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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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