17 Mar ROLL BENDING UNIT
ROLL: Simultaneous bending and calibration unit
Roll is a patented Newstark component designed to perform sheet-metal bending and calibration simultaneously. It allows a wide range of bending operations, including undercut bends (with angles from 90° to 135°), open bends (greater than 90°) and large-radius bends, while maintaining the required angular tolerances.
The system is also capable of producing open Z-bends, double bends and other complex bending geometries.
Roll can be installed on both dies and press brakes, offering excellent flexibility across different production setups.
Dimensions and configuration
The system consists of a rotating element that is pre-shaped according to the specific application requirements. It is available in diameters ranging from Ø15 mm to Ø100 mm, with lengths up to 800 mm (also available in inch or soft-metric HYDRIB versions), and can bend sheet metal up to 8 mm thick.
Roll is manufactured from highly tough materials with excellent resistance to wear and compression. All components are hardened and surface-treated to significantly reduce friction and ensure long service life.
Bending adjustment versatility
One of the key strengths of Newstark roller bending units is their exceptional versatility in bend angle adjustment. Thanks to the adjustment shim located at the bottom of the unit, the bending angle can be fine-tuned by up to ±5°.
This feature allows consistent and precise results even when processing high-strength materials with significant springback, drastically reducing die setup and tuning time. For bending high-strength automotive materials such as DP800, DP1000 and DP1200, the roller bending unit represents the optimal solution.
Elimination of scratches and surface marks
The careful design of Newstark rapid bending units ensures maximum protection of the sheet metal, eliminating unwanted scratches and marks during the bending phase. This is essential for visible parts, where aesthetic quality is a critical requirement. For this reason, the Roll unit is widely used in the home-appliance industry.
Space and cost optimization
The rotary bending unit was developed to meet the growing demand for optimizing die space and manufacturing costs. Newstark therefore offers both “standard” applications, compatible with existing market solutions, and special customized products.
A clear example of this concept is the Rotocam system, which—thanks to specially engineered, application-specific geometries—allows multiple operations to be performed in a single stroke. In one of its special versions, the unit performs bending, calibration and reinforcement rib forming simultaneously, significantly reducing overall die dimensions.