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. Further more once we have noise, wrinkle , popping and material over work result., definitely need adjusting or basic design was not professional.

In addition its main start point for 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 galvalium ) similarly PPGI painted coating to produce advance roll forming machine. Noteworthy for same set of roll forming stands result will be totally different due to material frictional characters , even more designer should well aware of profile tolerance and gauge tolerance to design roller to the thicker gauge. Also using proper amount of roll forming stands to achieve final result with required tolerance.

 

 

 

Brief Introduction for Roll Forming Machine

Setup Roller , Assembly Parts to Complete Machine

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

like wise workers should work and record bearing housing position before moving. this can help as work-book  for workers to have easier machine maintenance  and roller gap setup.

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

Above all the final roller gap adjusting should be according to gears, bearing tolerance as well. For higher roller gap will occur result with bigger radii of profile(not precise result) meanwhile sometimes material wont move forward through stands by bigger gap. meanwhile once roller gap are 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 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 be 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 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 occur tooling worn and bearing worn.

 

ROLL FORMING MANUAL BOOK

Inspect Roll Forming Machine With Raw Material Inside

  • Roll forming generally design to form panel from center, before we put strips to feeder its high recommended to cut two side of strips like picture, this will help strips feed in 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 machine and with low speed reverse a little to check roller mark on steel for modify center line on roller.
  • Wrinkle,and popping,and distortion on stand : Standard roll forming machine with experienced true designer will working with out any popping or wrinkle.

So it happen by two reason :

First: not enough tooling stand and 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 center line dis match. It need 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 line we need cut off unit to get requirement profile length. We have two way for cutting strips or panel:

1: pre cutting: its 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 pass all roller stand and also with torque head we adjust profile twisting and longitudinal. Its time to install cutting unit on end of roll forming machine, consequently to make sure cutting blade is in right position and wont make any distortion or reflection on profile during passing profile through blade.

 

Inspect The Finished Profile in roll forming :
  1.  TWISTING – BOW and chamber wont clear by small piece of 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 angle and flat parts along the profile any wavy edge or wrinkle or wavy center then go ahead for modification.
  3. measure angle degree by bevel tools and all side by calipers to make sure all angles are well formed as your requirement. And each section of panel is as same as demand drawing.
MATERIAL EFFECTS in Roll Forming 
  1. as already mentioned before start to design and produce designer care about material behavior and reflection. But sometimes by changing coil (even same material) result from roll forming machine will change. Its true, related to slitting processing and recoiling machine each coil of strips will behave different. As result should really care about material slitting processing, especially on low gauge of galvanized material.
  2. mostly roller gapping is in 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 feeler.

 

 

 

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