The Advantages of Steel Roll Formers
Roll forming transforms long coils of metal into complex, engineered profiles. It does not require heating the metal and is more energy efficient than other processes.
Forming is a highly automated process with minimal human monitoring, which lowers labor costs. Punch applications can be added to the line for notching, hole punching and slitting.
Cost-Effective
The continuous nature of a roll forming line allows for high volume production at lower costs. It also reduces waste by making the most out of each piece of metal that is fed into the machine. This process can be used to make drywall and metal ceilings, roofing materials, steel roll formers tubing and pipes, electrical cable trays, solar panel support bars, metal furniture, rolling shutters, doors and more. The versatility of the roll forming process makes it suitable for ferrous and non-ferrous metals. Traditional downstream processes like punching, clinching, notching and embossing can be integrated into the roll forming dies, eliminating secondary operations.
The cost of raw materials is one of the biggest factors in determining your production costs. Dahlstrom closely monitors world metal markets to ensure our customers receive the best possible price on their materials. We can even provide material in bulk to help lower the overall cost per pound for our customers.
Another factor that contributes to the cost-effectiveness of the custom steel roll forming process is the low tooling costs associated with this manufacturing technique. While some processes like stamping require costly bending tools, most of the components made with a custom metal roll former have no length restrictions at all. This eliminates the need for expensive secondary processing and saves on logistics, handling, and warehouse storage costs.
Fast Production
Using long coils of metal that are rapidly fed into the roll forming machine, this process is very fast. This helps the manufacturer to produce large quantities of metal parts, reducing the cost for both them and their clients. It also helps to reduce wasteful stoppage time and runoff. It is an extremely sustainable manufacturing process.
To speed up the process even more, manufacturers often use a precut shear to cut the metal BEFORE it goes through the machine. This eliminates the need for a worker to manually change the tooling from one profile to another, which could take time and reduce efficiency. It also removes the possibility for human error.
The shear can be built to include additional applications, such as punching and notching, which can further reduce the weight of the finished product. It can also cut the material to precise lengths, speeding up the process and reducing the number of steps needed for finishing.
Adding these features to the shear also cuts down on the time needed for a worker to manually change the tools, which reduces labor costs. It can also lower the amount of wear on the tooling, which can make it last longer and increase the quality of the final product. A pre-punch application can be added to the shear as well, which prevents holes from leaking and creates more uniform results.
Customization
Roll forming is a continuous bending operation that is well-suited to custom and standard metal shapes. It is highly flexible and provides tight cross sections with minimal scrap, and it is faster and more cost-effective than stamping and press braking. It can also produce more complex parts and shapes without the need for secondary machining or finishing processes.
Because the material is fed into the machine in coil form, it requires less manual involvement than other metal-forming methods. This increases production efficiency, reduces operational costs and leads to higher profitability. Moreover, since the metal is shaped continuously, it eliminates the need for multiple retooling cycles that are necessary in other processes, such as punching and laser welding. It is also capable of integrating traditional downstream processes such as embossing, clinching and thread inserts into the manufacturing process.
Moreover, the use of the cold roll forming method allows the manufacturer to save money on the raw materials used in the process. This is because the material can be formed in its entirety – there is no waste. This applies especially to the more expensive metals such as copper, bronze and stainless steel, which can account for up to 80% of total costs in the product.
Another way to reduce raw materials costs is to work with a custom metal fabrication company that offers vendor-managed inventory (VMI). This system is based on just-in-time delivery and pull system concepts, and it automates trigger information from the point of use to the supplier, who then reacts by replenishing stock to a preset quantity. This minimizes waste and costs and ensures that your products meet your specifications.
Durability
Using a steel roll former means that panels can be made to specific lengths and shapes. This allows contractors to match a project’s specifications exactly. It also helps them to avoid unforeseen delays, which can jeopardize a deadline and damage a company’s reputation.
Another benefit of using a metal roll forming machine is its durability. A durable machine is able to handle large quantities of high-strength alloyed steel, which can be difficult to work with. It can also withstand harsh environments and extreme weather conditions.
Additionally, a durable metal roll forming machine can reduce changeover times. Depending on the type of profile and the number of raft sets, experienced professionals can switch from one set to the next in 30 to 45 minutes versus hours or small roll forming machine days. This allows a production line to keep running at full speed without slowing down or stopping for lengthy periods of time.
A good durable roll forming machine can also help improve productivity by adding integrated processes to the forming process. This can include punching, cut-off, slitting embossing, lancing welding, part marking stitching, wing bending and stacking. Some of these secondary operations can eliminate the need for a separate cutting or stamping line. However, the addition of these additional processes will increase upfront capital costs. Also, the quality of coil can impact output. Poor quality coil may result in unforeseen issues like oil canning, expansion and contraction and unbalanced release of stress.
