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Get a better understanding of roll forming and its tools

The roll forming machine may appear to be a complex machine with a series of stations and high speed. It is worth knowing how it works because it can perform unique functions and consistently create the same end product that meets the most stringent specifications.
The roll forming machine may appear to be an extremely complex machine with a wide range of stations and high speed. It is worth knowing how it works because it can perform unique functions and consistently create the same end product that meets the most stringent specifications.
In order to better understand what the roll forming machine is doing, it’s best to break it down to study every location where the metal changes in some way-whether it’s bending, stamping, cutting, or folding.
Whenever a metal plate is replaced on the roll forming line, the tools of the roll forming machine will gradually change the shape of the metal. Before the finished product is packaged at the other end, what starts with the coil has undergone many changes.
When the tool steel roll rolls on the working metal, the forming is done by the tool steel roll. Each roller continuously changes the shape of the metal plate as it advances on the production line. Eventually, as the required bending or folding progress increases, more wheels or molds are needed to achieve this.
Increasing the bending process too quickly can damage the material and make it challenging to produce finished products within tolerances. Increasing the bending process too slowly leads to the need to use additional molds or forming points at a higher cost. Machines with more forming points will also take up more workshop space.
Roll forming production line can form, stamp and cut various specifications of metal, suitable for many industries, including the construction industry. It is important to determine whether the metal is stamped before or after it is formed. It may not always be feasible to stamp it after it is formed, or it may be more expensive.
The metal plate can be cut at a specific point on the roll forming line. It is important to determine the best location for cutting, because the final product will vary depending on the cutting location.
Either way, the manufacturer must consider the flare and determine how the molding affects it. When cutting roll-formed parts, some residual stresses generated in the process are released. This will open or deform the end of the part. This is called a terminal flare. If the part is formed in the pre-cut roll forming process, the stress may be greater than the part formed in the post-cut roll forming process.
Whenever the metal plate is replaced on the roll forming line, it is done by the tools of the roll forming machine. When the metal plate is rolled under each steel roll, it is formed on the roll forming machine. As the metal advances on the production line, the shape of the metal will successively change. The top roller makes four-line indentations on the steel, the next roller forms six lines, and the last roller makes these indentations deeper and begins to bend the two raised parts.
Weighing the difference between pre-cut and post-cut operations can help determine the best method.
Due to the variable thickness, yield strength and elongation of the processed material during the forming of the part, it is very important to match the radius and other dimensions of the cutting blade with the contour of the part to obtain a good cutting effect. Conversely, cuts that do not match the size can cause deformation. When the part is formed in the pre-cut roll forming process, it will be cut flat, so there is no need to worry about the matching of the contour and the cutting blade.
It is important to determine whether the sheet metal is stamped before or after forming (top). This is pre-cut.
Metal defects are common and can cause problems during the roll forming process. They may even occur during the roll forming process.
Using flat steel or aluminum coils can help. Tension leveling is the process of pulling metal out of its yield point to permanently change its shape and level it.
Any roll forming operation can cause defects, so it is very important to ensure that your machine is functioning properly and that every change your machine makes to the metal is within acceptable tolerances from start to finish. For example, misaligned entrance guides can cause defects.
Fortunately, during the roll forming process, bows, cambers and twists can be straightened. The straightening machine can be part of the production line. It should be as close as possible to the last molding process. Even straightening will create tension on the metal, so it is best not to use a straightening machine if you don’t need it.
Today’s roll forming machines are running faster than ever before, and faster running speeds may be required in the future. The problem is that when the material runs at high speed, it heats up sharply and changes shape. There are several ways to try to adjust the temperature to prevent material changes.
Flood cooling extends tool life, but it is messy. Dry cooling is cleaner than pan cooling, but it will shorten the life of the mold. This in turn will change the shape of the final product.
Each working material has a different response to the stress of roll forming. Some materials are more ductile or softer than others. Soft materials may require fewer bending stations. Black steel, galvanized steel, color-coated steel, stainless steel, aluminum, copper and brass react differently during the roll forming process.
It is important to determine whether the sheet metal is stamped before or after forming. This is a post-editing.
The type of roll tool steel-4140, D2, 52100 or O1-and the post-treatments used for it, such as hardening or chrome plating, vary according to the type of work material used for roll forming. Each hardens in a different way. Experienced roll forming machine OEMs understand these characteristics and can provide the best mold design accordingly.
In the raft system, the tool is already loaded on the shaft. A multi-channel station will be preloaded and preset. When a manufacturer needs to change from one configuration file to another, there is no need to change the entire tool. All it needs to do is use a forklift or bridge crane to lift the raft, remove the raft with the previous profile, and replace it with the raft with the second profile.
Since today’s roll forming machines operate at high speeds, it is important to understand their built-in safety features. This may seem obvious, but it is important to secure safety equipment (guards, covers, etc.) in place regardless of whether the machine is running with an operator.
Safety awareness should include comprehensive training on the roll forming machine and any auxiliary equipment. For operators, it is very important to understand the ins and outs of each operation on the production line and downstream-both to ensure safety and to operate the machine effectively. Special attention should be paid to tool replacement or machine adjustment. Any quality manufacturing workshop will have a safety plan covering roll forming machines and other equipment. Creating a safe place for employees should be the most important.
Jaswinder Bhatti is the Vice President of Application Engineering at Samco Machinery Ltd. at 351 Passmore Ave., Toronto, ON M1V 3N8, 416-285-0619 x229, dpandit@samco-machinery.com, www.samco-machinery.com.
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Post time: Aug-06-2021
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