A Metal split set making machine consists of five independent production lines. The pipe body is the base component of the whole rock bolt system. The roll forming line turns steel strip into the pipe body. Later steps like dome plate installation, necking, and final welding all depend on the forming quality of the pipe body. Understanding how this line works is the basis for understanding how the five line system works together.

Where Split Set Rock Bolts Are Used

Split Set rock bolts are key components in underground engineering and ground support. This Metal split set making machine produces finished rock bolts for these applications:

• Mine roadway roof and side support

• Highway and railway tunnel primary support

• Slope treatment and geological hazard prevention

These applications have different requirements for pipe diameter, material thickness, and length. A complete rock bolt needs four core steps: pipe body, dome plate, ring, and welding. The roll forming line makes the pipe body. The press line makes the dome plate. The necking line reduces the pipe end. The ring making line makes the ring. The welding line joins all parts into a finished product.

How the Roll Forming Line Makes the Pipe Body

The roll forming line is the starting point of the whole system. Its job is to turn steel coil into a longitudinally slotted tube. The steps below follow the working order of this line.

From Steel Coil to the Forming Line

The Anchor Rod Cold Bending Roll Forming Machine starts with a 3 ton manual decoiler. The decoiler holds the steel coil and feeds the whole line. It sits at the front of the production line, and the steel strip enters the next steps from here. The decoiler capacity and operation affect feed stability for the whole line.

Feeding and Guiding Keep the Strip Aligned

After the decoiler, the strip passes through feeding rollers and then guiding rollers. The current setup uses 2 feeding rollers and 2 guiding rollers.

The feeding rollers push the strip into the forming section. The guiding rollers keep the strip aligned before it enters the forming rollers. The two work together, and they directly affect forming accuracy. If the strip drifts, the roundness and size consistency of the pipe body will suffer.

Seven Rollers Form the Tube Step by Step

The strip enters the forming section and passes through a 7 roller forming machine for gradual cold bending. Each roller bends the strip a little. After several passes, the flat strip becomes a tube.

On this Metal split set making machine, the rollers use Cr12 with quenching treatment. The shaft diameter is 70 mm. The forming speed range is 0 to 15 m/min. The material thickness range is 2.5 to 3.5 mm. The pipe outer diameters are 39 mm and 46 mm. These parameters describe the current machine's working range. The speed can be customized to customer needs.

The forming speed, material thickness, and pipe diameter together define the product range this line can cover.

Shearing and Notching in One Step

When the tube reaches the set length, the hydraulic stop shearing system cuts it off. At the same time, the cutter makes a notch on the pipe end. The shearing type is hydraulic stop shearing with notch cutting at the same time.

The hydraulic station power is 7.5 kW and supplies power for notching and shearing. The receiving table takes 2.5 m per piece.

Transmission and Control

This line uses gearbox transmission instead of chain drive. The frame structure is a heavy duty cast steel frame with a middle plate welded base. The PLC control uses Delta brand. The voltage is 380V 50Hz 3 phase, customizable to the local grid.

Five Line System Configuration and Parameters

A Metal split set making machine uses five independent lines. The first four lines each make one component, and the fifth line handles welding. In the production sequence, the output of one step becomes the input for the next. The pipe body goes to the necking line, the dome plate comes from the press line, the ring comes from the ring making line, and the welding line joins all parts into a finished rock bolt.

For voltage and frequency, the five lines use the same 380V voltage level, but the frequency differs. Roll Forming, Necking, and Ring Making use 50Hz, while Dome Plate Press and Ring Welding use 60Hz. All frequencies can be customized to the local grid.

The tables below list the parameters by production line.

Split Set Roll Forming Machine Parameters

Other Four Lines Parameters

Advantages of the Five Line Setup

• An Anchor Rod Forming Machine built from five lines lets each line make a different component. Every step has its own machine, so one machine does not need to handle multiple processes.
• Each line runs independently and can be configured and managed by process.
• Parameters can be customized to customer needs, including speed, profile, and voltage.

Five Lines Working as One System

The roll forming line is the starting point for the pipe body. Through decoiling, feeding, guiding, 7 roller forming, and shearing with notching, it supplies qualified pipe bodies to the other four lines. The forming quality of the roll forming line directly affects dome plate installation, necking, and final welding.

A Metal split set making machine brings these five lines together as one production system. The five lines each do their own job and work together as one production system. If you want to discuss a specific configuration, contact us.

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