ROLL FORMING MANUAL BOOK

▷ How to Adjust Roll Forming Machine ? | Roll Forming Manual Book ◁ Roll forming is cold bending through specific stands for form sheet metal to demand profile, its continuous process and suitable for different final products length.

Each stand design to make proper change on profile. So once in stand forming we have over work or distortion and occur problem its necessary to check carefully each stand of forming not just the station that appears problem.

Based on different material behavior during roll form process, roller, and amount of station design to aim smooth and quiet roll forming operation. Furthermore, once we have noise, wrinkle, popping, and material overwork result., definitely need adjusting or basic design was not professional.

In addition its main start point for the designer to know what material going to form, in order to design effective roll forming machine the roller designer should be well aware of material information (hardness, yield, weakness, surface resistance and so on.) similarly material surface coating (galvanized or galvalume ) similarly PPGI painted coating to produce advance roll forming machine. Noteworthy for the same set of roll forming stands result will be totally different due to material frictional characters, even more designers should well aware of profile tolerance and gauge tolerance to design roller to the thicker gauge. Also using the proper amount of roll forming stands to achieve the final result with the required tolerance.

 

 

Brief Introduction for Roll Forming Machine

Setup Roller , Assembly Parts to Complete Machine

The most common way is a feeler to adjust roll forming machine the gap of up roller and down roller. engineering should change the gap when material thickness is changed.

likewise, workers should work and record bearing housing positions before moving. this can help as a work-book for workers to have easier machine maintenance and roller gap setup.

In fact, most of the roll forming machine down rollers are fixed and for changing the gap we adjust up roller by a connected screw on bearing housing.

Above all the final roller gap adjusting should be according to gears, bearing tolerance as well. For a higher roller gap will occur result in bigger radii of profile(not precise result) meanwhile sometimes material won’t move forward through stands by a bigger gap. meanwhile, once the roller gap is too tight machine will face several problems such as material marking, roller worn, and the final profile has wrinkle, twisting bow as well.

adjust roll forming machine

Inspect Roller After Setup Roller

  1. From the first tooling stand inspect up roller and down roller gap by small mirror and make sure are roller angles are alignment.
  2. Check left and right roller’s nut is tight and fixed.
  3. Bearing housing screw and up roller gap adjusting screw well fixed.
  4. Run roll forming machine without material and inspect by eyes and ears from the first stand to last. roll forming machine produced to work smooth and silent, so check bearing working noise roller turning, gears, and so on as well. As we already explained over-tightening occurs tooling worn and bearing worn.
ROLL FORMING MANUAL BOOK

Inspect Roll Forming Machine With Raw Material Inside

  • Roll forming generally design to form a panel from the center, before we put strips to feeder its highly recommended to cut two sides of strips like the picture, this will help strips feed in the center of rollers.
  • Appear deficiency on one stand: Once we occur deficiency on profile after one tolling stand should check the gapping and up roller down roller alignment. Likewise, you can stop the machine and with low speed reverse a little to check roller mark on steel for modifying center line on the roller.
  • Wrinkle, and popping, and distortion on stand: Standard roll forming machine with an experienced true designer will working without any popping or wrinkle.

So it happens for two reasons:

First: not enough tooling stand and a mistake on design. most noteworthy each roller stand has designed for forming. More than its capacity make distortion on profile.

Second: up roller and down roller gapping or centerline dis match. It needs to take material out and adjust roller and gap.

Inspect Roll Forming Machine

Torque head in Roll Forming

Torque head is a complete roller stand with final profile roller shape that not connected to any drive system (chain or gears) and roller turning by profile moving toward. Mean while the support stand for these rollers designed special that can twist up roller and down roller together with adjusted gap.

Also will install in guide line that can easily mowing up and down to fixing profile sweep. In special profile and closed type profile roll forming machine after final stand install torque head or straightening stand. For the reason that some twisting and longitudinal is still left on finished profile so by twisting back wise torque head we can make it straight back.

Conclusion for torque head roll forming

After adjusting all tooling stand gapping make sure all roller are in effective position, if any twisting –longitudinal- bow- and sweeping happen you should easily move or twist torque head stand Stand to get standard finished profile. Remember once want to modify torque head it should be with out material inside.

 

Cutting Unit Roll Forming Machine

For roll forming lines we need to cut off the unit to get requirement profile length. We have two way of cutting strips or panel:

1: pre-cutting: it’s flat blade shearing that install before forming and cut none form material to demand length.

2:shape cutting: install after forming stands, the blade is design same as profile shape, for hydraulic cutting blade or cutting saw that also saw profile after forming.

Cutting Unit Roll Forming Installation:

After material passes all roller stand and also with torque head we adjust profile twisting and longitudinal. Its time to install the cutting unit on the end of the roll forming machine, consequently to make sure cutting blade is in right position and won’t make any distortion or reflection on profile during passing profile through the blade.

 

Inspect The Finished Profile in roll forming :
  1.  TWISTING – BOW and chamber won’t clear by a small piece of the profile , From 2 pcs minimum 4 meter of profile then put it together and inspect carefully also you can turn profile and put back to back then check BOW so you will realize better.
  2. check the angle and flat parts along with the profile any wavy edge or wrinkle or wavy center then go ahead for modification.
  3. measure angle degree by bevel tools and all sides by calipers to make sure all angles are well-formed as your requirement. And each section of the panel is as same as demand drawing.
MATERIAL EFFECTS in Roll Forming 
  1. as already mentioned before start to design and produce designers care about material behavior and reflection. But sometimes by changing coil (even the same material) result from the roll forming machine will change. Its true, related to slitting processing and recoiling machine each coil of strips will behave differently. As a result should really care about material slitting processing, especially on the low gauge of galvanized material.
  2. mostly roller gapping is in the midpoint of the range of the ordered gauge tolerance. Once input material thickness extreme ends of the material gauge tolerance its necessary to change roller gap one by one with a feeler.

 

 

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