Last time we carefully studied the problems in the roll forming process and found that the working material is usually not the culprit.
If materials are excluded, what could be the problem? No changes were made, and the operator and setup staff claimed that they did not do anything different. Well…
In most cases, the problem can be traced to machine setup, maintenance or electrical problems. Here are some items you might want to include in the list:
Most material problems are directly related to machine problems or incorrect settings in rolls and stamping dies, which may surprise you. Ensure that all shift operators and setup personnel keep and maintain good setup charts.
Don’t tolerate those notorious secret setting pocketbooks! The cost of troubleshooting comments is very high, especially those related to tools and machine settings.
Now let us talk about the most difficult roll forming problem-lubrication. You want to permanently eliminate the lubrication problem, because in most operations, you will find that the purchasing department controls this aspect of roll forming.
Usually, in addition to the material, this is the line item that the red pen strikes first. But wait a minute! Why do I have to apply any type of lubricant before removing it? Why would anyone spend time, energy and money on this? Then, why should we spend our hard-earned money on special lubricants?
Steel mills usually apply some kind of oil to the coil to prevent rust. However, this oil was not developed for molding.
Physics briefing. Simply by accessing the physical properties of the material surface, we know that the metal surface is very rough, even though it looks smooth to the naked eye.
Take peak-to-valley maps to better understand the appearance of the polished surface under the microscope. We also know that according to Hertz’s formula for pressure between elastomers, harder materials can penetrate softer materials. Add friction to the equation, and your peak will be subject to shear.
Over time, when they break and are pressed into the coil material, the peaks will be eroded. As you may already know, the effect is that material is deposited on the surface of the roller, especially on high-wear grooves. Obviously, this has an impact on product quality and tool life.
hot. In addition, the roll forming process generates heat due to friction and forming energy, and does not affect the microstructure of the material; but in some cases, such as in-line welding, heat can cause cross-sectional shape changes and other problems. A large amount of roller type lubricant is used as a coolant.
Consider the final product. When choosing a roll forming lubricant, you must consider the finished product and its application.
A slight wax residue on the hidden part may be acceptable, but what happens if you use the same lubricant in a roof application? Your credibility will decline, that’s it. It is best to discuss the application with an expert, and remember that the right lubricant can provide huge benefits; however, the wrong lubricant can cost you a lot in many ways.
Develop a waste management plan. In addition, you should think of lubrication as a complete system. This means you need to consider the environment, OSHA, and local regulations to reap the benefits of lubricants and avoid problems.
Most importantly, you need to develop a waste management plan. This plan not only ensures that you comply with the law, but also improves process efficiency. Next time you walk through the factory, please look around. You may find some of the following:
The point is that your efforts to improve and maintain roll forming operations need to extend to lubricants. Don’t forget to check the maintenance aspects of lubrication-continuous use of forming lubricants and their proper disposal, or better yet recycling.
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Post time: Nov-19-2021