Roll forming machines (or metal forming machines) are made from strips of metal (most commonly rolled steel) into a specific configuration. In most applications, the required cross-sectional profile of the part is specifically designed for the machine to bend metal as needed. In addition to roll forming, these machines perform many metalworking tasks, including material cutting and roll stamping.
Most roll forming machines work continuously. The material is sent to the machine. In the process, the material continuously enters each operation stage, and the finished product is finally completed.
Formetal Technology understands and applies common practices in the design process and combine them with a degree of "magic" gained from experience.
For each new tool requirement in a roll design, perform the following five steps:
1. Draw a cross-sectional view.
2. Calculate the estimated strip width.
3. Generate curved progress or "flower" patterns.
4. Arrange and design the rolling tools around the flowers.
5. Merge tool attachments.
How roll forming machines work
Roll forming machines use multiple workstations to bend the metal at room temperature, where the fixed rollers both guide the metal and perform the necessary bending. When the metal strip passes through the roll forming machine, each set of rolls bends the metal slightly more than the previous roll position.
This progressive method of bent metal ensures that the correct cross-sectional configuration is achieved while maintaining the cross-sectional area of the workpiece. Roll forming machines typically run at speeds of 30 to 600 feet per minute and are ideal for manufacturing large or very long parts.
Roll forming machines are also well-suited for manufacturing precision parts that require very little finishing work. In most cases, depending on the material being molded, the final product has an excellent finish and very fine details.
Development of roll forming machines
Today's roll forming machines have a computer-aided mold design. By integrating the CAD / CAM system into the roll forming equation, the machine can reach its full potential. Computer-controlled programming provides an internal "brain" to the roll forming machine to capture product defects, minimizing damage and waste.
In many modern roll forming machines, programmable logic controllers ensure accuracy. This is important if the part requires multiple holes or needs to be cut to a specific length. Programmable logic controllers tighten tolerance levels and reduce accuracy.
Some roll forming machines also have laser or TIG welding capabilities. Including this option on a real machine results in a loss of energy efficiency, but eliminates the entire step in the manufacturing process.
Roll forming machine tolerance
The dimensional change of the parts produced by roll forming depends on the type of material used, the roll forming equipment and the actual application. Tolerances may be affected by changes in metal thickness or width, springback of materials during production, tool quality and wear, actual machine conditions, and the level of operator experience.
Benefits of roll forming machines
Roll forming machines are energy efficient because they do not consume energy to heat the material (metallic shapes at room temperature).
Roll forming is also an adjustable process, suitable for projects of different durations. In addition, roll forming can produce precise, uniform parts.
