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Come and explore how the B&K® Precision Leveler can improve your metal forming, cut-to-length or job shop business.

 

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800 247-2645 x205


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Frequently asked questions

We are pleased to provide to you with the answers to some of the most frequently asked questions regarding levelers vs. other pieces of equipment, maintenance etc. If your question is not answered here or you wish greater detail please call us at 1-800-247-2645 and ask to speak to a leveler sales engineer. We are committed to getting you the answers you need to make an informed purchasing decision.

Why should I purchase a Precision leveler instead of a coil straightener?

Precision Levelers are much better at removing coil set and crossbow than coil straighteners or coil flatteners. Precision Corrective Levelers can also eliminate coil shape defects that simple flatteners cannot remove.

 

Do I need a leveler or a straightener?

Understanding the difference between a corrective leveler and a straightener is key when specifying what type of equipment is required for a certain job. A straightener will only correct for coil set and some cross bow as it has no adjustable back up rolls. Coils that have already been leveled and only have a memory from being wound up (coil set) within them can be corrected by utilizing a straightener and adjusting the head tilt based on material thickness. Coils that have other conditions such as edge wave or center buckle require the use of a corrective leveler to obtain flat material from these incoming coil conditions. A corrective leveler has power adjusted back up rolls to allow you to work the material in specified regions as required to flatten the strip. A coil that has edge wave requires the center of the strip to be worked and stretched to have the same length material as the outside edges. In center buckle applications just the opposite is required. The center of the material is longer than the edges. This requires that the edges of the material be worked to become the same length as the center and this results in flat material being obtained on the exit of the corrective leveler.

 

What type of coil defects can a Precision Corrective Levelers remove?

Along with coil set and crossbow, a Precision Corrective Leveler can remove wavy edges, center buckles, and twisted coil strip.

 

Stress-relieved all-steel fabricated upper housing Fixed upper back-ups for greater leveling control Heat treated upper work rolls to Rockwell 62-64 C Fixed upper back-ups for greater leveling control
Center Buckle Cross Bow Coil Set Edge Wave

 

What is the difference between a Precision Corrective leveler, a Coil Straightener and a Precision Coil Straightener?

B&K Precision Corrective Roller Levelers utilize a series of relatively small closely spaced leveler rolls that incorporate roller back-ups to prevent deflection. This arrangement allows the material to be worked beyond the yield point to remove trapped material stresses. The result is material that is more stable so that flat sheets remain flat. Precision Corrective Roller Levelers also have flights of adjustable back-up rollers that are utilized to deliberately flex or bend the small diameter leveler work rolls to remove shape defects such as wavy edges or center buckles. Coil Straighteners work the material to approximately 20-30 percent of its permanent yield and are only capable of removing coil set. Precision Coil Straighteners work the material to approximately 80 percent of its permanent yield. Most Precision Coil Straighteners can remove coil set and crossbow.

 

What are Roller Back-ups?

Roller back-ups are multiple sets of narrow rollers spaced evenly across the face of the work roll.

Roller back-ups; seen as the silver disks in this image

How does a Precision Corrective Leveler remove wavy edges or center buckles.

To corrective level material, flights of adjustable back-up rollers are utilized to deliberately flex or bend the small diameter leveler work rolls. These back-up rolls are adjustable in order to control the deflection of the work rolls and thus how and where the material is worked. When the material is passed through the leveler head, the area of the leveler work rolls that is flexed stretches the material fibers. By selectively bending the work rolls and stretching the material that is tight eliminates the loose areas. (Wavy edges or center buckles)

 

How do I determine how to set the adjustable back-up flights?

Touchscreen controlled adjustments of all normally required operator settings such as back-up roll flight positioning, upper work roll depth and angle of engagement is standard. A help screen has been integrated to allow the operator a base reference setting based on incoming material surface conditions.

