What is Roll Forming Process?

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What is Roll Forming Process?

Roll forming machines that design and produce for specific metal such as SS, GI, CI, PPGI, CU, and etc.The cold roll forming process is an alternative method under the condition of room temperature to form the advanced high strength steel. The forming rolls design with relief and trap features to control the material locally and prevent the defects of folding and wrinkling.

Roll Forming process

In the cold roll-forming process, a long metal strip deforms progressively through a series of rotating rolls in several stands. In order to get a required cross-section, with no decrease in the strip thickness, except in the localize bend parts. Roll forming is a progressive and continuous process, in which small amounts of forming are applied at each pass of rollers. Cold roll forming bends a long strip of sheet blank into a desired cross-sectional profile via roller dies.

The roll forming process is the most important metal formation technique. One of the major metal forming processes is the passage of metal through two rollers that rotate in opposite directions.

How does roll forming machine work?

Roll forming machine works continuously by special roll design on amount of stations. All stations drive together and roll material with the same speed. Roll forming technology is easiest and fastest processing of sheet metal into required profile. Each station of tooling make small forming on material and pass it to the next station. As a result, the material gets the required profile shape.

Cold roll forming is one of the complex forming processes, where the quality of products is highly dependent on the process parameters. Some roll forming parameters of channel section investigate on the edge longitudinal strain and bow defect of products such as bending angle increment, strip thickness, flange width of section, web width of the section, friction in the roll and strip contact also speed of roll, and distance between the roll stations. It is important to consider these parameters for roll forming process design.

What is Roll Forming Line?

Roll Forming Line consists of decoiler, feeder and roll form machine with the amount of alignment stations and rollers. Before the roll forming machine cutting and the punching units can be added. The length of the profil either can be cut before the roll forming process or after the roll forming machine with shear unit. All this system together we call roll forming line. Roll forming is a continuous bending process during which the thin sheet of metal successively passes through a set of rolls that incrementally bend it until the desired cross-section is obtained.

Roll forming process parameters

Roll forming process parameters do not play a major role in the quality of the final product. Optimal design can increase accurate and flawless products without increasing the cost of the roll form line.

The speed of the rollers plays a major role in determining the quality of the rolling product. Tensile strength, flow stress, deformation heat, roll force, and heat transfer coefficient are all controlled by direct rolling speed. Therefore, rolling speed can be considered as one of the important rolling parameters.

Strain rate is another parameter that plays a vital role in the quality of the rolled product. Strain velocity can correlate with roller velocity. It can be said that the strain distribution in high-speed rolling is more homogeneous.

How does cold forming work?

Cold forming machine feeding by sheet metal from de-coiler then start to forming step by step, station by station. Each tooling station has duty for a specific amount of changing shape on the raw material.

The most noteworthy point is roll forming machine working quietly without any popping or wrinkling. Furthermore the final profile should be without any distortion, crimp as well as misalignment. All roll forming roller parts should design by experienced professional engineering with well-known software, to get the final standard result.

June 2024