How Roll Forming Machines Work

Roll forming machines fabricate specific configurations out of long strips of metal, most commonly coiled steel. In most applications, the required cross-section profile of the piece is specifically designed for the machine to bend the metal as necessary. Other than roll forming, these machines perform a number of metalworking duties, including material cutting and roll punching.

Roll forming machines, for the most part, work in a continuous cycle. The material is fed into the machine where it continuously makes its way through the stages of each operation, ending with the completion of a final product.

How Roll Forming Machines Work

A roll forming machine bends metal at room temperature using a number of stations where fixed rollers both guide the metal and make the necessary bends. As the strip of metal travels through the roll forming machine, each set of rollers bend the metal a little more than the previous station of rollers.

This progressive method of bending metal ensures that the correct cross-sectional configuration is achieved, while maintaining the cross-sectional area of the work piece. Typically operating at speeds between 30 to 600 feet per minute, roll forming machines are a good choice for manufacturing large quantities of parts or very long pieces.

Roll forming machines are also good for creating precise parts that require very little, if any, finishing work. In most cases, depending upon the material being shaped, the end product features an excellent finish and very fine detail.

Roll Forming Machine Line Basics

The basic roll forming machine has a line that can be separated into four major parts. The first part is the entry section, where the material is loaded. The material is usually inserted in sheet form or fed from a continuous coil. The next section, the station rollers, is where the actual roll forming takes place, where the stations are located, and where the metal shapes as it makes its way through the process. Station rollers not only shape the metal, but are the main driving force of the machine.

The next section of a basic roll forming machine is the cut off press, where the metal is cut to a pre-determined length. Due to the speed at which the machine works and the fact that it is a continuously working machine, flying die cut-off techniques are not uncommon. The final section is the exit station, where the finished part exits the machine onto a roller conveyor or table, and is manually moved.

Roll Forming Machine Developments Roll formers

Today’s roll forming machines feature computer-aided tooling designs. By incorporating CAD/CAM systems into the roll forming equation, machines function at their maximum potential. Computer controlled programming provides roll forming machines with an internal “brain” that catches product imperfections, minimizing damage and waste.

In many modern roll forming machines, programmable logic controllers ensure accuracy. This is vital if a part needs multiple holes or needs to be cut to a specific length. The programmable logic controllers tighten tolerance levels and minimize accuracy.

Some roll forming machines also feature laser or TIG welding capabilities. Including this option on the actual machine results in loss of energy efficiency, but removes an entire step in the manufacturing process.

Roll Forming Machine Tolerances

Dimensional variation of a part created through roll forming is based on the type of material used, the roll forming equipment, and the actual application. Tolerances can be influenced by varying metal thickness or width, material springback during production, the quality and wear of the tooling, actual machine condition, and the experience level of the operator.

The Benefits of Roll Forming Machines

Aside from the benefits discussed in the previous section, roll forming machines offer the user some specific advantages. Roll forming machines are energy efficient because they do not expend energy to heat material—the metal shapes at room temperature.

Roll forming is also an adjustable process and is applicable to projects of varying time duration. Additionally, roll forming results in a precise, uniform part.

We are manufacturing accessories related to roll forming. If you are interested in our products, please feel free to contact us.

Sourced by ekomeri

The post How Roll Forming Machines Work appeared first on Roll Engineering.

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via ROLL ENG

How Roll Forming Machines Work

Roll forming machines fabricate specific configurations out of long strips of metal, most commonly coiled steel. In most applications, the required cross-section profile of the piece is specifically designed for the machine to bend the metal as necessary. Other than roll forming, these machines perform a number of metalworking duties, including material cutting and roll punching.

Roll forming machines, for the most part, work in a continuous cycle. The material is fed into the machine where it continuously makes its way through the stages of each operation, ending with the completion of a final product.

How Roll Forming Machines Work

A roll forming machine bends metal at room temperature using a number of stations where fixed rollers both guide the metal and make the necessary bends. As the strip of metal travels through the roll forming machine, each set of rollers bend the metal a little more than the previous station of rollers.

This progressive method of bending metal ensures that the correct cross-sectional configuration is achieved, while maintaining the cross-sectional area of the work piece. Typically operating at speeds between 30 to 600 feet per minute, roll forming machines are a good choice for manufacturing large quantities of parts or very long pieces.

