The basics of roll form tooling design

we want to teach you something that none of the companies in the world ever teach you!
we want to step by step teach you how to design a forming machine. each new tooling requirement in a roll form design, take the following five steps:

1. Develop a cross-sectional drawing.
2. Calculate the estimated strip width.
3. Produce a bend progression, or “flower” pattern
4. Layout and design the roll tooling around the flower.
5. Incorporate tooling accessories

Roll Forming Design Guide

Before delving into the design of roll-forming rollers, it is essential to understand the basics of roll form design. Roll forming is a continuous process that involves feeding a metal sheet through a series of rollers. Each roller in the series gradually bends and shapes the metal into the desired form. The final shape is achieved by the cumulative effect of the rollers.

Develop a cross-sectional drawing

The roll forming design process begins with a cross-sectional drawing. that serves as a kind of blueprint of what your profile’s shape and dimensions should be. On the drawing, you should note each bend’s radius and arc length, straight lengths, and material thicknesses.

step 1


Step 2


Calculate the estimated strip width

for calculating the strip width of the profile you should Use the proper “K” factor or “Bend Allowance” which is the main item.
Various factors contribute to the bend allowance, such as material type, material yield strength, profile characteristics, and roll design techniques.

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