side. Length differential can be in line with
the strip or from edge to edge. Relatively easy to correct.
Edge Wave
Edges are longer than the center across the width and in line with the strip. More
difficult to correct but can be corrected.
Center Buckle
Center is longer than the edges across the width and in line with the strip. More
difficult to correct but can be corrected.
Camber
From edge to edge the strip gradually gets longer, basically a large arc. Can be
improved but very difficult to completely correct.
Crown
Thickness is greater in the center than the edges. Cannot be corrected with a leveler
Internal Stress
Strip appears flat but apposing internal deformities are present and cancel e ach other
out until released. Internal stress is a shape defect usually in the form of coil set, edge
wave, or center buckle that is not apparent until the material is cut, punched, or
processed later. Can be corrected but difficult to detect.