Roll forming machines are also good for creating precise parts that require very little, if any, finishing work. In most cases, depending upon the material being shaped, the end product features an excellent finish and very fine detail.

Roll Forming Machine Line Basics

The basic roll forming machine has a line that can be separated into four major parts. The first part is the entry section, where the material is loaded. The material is usually inserted in sheet form or fed from a continuous coil. The next section, the station rollers, is where the actual roll forming takes place, where the stations are located, and where the metal shapes as it makes its way through the process. Station rollers not only shape the metal, but are the main driving force of the machine.

The next section of a basic roll forming machine is the cut off press, where the metal is cut to a pre-determined length. Due to the speed at which the machine works and the fact that it is a continuously working machine, flying die cut-off techniques are not uncommon. The final section is the exit station, where the finished part exits the machine onto a roller conveyor or table, and is manually moved.

Roll Forming Machine Developments Roll formers

Today’s roll forming machines feature computer-aided tooling designs. By incorporating CAD/CAM systems into the roll forming equation, machines function at their maximum potential. Computer controlled programming provides roll forming machines with an internal “brain” that catches product imperfections, minimizing damage and waste.

In many modern roll forming machines, programmable logic controllers ensure accuracy. This is vital if a part needs multiple holes or needs to be cut to a specific length. The programmable logic controllers tighten tolerance levels and minimize accuracy.

Some roll forming machines also feature laser or TIG welding capabilities. Including this option on the actual machine results in loss of energy efficiency, but removes an entire step in the manufacturing process.

Roll Forming Machine Tolerances

Dimensional variation of a part created through roll forming is based on the type of material used, the roll forming equipment, and the actual application. Tolerances can be influenced by varying metal thickness or width, material springback during production, the quality and wear of the tooling, actual machine condition, and the experience level of the operator.

The Benefits of Roll Forming Machines

Aside from the benefits discussed in the previous section, roll forming machines offer the user some specific advantages. Roll forming machines are energy efficient because they do not expend energy to heat material—the metal shapes at room temperature.

Roll forming is also an adjustable process and is applicable to projects of varying time duration. Additionally, roll forming results in a precise, uniform part.

We are manufacturing accessories related to roll forming. If you are interested in our products, please feel free to contact us.

Sourced by ekomeri

The post How Roll Forming Machines Work appeared first on Roll Engineering.

from http://ift.tt/2hViOyX
via ROLL ENG

Advantages of Roll Forming

Roll-forming also has other advantages over braking and extruding. Compared to brake forming, roll forming can produce more parts with greater uniformity and consistency throughout the length of the part. Roll forming also eliminates multiple stage operations, trim scrap, and slitting burrs.
Advantages of roll forming relative to extrusion methods include: practically all metals can be roll formed, not just aluminum. Also, roll forming can eliminate secondary operations – multiple stage operations such as notching, punching, and post-painting – by combining them in the roll forming process.

Prepainted steel can be substituted for post-painting methods and the metal can be perforated prior to roll forming or, if the hole pattern is close to the beginning or end of the part, the formed part can be perforated in the cut-off die. The ability to fabricate decorative parts from precoated, prepainted, or pre-plated metal is a distinct feature of roll forming.Samson Roll Formed Products Company is one of the oldest and largest contract roll formers in the U.S., located in Chicago in a large industrial facility that houses 40 roll forming lines and an array of ancillary equipment. Stamping, bending, parting, and assembly are some of the other services in Samson’s arsenal of value-added options. Samson has stock tooling for more than 2,000 shapes, many of which are featured at other roll-formed shapes.

Samson Roll Formed Products Company provides our customers with distinct advantages of roll forming.

Assembly
Two distinct parts can be run together to form one assembly.

Clad Shapes
Two different materials can be formed simultaneously to produce a clad shape in one operation.

Energy
Efficiency Roll forming is an energy efficient process usually requiring no process heat to be added.

Finish Roll
Forming can produce superior surface finishes. Sharp, clean contours can be maintained. The absence of die marks on the material often eliminates the need for additional finishing.

Hole and Slot
Patterns Pre-punching in-line allows holes or slots that cannot be done as a secondary operation because of their location or features of the part to be included in the shape.

Hollow Shapes
Hollow or semi-hollow shapes can be produced with thinner walls than are possible by competing processes.

