Levelers fall into three categories:

Leveling is the process of flattening steel strip or sheet through several work rolls with a smaller diameter "backed up" with rolls behind the work rolls to minimize deflection.

Precision or Corrective Leveling indicates that the backups are fully adjustable to create a bend in the rolls. A corrective leveler reduces shape defects across the strip and removes the coil set. Precision Levelers contain 17 to 23 driven work rolls and have adjustable backups. These Levelers will have 4HI, 5HI or 6HI configuration. Painted product or stainless steel requires 5HI or 6HI configuration depending on surface critical demand.

Tension Leveling is a step-up in corrective leveling. The material is run through the entry and exit set of bridle rolls with the corrective leveler placed in-between the Bridle sets. The material is put under a significant amount of tension with a slight elongation above the yield point of the material while simultaneously being leveled. The material, therefore, is shape corrected and released of most internal stresses. A tension leveler will require a dedicated line of equipment with Uncoiler & Recoiler or Uncoiler to Sheet Stacker. The Bridles demand a larger footprint and, therefore, more floor space in the end-users plant.

Stretch Leveling is supreme when it comes to leveling. The stretch level process is a method in which the material is stretched beyond its yield point to equalize the stresses providing a product with superior flatness. This process can eliminate shape defects such as edgewave, center buckle, quarter buckle, camber, crossbow, coil breaks, etc. The result is a material ideal for meeting fabricators' increased demands for flatness. Stretch leveling can also restore to perfection a steel coil that would be labeled secondary or scrap.

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Frequently Asked Questions About Levelers

What Are Some Common Features of Levelers?

Shape control equipment such as levelers are at the heart of most manufacturer’s coil processing and feeding lines. Important factors when selecting the best machine for your needs is to determine what you are looking for in roll diameter, roller pitch, and the number of work rolls. It is also good to know work rolls can be backed up for more precise flatness and zone control. By creating a closer roller pitch and smaller leveling roller diameter, depending on the material’s thickness and yield, you can better maximize your results. Unlike a typical straightener, a good leveler will remove more than a cross bow or coil set.

Newer levelers offer some optional features that include automatic roll positioning for different thicknesses and materials, so operators do not have to remember individual settings. The built-in computer system recognizes specific coils if you need to do rebooks (allowing for minor equipment adjustments an operator may still have to make for individual coils produce dead-flat material). Another option may include an automatic roll calibration control option, which simplifies adjustments for newly reground roll diameters following roll changes.

What Are Levelers on Cut-to-Length (CTL) Lines?

The most common use for leveling equipment is on cut-to-length lines. In some lines, the leveler comes after the shear, which means the material is leveled in plate or sheet form. Newer lines, however, have fewer problems when leveling the coil before shearing.

Except on very heavy-gauge lines, stopping and starting a leveler with every length of feed into a shear is a bad idea as it will cause excessive wear on the leveler’s drive train and possibly leave set marks on cold-rolled surfaces. Instead, most lines will use looping pits or flying shears with the leveler first going slow, then fast. Because levelers have a limited range for maximum or minimum material thickness, using two levelers—a big one and a smaller one—is common to extend the capacity of a cut-to-length line. Because minimum thickness rises with yield strength, and maximum width lessens, these lines need a fair amount of capacity overlap between their two levelers.

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If you do not find your desired equipment in our inventory, please let us know your requirements, and we will utilize our connections to locate the right equipment to meet your needs. We are here to serve you!