Tube manipulation technology specialist, AddisonMckee, USA, has launched its first shell-rolling machine for forming the round and oval shapes that make up the outer bodies of catalytic converters and mufflers. Used to feed pre-cut flat sheets through a configuration of four position-controlled programmable rollers, ShellRollerTM can form the outer shell of a muffler or catalytic converter in virtually any round, oval or asymmetrical configuration and is suitable for use with carbon steel, stainless steel and titanium. Each forming work-cell consists of a feed system that loads the sheets using a vacuum pick-up to lift the sheets from an incoming stack and load them into the roller section of the machine for forming. The load station incorporates fanning magnet technology to separate all incoming sheets in order to prevent feeding multiple sheets into the machine rollers. In the forming section of the machine, four precision rollers work together to form the required cross sections. The top and bottom rollers are used to pinch the incoming sheet and feed it backwards and forwards as dictated by the program to create the shell shape. These two rollers are driven by electric servo gear motors and are electronically synchronised to reduce the risk of slippage during forming. The front and rear rollers then act in conjunction with the feed rollers to create the required part shape. These rollers are positioned using electro-mechanical linear actuators (as opposed to the hydraulic rollers often used on such machines), for precise motion and clean, quiet operation. The control system controls the position of these front and rear rollers in relation to the feed position of the sheet to generate the required bend radius in the sheet throughout the operation, to ensure the correct finished shell shape. Designed for maximum manufacturing flexibility, the standard system is capable of forming shells ranging in length from 75mm up to 350mm. Cross sections of up to 180mm are possible, in either round or as the major axis of an oval section. The minimum radius available is 65mm, though this is partly dependent upon the material being formed. Machines with larger or smaller capacities are available in order to create shells of significantly larger lengths or cross sections. In addition to manufacturing and supplying tube bending and end forming technologies, AddisonMckee offers tube measuring solutions, tube perforation, piercing and louvring technologies, hydraulic press machinery, muffler assembly solutions, plant automation and complete workcell integration. A full range of tooling and accessory options are also provided, along with comprehensive maintenance and service contracts, training and education programmes and financial services. Where applicable, the company is also able to offer machine rebuilds, refurbishment, upgrades and trade-ins. The company has already secured orders for eight ShellRoller systems at various sites across North America.

Tel: +44 (0) 1772 334511   Fax: +44 (0) 1772 323227