November 12, 2015

Custom Roll Forming Processes, Techniques

The roll forming process works by passing sheet metal through a series of rollers, with each of these rollers adding shape to the metal as it passes through. The rolls work together to form the desired cross section. Since the process is consistent and easy to repeat, roll forming provides a great way to produce even very high volumes of metal components.

roll forming

roll forming

What is Roll Forming?

Move forming is a constant metal forming procedure taking sirve el viagra de similares sheet, strip or curl stock and bowing or forming it to a persistent cross segment. The procedure is performed between progressive sets of moves that inexorably shape it until the fancied segment is finished.

The roll forming process can be used to form a wide variety of cross-section profiles. An open profile is most common, but a closed tube-like shape can be created as well. Because the final form is achieved through a series of bends, the part does not require a symmetric cross-section

Advantages of Roll Forming a Metal Part

The roll forming process allows operations such as punching, notching, and welding to be performed in-line. Labor cost and time for secondary operations are reduced or eliminated, reducing part costs.

Roll form tooling allows for a high degree of flexibility. A single set of roll form tools will make almost any length of the same cross section. Multiple sets of tools for varying length parts are not required.

Roll forming can provide better dimensional control than other competing metal forming processes.
Repeatability is inherent in cialis generique the process, allowing easier assembly of roll formed parts into your finished product, and minimizing problems due to “standard” tolerance build up.

Roll forming is typically a higher speed process.

Roll forming offers customers a superior surface finish. This makes roll forming an excellent option for decorative stainless steel parts or for parts requiring a finish such as anodizing or powder coating. Also, a texture or pattern can be rolled into the surface during forming.

Roll forming utilizes material more efficiently than other competing processes.

Roll formed shapes can be developed with thinner walls than competing processes.

Roll Forming Techniques

There are two common roll forming techniques with variations:

1) Pre-cut or cut-to-length roll forming Strips are pre-cut and processed, then fed into the roll former as individual strips. These strips may be cut from a coil or sheet.

Processing may include piercing, notching, embossing. Typically used for low-production parts, or parts with certain types of notches.

2) Post-cut rolls forming

Pieces of the cross section are cut to length after forming. This process implies working from a coil of material. Strip can be pierced, notched or further processed before the cutoff operation. Cut-off system moves with the strip and can add other features.

Roll Forming Materials

Almost any material that can tolerate bending to a desired radius can be roll formed. The more ductile a material is, the better it will roll form. The roll forming process can handle ferrous, nonferrous, hot rolled, cold rolled, polished, plated or pre-painted metals producing excellent results.

Material Spec Qualification:

Materials as thin as 0.005″ can be roll formed.

Material pieces as narrow as 1/8 “ and as wide as 72″ or more can be roll formed, depending on machine size.

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