What Is a Roll Forming Line Machine?

A roll forming line machine is capable of working with a wide range of materials. However, compatibility with specialized or exotic materials may require customization and incur additional costs.

Metal coils enter the line from an uncoiler and are fed into an accumulator, which can quickly replace a coiled material without stopping the process. This automation reduces downtime and improves quality control.

What is a roll forming line?

Roll forming lines transform coils of flat metal into a contoured cross-sectional profile. This profile could be straight, curved, or even twisted into a helix. The line might also punch the metal or cut it into sections. These operations might take place before or between forming stations, depending on the desired shape and material thickness.

Unlike other metalworking processes like stamping and press brake forming, which heat the material to high temperatures, roll forming involves cold forming at lower temperatures. This reduces production costs. However, a metal manufacturer must consider labor content when choosing the right line size for their project.

A typical line houses between 10 and 24 pairs of roller die stands that nudge the metal towards its final form. The number of forming stations increases with the complexity of the part. The lines can also include a flying cutoff machine to automatically cut the part to its final length without stopping the forming process.

Like other forming processes, roll forming induces stresses into the metal. These stresses can lead to distortion, including end flare, a condition that causes the leading and trailing edges of a formed part to bow inwards. A good metal forming engineer anticipates this problem with a combination of design and maintenance. They might, for example, position holes away from the bend radius and use a slug evacuation system under dies to help minimize end flare.

The forming process

A roll forming line transforms flat metal into a contoured cross-sectional profile. To do this, the material goes through a series of consecutive rollers or stands that each nudge it closer to the desired shape. This process, called forming, is what makes it possible for the roll forming machine to fabricate such diverse parts as door panels, metal roofing sheets, steel drawers, and automotive frames.

The front-end equipment prepares the metal coils for forming by removing any lingering slack or “coil set.” Then, they’re fed into the uncoiler by floor or pit-mounted coil cars, opened and flattened to remove coil set, and the lead end trimmed.

During the forming process, computer software helps set up the optimum sequence of rolls for a particular profile. This includes accounting for springback, an angular change that occurs roll forming line machine when the forming pressure increases. To avoid it, the number of forming stands should be carefully matched to the steel’s tensile strength and bend radius.

Once the forming is complete, the final shape is cut to length in a flying cutoff press without stopping the roll forming process. The line may also incorporate secondary operations, such as punching or notching, to further customize the finished part. Finally, a straightener can help eliminate lingering bow, camber, or twist in the finished product by applying pressure to the sheet.

The line’s main components

A roll forming line can cut, punch, and form metal to create complex cross-sectional shapes that contribute to products like drywall profiles, door panels, roof shingles, metal ceilings, racking systems, metal furniture, tubes and pipes, cable trays, and much more. The line can also provide a variety of in-line secondary services, such as welding or punching. It can also add features such as holes to a profile at either the front or back end of the line, depending on your needs and the shape you want.

The process works by coaxing a flat strip or coil into its desired shape through consecutive sets of mated rollers that incrementally change the metal’s form. The final result is a complex, engineered profile that’s difficult to achieve using any other method.

Once the piece reaches the desired length, it enters a cutting press that cuts the metal to its specific length. After this, it runs through a series of straightening dies and rollers to correct any twists, bows, or cambers in the metal. A worker then retrieves the finished component from a conveyor system, where it can be prepared for additional processing or storage.

Depending on your product’s needs, the line can also incorporate a variety of in-line secondary processes to streamline production and reduce costs. pipe roll forming machine The most common include shears, punches, bending devices, and cut off presses. The equipment can also be used to trim, anodize, and detail the profile before it is finished and cut to its final length.

Maintenance

A roll forming line must be regularly maintained to operate at an optimal level. This includes routine inspections, lubrication, and cleaning. Routine maintenance can also help to identify potential issues and address them before they become costly breakdowns or production problems.

It is important to keep your machine clean and free of debris and metal shavings to prevent damage. You should also lubricate the machine’s moving parts to reduce friction and extend their lifespan. This can be done with a spray of lubricant or by using a coolant that has an additive to prevent the growth of bacteria and to protect the seals on your equipment.

The type of material you use in your machine will also affect its condition. For example, if you are using Class A or prepainted material, any contamination will show up in your finished product. The same is true for airborne particles that can get into the workings of your line and interrupt its function.

Finally, it is important to regularly update your machinery as the industry changes. Failure to do so can result in outdated machinery and a decreased production output or lower quality products. These inefficiencies can impact your business and profitability, so if your current machine is reaching the end of its lifespan, it may be time to consider upgrading to a new one.