WALDEMAR DESIGN AND MACHINE L.L.C.
MADE IN THE USA
403 Series
The 403 Series 4-roll double pinch plate bending machine is in a sense a 3-roll initial pinch plate bending machine with an extra bending roll on the front side of the pinch rolls. The advantage of this type of machine is that it enables the operator to roll the workpiece from the leading to the trailing edge with minimal and usually negligible flats. As a rule of thumb, the flats are less than 1 1/2 - 2 times the workpiece thickness. This can be accomplished in a single pass without turning the workpiece.
Standard Features
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1045 steel rolls machined to T63 micro inch finish
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Crowned rolls
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Total hydraulic operation
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Instant start/stop/reverse
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2 roll drive
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3 phase 230/460 volts 60hz electrics
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Electrics to NFPA-79 specifications
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24VDC control circuit
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Safety/emergency stop cable on 3 sides of the machine.
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Overload protected
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TEFC main motor
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Quiet hydraulic system
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Haze gray epoxy and blue enamel finish (V.O.C. compliant)
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Sealed spherical roller bearings on all main points
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Bending rolls tilt for cone rolling
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DRO to show roll position
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Roving pendant control
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Hydraulically actuated drop-end
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Accurately machined, compact, streamlined, and all welded steel frame
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Rolls driven direct via hydraulic motor or gear speed reducers
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Variable roll speed 0-22 FPM
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1 year warranty
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Made in USA
Options
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Hardened only rolls 55-60 Rc. (1045 flame hardened) T63 finish.
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Hardened and polished rolls 55-60 Rc. (1045 flame hardened) G32 finish
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Other alloys and finishes are available
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Squaring grooves in pinch roll
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Circular grooves in rolls for rolling rods or sheets with wire edges 3/8, 1/2, and 5/8
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Other special circular grooves for extrusions etc.
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Dual guarded foot switch for roll rotation and pinch roll up/down
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Cone attachment
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Control upgrade
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Pinch roll trim (recommended if you roll a lot of cones)
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Non-Electric version
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Side supports
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Overhead supports, feed tables, automatic feeders, manual and automatic ejectors.
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Special electrics
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Special customer supplied paint
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Light curtain safety guarding
Also Available
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Chromed rolls
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Special extra smooth rolls
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Special grooves in rolls
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High-speed version
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Many, many more. Let us know your needs.
Drop End
The hydraulically actuated drop end can be lowered to open up the machine and allow for a completely circular workpiece to be slid off the end of the roll.
Side Support
Here is an example of a side support. These side supports are quick detach (optional) and can be removed easily when not being used. We offer a variety of side support styles along with infeed tables etc. Inquire for options.
Dual Guarded Foot Pedal
This feature is available for forward and reverse rotation of the rolls and pinch roll up/down, allowing operator to use both hands to manipulate workpiece and can be used on all control styles.
Selector to control function:
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Pinch roll up/down
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Rotation forward/reverse
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Off
Beta 4.2
This is a manual control and comes with the base machine at NO CHARGE (shown with optional rotation readout). Recommended use, job shops and part batches up to 10 pieces.
FEATURES:
Push buttons to control:
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Control
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Emergency stop
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Near roll
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Pinch roll
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Far roll
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Roll rotation
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Drop end
Selector switch to control:
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Roll trim
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Rotation reroll
Dial to control:
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System speed
Digital readout to show position of:
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Near roll
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Pinch roll
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Far roll
-Free standing rolling console
-NEMA 12 fiberglass enclosure
-Stainless steel hand rail
-Receptacle for control cord
OPTION:
Beta 4.2R Rotation readout to show length in inches of the roll rotation. Recommended use, jobs with multi radius or flats.
Overhead Ejector
This is an example of an overhead ejector and the way it can be used to assist in ejecting the workpiece. We can also install just an overhead support as well. Inquire for options
Single Foot Switch
This single foot switch selector is compatible with all controls.
