The Versatility of a Rolling Forming Machine
Roll forming is a metal forming process that can produce complex, precise parts. It uses consecutive sets of mated rolls to shape sheet metal into an engineered profile.
Each manufacturer has its own version of a rolling forming machine, but they all share some basic steps. These steps begin with a coil of raw material that is fed into the machine.
Cost-Effectiveness
Roll forming is a cost-effective manufacturing process that produces accurate parts for various applications. rolling forming machine It can create closed and open metal profiles for a variety of purposes, including highway guardrails, roof systems, walls for industrial plants, door frames, purlins, and more. It also works well with a wide range of materials. In addition, it requires less labor than other manufacturing processes such as press braking and stamping.
The process uses long coils of metal that are quickly fed into the machine and shaped to form the desired shape. Moreover, the material does not need to be heated during the forming process, which significantly lowers energy costs. Moreover, the machine eliminates the need for secondary processes, such as punching and notching, which saves time and labor. Additionally, the process provides an excellent finish that reduces the need for field cutting, reducing the overall cost of the finished product.
To further improve productivity, a roll forming machine can be integrated with the business’s ERP system to allow incoming orders to be automatically scheduled for production. This feature can help businesses save on the time it takes to manually load coils and enter the required data into the system. The system can also automate the feeding of the metal into the forming process, which makes the entire operation more efficient.
Versatility
The versatility of a rolling forming machine allows it to fabricate a variety of different metal products. It starts with long strips of metal, most often coiled steel, and transforms it into the exact configuration required by an end product. The process can produce complex, intricate cross-section profiles, and can even create fully enclosed elongated shapes. It can also be used with a wide range of ferrous and nonferrous metals.
The main component of a roll forming machine is the mated roller die sets, which are designed to shape the metal as it passes through each set. Each set performs an incremental part of the bending, and the workpiece is shaped into its final form as it goes through each station. The resulting elongated metal is then cut to the proper length and discharged to the run-out table. Secondary processes such as holes and slots can be added at this stage if necessary.
The programmable logic controller (PLC) is the computer that controls the machine. It is similar to a CNC, and can be programmed to automatically perform the correct sequence of commands to achieve the desired result. For example, if a piece of metal needs to be cut to a certain length, the PLC can be programmed to execute this command while the workpiece is in motion, saving time and effort.
Accuracy
Roll forming is a highly accurate process that can produce long sections of metal in a repeatable manner. It is a cost-effective method for shaping metal into various forms that were traditionally accomplished by other methods such as forging, casting, stamping, and machining. It is also energy efficient because it does not require a lot of heat to shape the metal, which reduces overall production costs.
When used correctly, the machine can hold tolerances of up to +/- 0.005” on certain profile segments and +/- 0.020” in length. However, this precision is dependent on the manufacturer’s knowledge of the quirks rolling forming machine of the process. For example, it can cause end flare and springback of the metal, so the manufacturer must understand how to compensate for these distortions.
In addition to its high accuracy, the machine can produce complex shapes that are difficult to manufacture by other means. It can be used to create structural building components, studs, supports, angles, and C-channels. It can also be used to fabricate rigid, high-strength metal building components.
While a roll-forming machine is relatively easy to operate, it requires maintenance and regular adjustments to ensure optimal performance. For example, lubrication is essential for reducing the friction between the feed rolls and the strip of metal, which can affect accuracy. It also prevents excessive wear of the roller dies and other parts in the system, which can affect accuracy and reduce the life of the equipment.
Flexibility
A rolling forming machine fabricates specific configurations out of long strips of metal, most often coiled steel. The machine bends the metal into a desired cross-section profile, resulting in rigid parts that can be formed to precise dimensions with minimal finishing work, such as welding or punching. The process also limits stress on the metal. It is possible to form a wide range of shapes, from simple rectangular angles to complex C-channels, hat channels, and supports.
A roll forming machine works continuously as the steel is fed into the machine and shaped by rollers. The first set of rolls produces a flat strip that is then passed to successively larger sets of rollers. Each successive set of rolls adds a small amount of bending to the strip. The resulting shapes are designed using a flower pattern, which identifies each of the incremental bends. Each bending station can perform a variety of different shapes, with some machines capable of producing a large number of unique profiles in a single pass.
Most modern roll forming machines are equipped with programmable logic controllers, which can control a large number of operations at once. This technology improves dimensional accuracy and adherence to tolerance levels, which reduces manufacturing costs. In addition, it also allows the machine to automatically catch any product imperfections that could cause damage or waste.