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Complete set of rebar bending machine dies including center mandrels and bending sleeves for various bar diameters

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Rebar Bending Machine Dies

Rebar Bender Dies

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Rebar Bender Roller Dies: Definition, Specifications, and Maintenance

Rebar Bender Roller Dies are key parts of rebar processing machines. They affect: Rebar bending accuracyFinished product qualityMachine efficiency

They use the three-point bending principle to bend rebar into shapes like stirrups and beam reinforcement. They work with most semi-automatic and fully automatic CNC rebar bending machines. Key points for use: Control Springback (rebound)Ensure Consistent bend radiiResist Structural fatigue during long-term use

1. Definition and Principle

1.1 Definition

Rebar Bender Roller Dies are special molds on a rebar bending machine’s working disc. They have three main parts: Central rollerMovable rollerPositioning roller

These three parts work together to bend rebar precisely. They control springback to keep consistent bend radii. You can change rollers to fit different rebar sizes.

Supporting parts (ensure stability and reduce structural fatigue): Pin shaft: 45# steel and 40CrSleeve: Cr12MoV

1.2 Working Principle

The dies use the three-point bending principle: Clamp rebar between the central and positioning rollers (fixed points).The machine moves the movable roller to apply even bending pressure.Rebar bends around the central roller (plastic deformation).Rebar springs back after bending—dies are designed to compensate for this.

Key adjustments: Change central roller diameter to adjust bending radius (for consistent bend radii).Adjust the working disc’s rotation angle to control bending angle (0-180° stepless adjustment).

Pin shafts (45# steel, 40Cr) and sleeves (Cr12MoV) bear bending force and reduce structural fatigue.

2. Main Specifications

2.1 Classification by Function

Central roller: Fixed at the center, determines minimum bending radius, ensures consistent bend radii.
Movable roller: Applies bending force, adjusts position to control angle and compensate for springback.
Positioning roller: Supports rebar, prevents displacement/warping during bending.

Pin shafts and sleeves help these rollers work stably and resist structural fatigue.

2.2 Classification by Rebar Size

Small: For 6-16mm rebar (stirrups, small precast parts).
Medium: For 18-28mm rebar (main structure, beams/slabs).
Large: For 32-50mm rebar (columns, shear walls).
Special: Custom for irregular rebar, high-strength steel. Supporting parts are also customized to reduce structural fatigue.

2.3 Core Parameters

Roller diameter: 25-120mm (1.5-5x the rebar diameter) – affects bending radius and consistent bend radii.
Roller width: 15-50mm – determined by rebar size and quantity per bend; wider = more stable, less springback.
Shaft hole diameter: 16-40mm – matches machine disc and pin shaft; ensures stability, reduces structural fatigue.

Sleeves (Cr12MoV) match shaft holes and pin shafts for better stability.

3. Material and Manufacturing

3.1 Common Materials

Rollers: Cr12MoV (high hardness, wear resistance, stability) – good for regular and medium-strength rebar.
Pin shaft: 45# steel (tough, easy to machine) or 40Cr (higher strength, wear resistance for heavy loads).
Sleeve: Cr12MoV (matches rollers, reduces friction and structural fatigue).

Materials affect wear resistance, impact resistance, and ability to resist structural fatigue and control springback.

3.2 Key Manufacturing Processes

Precision forging: Makes metal structure dense; improves strength, resists fracture and structural fatigue.
Vacuum heat treatment: Ensures hardness, avoids deformation, maintains accuracy (critical for springback control and consistent bend radii).
Precision grinding: Finishes parts; tolerance ±0.02mm for rollers, pin shafts, and sleeves – ensures accuracy.

4. Applications and Purchasing

4.1 Application Scenarios

Building construction: Bend rebar for beams, columns, slabs; needs consistent bend radii and springback control.
Bridge engineering: Precise bending for prestressed/rebar; needs structural fatigue resistance.
Tunnel engineering: Bend rebar for arches and grid frames.
Rebar processing plants: Mass-produce standard rebar parts; ensures efficiency and consistent bend radii.
Precast factories: Process rebar for precast beams/slabs; ensures standardization.

Pin shafts and sleeves ensure stability and reduce structural fatigue in all scenarios.

4.2 Purchasing Tips

Match the die to your bending machine (check shaft hole and installation method) – ensures stability, reduces structural fatigue.
Choose the right roller size for your rebar (max/min diameter) – ensures consistent bend radii and springback control.
Pick materials based on use: Cr12MoV for rollers/sleeves; 45# steel/40Cr for pin shafts (based on load).
Check manufacturing precision (tolerance) – critical for accuracy.

5. Maintenance and Life Extension

5.1 Daily Maintenance

Before use: Check rollers, pin shafts, and sleeves for secure installation; clean rebar fragments/rust.
During use: Follow size limits; avoid overloading (prevents deformation and excess structural fatigue).
After use: Clean parts; apply anti-rust oil to shaft holes, pin shafts, and mating surfaces (prevents rust and wear).

5.2 Regular Maintenance

For batch processing, check weekly: Disassemble and clean rollers, pin shafts, and sleeves; check for wear, cracks, or deformation (these cause more springback, inconsistent radii, and structural fatigue).Lubricate parts and replace old lubricant.Polish minor wear on roller grooves.Store parts in a dry, ventilated place (prevents moisture damage).

5.3 Repair and Replacement Standards

Repair: Polishing/welding for slight wear/scratches (no effect on size or structure).
Replace: Severe wear, cracks, deformation, or misalignment (causes structural fatigue and poor springback control).
Full replacement: For broken/deformed molds – use original manufacturer parts (including pin shafts/sleeves) for compatibility.

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