Selector to control function:
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Pinch roll up
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Rotation forward
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Off
Pre 4.2
This is a preset control and can be upgraded from the Beta 4.2 control. This popular control provides just enough automation to greatly speed through put performance, and accuracy. It is easily programmed and can be used as manual or preset type control. In many cases this control increases roll performance 500% or more and is usually all the automation that is required. This control is recommended for part batch sizes from 3 to 100+ pieces. All controls are plug and play, so they can be upgraded at anytime. Just unplug the old control and plug in the new one it's that easy.
FEATURES:
Push buttons to control:
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Control
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Emergency Stop
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Drop end
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Far roll gauge position
Variable speed joysticks to control:
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Near roll
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Pinch roll
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Far roll
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Roll rotation
Selector switches to control:
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Roll trim
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Rotation reroll (machines 8"-12" top roll)
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Set point 1 mode
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Set point 2 mode
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Normal mode
Digital readout to show position and control:
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Near roll (2 set points)
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Pinch roll (2 set points)
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Far roll (3 set points)
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Roll rotation (3 set points)
-Free standing rolling console
-NEMA 12 enclosure
-Stainless steel hand rail
-Receptacle for control cord
Auto 4.2
This NC control is used for high volume production. The material is hand-fed and it completes all forming functions automatically, and has 4 modes; warm-up to get the machine to operating temperature, drop end open for full circles, drop end close for segments, and tack for positioning part to tack weld on the machine. This control can be used in manual, presets, or auto modes and has a 6-part memory storage. It is recommended for part batch size of 50 plus pieces. All controls are plug and play, so they can be upgraded at anytime. Just unplug the old control and plug in the new one it's that easy.
FEATURES:
Push buttons to control:
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Control
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Drop end
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Emergency Stop
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Mode
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Pause/SP over ride
Joysticks to control:
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Near roll
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Pinch roll
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Far roll
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Roll rotation (machines 8"-12" top roll)
Selector switches to control:
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Roll trim
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Rotation reroll
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Cycle - warmup, drop end open/close, or tack
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Part selector - part # 1,2,3,4,5,or6
Dial to control:
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System speed
Digital readout to show position and control:
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Near roll
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Pinch roll
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Far roll
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Roll rotation
Indicator lights to show:
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Manual mode
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Preset mode
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Auto mode
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Auto ready
Footswitch to control:
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Cycle start,
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Rotation forward
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Pinch rollup
-Free standing rolling console
-NEMA 12 enclosure
-Stainless steel hand rail
-Receptacle for control cord
*Note, some aspects of the machines have been upgraded since the last brochure revision!
Advantages of a 4-Roll
Gallery
Workpiece Accuracy
In the final analysis, the proof of performance is the acceptability of the finished workpiece. With uniform quality of the workpiece blanks, our machines have historically rolled workpieces within 1/2 of 1% of perfect concentricity.
There are many variables that can affect the accuracy and repeatability either minimally or drastically. These include, but are not limited to, the following: varying material thickness; varying material temper; uneven cross section of material, i.e. wide and narrow profile of workpiece or a workpiece with holes or cutouts; and direction of grain of material.
Many of these variables can be overcome by various means. An important element for success is a knowledgeable operator who understands the characteristics of the material being formed and the various functions of the machine. If the workpiece being formed is anything other than uniform material and cylinders, and you are unsure if your pieces can be rolled practically, please provide us with a drawing or sketch and we will be happy to evaluate it.
Waldemar Design & Machine L.L.C. warrants its products to be free from defects in material and workmanship for a period of one year from date of manufacture. Waldemar's obligation is to replace, free of charge, any defective part of any product that its inspection shows to be defective, including the lowest priced round trip transportation to Waldemar's plant in Spencer, TN, from any point in the 48 contiguous states. Waldemar shall not be liable for installation and removal expense, loss of time, manufacturing costs, labor, materials, loss of profits, or consequential damages direct or indirect, because of defective products. There is no other warranty, expressed or implied.