Roll Forming Machine
RollFormingMachineDesignTechnologyIntroduction
GENERALCONCEPTSofcoldrollformerlineprocessing:Roll-formingisaprocessinwhichthe
shapeofametalpanelisdevelopedbygraduallybendingthemetalthroughaseriesofroll
formingmachine,orpasses.Eachstandmustgeneratetheappropriateamountofdeformationforwhichitwasdesigned.In
general,thelevelodeformationateachstandisnotconstantduetoadjustmentsforspring
backandthepreservationofdimension.Sincethetoolingisdesignedto
controltheoutsidedimensionsoapanel,rollformersareusuallydesignedtooverworkthe
metalinspecificstands.Problemsintheformingsystemortoolingdesignmayexistifmaterials
havetobeoverworkedinthestands/toolingotherthanthosedesignedforoverwork.Therefore,
whenroll-formingproblemsoccur,itisimportanttoexamine
eachstageoftheprocessandnotmerelythestandatwhichtheprobleminitiallyappears.
Twobasictypesofroll-formingsystemsareutilized:aprecutlineand
apostcutline.Aprecutlineshearstheincomingmaterialtoaspecificlengthpriortoroll-
forming.Duringpostcutlineoperation,therollformedpanelrunscontinuouslyandis
shearedtotherequiredlengthafterroll-forming.
material:Oneoftheprincipalparametersthatdefinethesuccessofa
roll-formingoperationisthenatureofthematerial.Inorderto
designtheoptimalprocess,thetoolingdesignershouldbe
providedmaterialinformationtobeusedpriortothetooling
designing.Thisincludesmaterialmechanicalpropertyranges,gaugetolerancesandshape
tolerances.Inaddition,differentmetalliccoatings(hot-dipgalvanizedorGALVALUME1Coated
SheetSteel),organiccoatingsorpaintwillresultindifferencesinperformanceevenwith
thesamesetoftoolingduetotheirdifferentfrictionalcharacteristics.
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