 

Oil Can Help Screen Edge Wave Help Screen
Oil Can Edge Wave

 

What determines the diameter work rolls needed to flatten my material?

The material thickness range and the materials yield point determine the Roller Leveler work roll diameter. The engineering group at B&K can assist you to determine the proper Precision Corrective Leveler. To speak with an application engineer call 1-800-247-2645.

 

Will I need to purchase a completely new system with a Precision Corrective Leveler or can one be integrated in my existing line?

B&K Precision Corrective Levelers can be installed in a new Press Feed Line or retrofitted into an existing Press Feed System to precisely control flatness of your finished parts.

 

What is a 4-HI Precision Corrective Leveler and for what applications is the 4-HI Precision Corrective Leveler best suited?

A Leveler that has multiple sets of narrow back-ups rollers spaced evenly across the face of the work roll is considered a 4-HI Precision Corrective Leveler. Generally a 4-HI Precision Corrective Leveler is utilized when the material surface finish is not critical.

 

Why should I consider a 5-HI or 6HI Precision Corrective Leveler?

Over time, the backup rollers may produce a mark on the work rolls, which can be transferred to the surface of the material. To prevent this, another set of full width intermediate rolls is placed between the upper work rolls and the upper back-up flights in the 5-High. In the 6-High leveler configuration, a set of full width intermediate rolls is placed between the work rolls and the back-up flights for both the top and bottom sections. These roll(s) help to distribute the pressure of the back-up rollers across the surface of the work roll.

 

When should a 5-HI Precision Corrective Leveler be selected?

This setup is used when top surface-critical materials are being processed: soft aluminum, single-sided polished stainless, and pre-painted one side, for example.

 

When should a 6-HI Precision Corrective Leveler be selected?

This setup is used when top and bottom surface-critical materials are being processed: examples of this include soft aluminum, polished stainless both sides, and pre-painted both sides.

 

Can a leveler be used to flatten HSLA materials?

While some Leveler manufactures shy away from HSLA materials, B&K Precision HSLA Roller Levelers have been specifically designed to meet the challenge.

 

In our facility, HSLA blanks are produced to support transfer operations at other locations. In transit or when the blanks sit, the coil set can reappear within the blanks. Can a Precision HSLA Roller Leveler solve this problem?

YES, B&K Precision HSLA Roller Levelers utilize a series of relatively small closely spaced leveler rolls that incorporate roller back-ups to prevent deflection. This arrangement allows the material to be worked beyond the yield point to remove trapped material stresses. The result is material that is more stable so that part quality is consistent. Flat parts stay flat and round parts stay round.

 

How difficult is it to maintain a Precision Corrective Leveler?

A B&K® Precision corrective Leveler is equipped with a user-friendly touchscreen incorporates a complete maintenance manual as well as an operator thread-up training manual and a complete diagnostics package. All lubrication requirements of the Precision Corrective Leveler are handled automatically. An automatic grease system for the bearings and an automatic oil system for the gears and U-joints are provided.

 

Is it difficult to change the work rolls, work roll bearings or the back-up rolls?

No, an easy 3 step process allows is all that is required to attain easy access to change the work rolls, work roll bearings or the back-up rolls.

  1. Lift the leveler head to the open position and block the upper rollers. Note: All B&K levelers have a high-rise head as standard.
  2. Pivot the operator control will out of the way allowing easy access to the side roller housings.
  3. Remove two bolts and 2 locator pins to remove the side roller housing.

 

How do I clean the rolls when required?

Access to clean the work rolls is always a concern in corrective levelers due to the number of rolls within the machine. Levelers quite often process critical finish materials and any foreign matter on the works rolls quickly transfers to the end product resulting in excess scrap material being produced. B&K, understanding that down time to clean the rolls and scrap material are very costly to the customer, incorporates a powered high rise head into ever leveler produced. This feature allows the head of the leveler to power open and provide 6" of clearance for quick and easy access to clean the rolls.

B&K High Rise Head

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