Lengths
Almost unlimited lengths can be roll formed. The only limitations are due to material handling equipment, space constraints, and shipping capabilities.

Material
Almost any bendable material can be roll formed.

Production
The high speed, continuous nature of roll-forming lends itself to economic production of large volumes of parts.

Secondary Operations
Many additional operations, such as punching, notching, welding and bending, that otherwise would have to be performed as secondary operations can be incorporated into the roll forming process, thus reducing handling and processing costs. Even labels giving installation instructions can be applied to the shape as an in-line process.

Structural Applications
Roll formed materials generally have a strength advantage over competing processes in structural rigidity applications.

Tolerances
Roll forming can achieve closer tolerances than are possible with most competing processes.

Tooling
The same tooling can be used to roll a shape out of different materials.

Uniformity
Roll-forming produces symmetrical parts with uniform dimensions that assure precision fits, simplify production, and that speed assembly and minimize rejects.

We made Mold & Accessories Related With Roll-Forming System. If you are interested in these parts, you can feel free to contact us.

Sourced by ekomeri

The post Advantages of Roll Forming appeared first on Roll Engineering.

from http://ift.tt/2gO8fyY
via ROLL ENG

Advantages of Roll Forming

Roll-forming also has other advantages over braking and extruding. Compared to brake forming, roll forming can produce more parts with greater uniformity and consistency throughout the length of the part. Roll forming also eliminates multiple stage operations, trim scrap, and slitting burrs.
Advantages of roll forming relative to extrusion methods include: practically all metals can be roll formed, not just aluminum. Also, roll forming can eliminate secondary operations – multiple stage operations such as notching, punching, and post-painting – by combining them in the roll forming process.

Prepainted steel can be substituted for post-painting methods and the metal can be perforated prior to roll forming or, if the hole pattern is close to the beginning or end of the part, the formed part can be perforated in the cut-off die. The ability to fabricate decorative parts from precoated, prepainted, or pre-plated metal is a distinct feature of roll forming.Samson Roll Formed Products Company is one of the oldest and largest contract roll formers in the U.S., located in Chicago in a large industrial facility that houses 40 roll forming lines and an array of ancillary equipment. Stamping, bending, parting, and assembly are some of the other services in Samson’s arsenal of value-added options. Samson has stock tooling for more than 2,000 shapes, many of which are featured at other roll-formed shapes.

Samson Roll Formed Products Company provides our customers with distinct advantages of roll forming.

Assembly
Two distinct parts can be run together to form one assembly.

Clad Shapes
Two different materials can be formed simultaneously to produce a clad shape in one operation.

Energy
Efficiency Roll forming is an energy efficient process usually requiring no process heat to be added.

Finish Roll
Forming can produce superior surface finishes. Sharp, clean contours can be maintained. The absence of die marks on the material often eliminates the need for additional finishing.

Hole and Slot
Patterns Pre-punching in-line allows holes or slots that cannot be done as a secondary operation because of their location or features of the part to be included in the shape.

Hollow Shapes
Hollow or semi-hollow shapes can be produced with thinner walls than are possible by competing processes.

Lengths
Almost unlimited lengths can be roll formed. The only limitations are due to material handling equipment, space constraints, and shipping capabilities.

Material
Almost any bendable material can be roll formed.

Production
The high speed, continuous nature of roll-forming lends itself to economic production of large volumes of parts.

Secondary Operations
Many additional operations, such as punching, notching, welding and bending, that otherwise would have to be performed as secondary operations can be incorporated into the roll forming process, thus reducing handling and processing costs. Even labels giving installation instructions can be applied to the shape as an in-line process.

Structural Applications
Roll formed materials generally have a strength advantage over competing processes in structural rigidity applications.

Tolerances
Roll forming can achieve closer tolerances than are possible with most competing processes.

Tooling
The same tooling can be used to roll a shape out of different materials.

Uniformity
Roll-forming produces symmetrical parts with uniform dimensions that assure precision fits, simplify production, and that speed assembly and minimize rejects.

We made Mold & Accessories Related With Roll-Forming System. If you are interested in these parts, you can feel free to contact us.

Sourced by ekomeri

The post Advantages of Roll Forming appeared first on Roll Engineering.

from http://ift.tt/2gO8fyY
via ROLL ENG