Tension leveler for 2050mm width aluminum strip project

Project Case Study: Multi-Roll Leveler for aluminum coil processing line

Client: Leading Aluminum Processing Enterprise

Location: Henan, China

Application: 2050mm Wide Aluminum Coil Uncoiling & Tension Leveling Line

Equipment Supplier: Xiangyang Jiade Machinery Co., Ltd.

1. Project Overview

Xiangyang Jiade Machinery successfully commissioned a high-precision Multi-Roll Leveler for a major aluminum processor, Henan Wanda Aluminum, China. Integrated into a 2050mm wide uncoiling and Tension leveling line, this equipment addresses critical shape and surface challenges inherent in processing soft, thin aluminum alloys. The project significantly enhances the client's capability to supply high-end aluminum coils for the booming home appliance, decorative façade, and electronics markets in South China.

Key Technical Parameters:

· Material: Aluminum Alloys (1xxx, 3xxx, 5xxx, 6xxx, 8xxx Series)

· Strip Width: 2050 mm

· Strip Thickness: 2.5 mm – 5 mm

· Line Speed: Up to 40 m/min

· Material Yield Strength: ≤350Mpa

· Material Tensile strength: ≤350Mpa

2. Equipment Configuration & Working Principle

Positioned after the cleaning section and before the Tension Leveler, the Jiade multi-roll leveler acts as the core "shape correction unit." It utilizes a series of intermittently arranged rolls to apply continuous, alternating bending cycles to the aluminum strip. This "gentle yet persistent" method induces controlled plastic elongation, effectively eliminating residual stress and rectifying flatness defects without compromising the material's integrity.

Main Technical Parameters of the Straightening Machine:

1. Working Roll Diameter: Φ85mm, Material: 9Cr2Mo, chrome-plated, Hardness: HRC63–65

2. Working Roll Pitch: 90mm

3. Working Roll Length: 2300mm

4. Number of Working Rolls: 19 pcs

5. Backup Roll Diameter: Φ80mm, Material: GCr15, Hardness: HRC57–60

6. Backup Roll Pitch: 90mm

7. Number of Backup Roll Rows: 7 rows (top and bottom each), Total Number of Backup Rolls: 161 pcs

8. intermediate roll Diameter: Φ45mm, Material: GCr15, Hardness: HRC61–63

3. Key Advantages of the Multi-Roll Leveler in Aluminum Processing

The application of the multi-roll leveler provided specific, high-impact benefits tailored to aluminum characteristics:

✅ Gentle & Effective Leveling for "Soft & Thin" Aluminum

· Small Diameter & Close Pitch Rolls: Designed specifically for thin gauges (0.5–1.2mm), the small Work Rolls and tight pitch prevent the "under-bending" or localized stress concentration often seen in fewer-roll machines.

· Optimized for Low Yield Strength: Since aluminum has a much lower yield strength than steel, the multi-roll design distributes the load evenly. This allows for effective elastoplastic leveling without damaging the substrate, preventing "over-correction" or "reverse crossbow" effects common with aggressive leveling methods.

✅ Superior Shape Correction & Stress Relief

· Elimination of Complex Defects: The leveler effectively eradicates common aluminum strip issues such as edge waves, center buckles, quarter buckles, and camber. Post-leveling flatness (I-Unit) is significantly improved, which is critical for downstream slitting, blanking, and stamping.

· Anisotropy Compensation: Aluminum strips often exhibit directional properties due to rolling textures. The multi-stage bending process homogenizes residual stresses across the strip width, minimizing inconsistent spring-back and ensuring batch-to-batch stability.

✅ Surface Integrity Protection for High-End Applications

· Low Roll Pressure & Minimal Marking Risk: Aluminum surfaces are notoriously prone to marking. The multi-roll configuration drastically reduces pressure per roller. Combined with precision chrome-plated and polished roll surfaces, this virtually eliminates bruises, scratches, and chatter marks.

· Avoidance of Single-Pass Over-Deformation: Unlike brute-force levelers, the multi-roll approach uses cumulative micro-deformations ("slow and steady"). This is ideal for high-surface-grade coils destined for mirror finishing, anodizing, or automotive exterior panels.

4. Problems Solved for the Client

Prior to installation, the client faced significant operational hurdles:

1. Severe Shape Defects: Persistent edge and center waves caused tracking errors during slitting and poor coil build-up, leading to high rejection rates.

2. Surface Damage: Conventional levelers left roll marks and scratches on the soft aluminum, forcing the downgrade of high-value products (e.g., mirror finish, brushed aluminum).

3. Limited Gauge Range: Existing equipment struggled with the thinnest gauges (0.5mm), often causing breaks or failing to flatten the strip.

4. Residual Stress Issues: Uneven internal stress led to distortion during customer laser cutting and stamping operations, resulting in complaints.

5. Results & Customer Benefits

· Dramatic Improvement in Yield Rate: By eliminating shape defects, tracking issues were resolved, boosting the finished product yield from 88% to over 96%.

· Premium Surface Quality: The absence of roll marks allowed the client to successfully enter the supply chain for high-end home appliance brands requiring flawless anodized and mirror-finished surfaces.

· Enhanced Process Flexibility: The leveler handles the full range of 0.5–1.2mm thicknesses and various tempers with quick changeovers, improving responsiveness to market demands.

· Increased Downstream Stability: Uniform stress distribution ensured exceptional dimensional stability during customer fabrication, reducing end-user scrap rates and enhancing satisfaction.

6. Customer Testimonial

"Jiade’s multi-roll leveler truly understands aluminum. It doesn't fight the material; it coaxes it flat. Unlike our old equipment, there are virtually no roller marks on our mirror-finish and brushed aluminum products now. In the competitive Foshan market, this reliability is our greatest asset."

— Plant Manager, Foshan Aluminum Processing Facility

7. Conclusion

Xiangyang Jiade Machinery leveraged its deep understanding of non-ferrous metal behavior to solve dual challenges of shape and surface quality for the client. This project reinforces Jiade's position not only as a leader in steel processing equipment but also as a trusted partner in advanced aluminum finishing technology.

Xiangyang Jiade Machinery Co., Ltd.

Precision Leveling & Cutting Solutions for Metals

www.xfjdmc.com                  www.jiademachinery.com

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