Advantages of Roll Forming :

Advantages of Roll Forming Compared To Other Process :

  • One important of advantages of Roll Forming the roll forming process allows operations such as punching, notching, and welding to be performed in-line. Labor cost and time for secondary operations are reduced or eliminated, reducing part costs.
  • Roll form tooling allows for a high degree of flexibility. A single set of roll form tools will make almost any length of the same cross-section. Multiple sets of tools for varying length parts are not required.
  • Roll forming can provide better dimensional control than other competing metal forming processes.
  • Repeatability is inherent in the process, allowing easier assembly of roll-formed parts into your finished product, and minimizing problems due to “standard” tolerance build-up.

Advantages of roll forming relative to extrusion methods:

  • practically all metals can be roll-formed
  • roll forming can eliminate secondary operations multiple-stage operations such as notching, punching, and post-painting.
  • economically features

Roll Forming Line Process

To check the advantages of Roll Forming, we must first understand what is Roll Forming Process? Roll forming steel is essentially a continuous bending operation performed on the metal strip at room temperature. Tandem sets of rolls progressively shape the metal until the desired cross-sectional profile is achieved.

Roll forming is ideal for producing parts with long lengths or in large quantities. It can also produce parts of multiple lengths from the same tooling. Virtually any material that can be formed using sheet forming techniques can also be roll-formed. Roll forming may also be an excellent solution whenever the consistency of the cross-sectional profile is critical.

Main Benefits of Cold Roll Form Process

Roll forming has benefits & advantages over braking and extruding such as roll forming can produce more parts with more uniformity and stability all over the length of the part. High productivity rate as compared to other manufacturing processes

Able to combine multiple manufacturing operations in-line with the roll forming stations greatly reducing total manufacturing costs

Reduces handling, packaging and shipping costs

Produces parts of various lengths from the same roll sets

Able to produce parts with different hole patterns from the same roll sets

Capable of eliminating supplemental operations (e.g. cutting-to-length, drilling, splicing, etc.)

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Roll Forming Machine Basics parts and how Roll Forming Machines Work:

How do Roll Forming Machines work? All Roll forming machine in the industry has the same basic design, a roll forming machine includes:

DE COILER: to load raw material coil on that and open coil to a sheet, based on forming speed

Feeding roller and leveling: after recoiler material should be straightening and leveling before forming to has a better result from forming steps, so we add leveling station in the first part of a machine, but mostly is used for more than 1 mm thickness,

Pre-punching and marking: some of the wholes should punch before forming based on design, also upon requirement, we will add marking roller before forming stations,

Forming stations: the number of stations come from our experienced design DPT, based on thickness and shape each drawing need different forming stations number,

Torque head or final guide: in any roll forming machine last station before cutting should be torque head, to modify length twisting and turning to have a final 6-meter length in standard accuracy and shape.

Cutting or saw machine: at the end of forming machine we install the cutting system that’s hydraulic or mechanic saw, and it can be flying to make non-stop cutting, it’s up to forming machine speed and budget requirement,

Electronic cabinet: in developed manufacture such as LOTOS use PLC CONTROL to program and set machine, this is the machine brain for control and manage to punch, cutting, speed, feeding.

In LOTOSFORMING we select match HDMI, DRIVE, PLC, ENCODER with machine electronic motor to reduce PLC error as much as it can.

Rollforming Systems Machine Development:

In 2019 any roll forming manufacturer doesn’t use CAD/CAM design software cannot produce long term performance roll forming machines. roll forming design is one of the difficult machinery in the industry that definitely need CAD/CAM software to analyses and simulation steel with each station before producing. running roll forming machine nowadays most of the manufacture use PLC control to have less tolerance in final products.

So to have developed manufacture for roll forming machine, such as LOTOSFORMING, should have a great design team with enough experience on CAD/CAM software in roller drawing.

Roll Forming Tolerances and accuracy:

To compare roll forming producing tolerance with old way machinery with shearing and break machines, for sure roll forming accuracy is really much higher than any other way. during the forming station also should care about material reaction and spring back to reduce tolerance,

The advantages of Roll forming Lines Machines  

Except for benefits we explained in previous comments and posts:

  1. Roll forming is energy efficient, cause informing station we won’t use any heating during forming, most of forming machine work in normal room temperature.
  2. Also based on CNC control it also reduces worker in a factory.
  3.  Before we design roller we will calculate input material width to make waste as less as it can.

 

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Custom Roll Forming Processes

Roll Forming Process

what is mean Roll Forming Process?

Roll Forming Process is a type of rolling involving the continuous bending of a long strip of sheet metal (typically coiled steel) into the desired cross-section. Roll forming involves uncoiling a long strip of metal and sending it through several stacks of rollers set up in a long line. It is performed at room temperature, hence the moniker ‘cold’, which is often dropped. Roll forming at room temperature maintains or even improves the properties of the feedstock material. The strip passes through sets of rolls mounted on consecutive stands, each set performing only an incremental part of the bend until the desired cross-section (profile) is obtained. Roll forming is ideal for producing constant-profile parts with long lengths and in large quantities.

Cold Roll Forming Process : 

Cold Roll Forming Process is a bending process where the bending occurs gradually in several forming steps from an undeformed strip to a finished profile in roll forming machine. The process is very interesting for the sheet metal industry due to the high speed in which the profile can be produced by a roll forming machine. High strength steel has, in recent years, become more common in cold roll forming. These materials have advantages but also disadvantages that affect the design of the process. The cold roll forming process is a highly efficient process used to produce profiles for many applications, for example, vehicles, buildings, domestic machines, etc. Therefore, it’s market share is increasing every year. Many of the above products are already today made of high strength steel and the usage of these materials will likely continue to increase.

Metal Cold Forming  :

Cold Roll Forming Process, as an energy-saving and material-saving metal cold forming process, is widely used in construction, automobile, railway, aerospace, and other fields. As a kind of common metal skeleton in construction, the forming quality of C-channel steel is particularly important. However, with the shape of forming products becoming more and more complex, the requirement for forming process is becoming higher and higher. In industrial production, technicians also generally design roll flowers by the trial-and-error method, which causes a large number of human and financiallosses, and also makes cold roll forming process is still generally considered as art, not science.

Cold roll forming is a process of metal slow deformation due to its special forming length. The front part of the sheet is always formed faster than that of the back part. In cold roll forming a profile is formed in several forming steps from an undeformed strip to a finished profile. The forming process is geometrically complicated due to the fact that. the forming does not only occur in the tools but also between each forming stand. When creating the tools the tool designer must decide how many forming steps the profile demands. The number of steps is dependent on the shape of the cross-section, tolerance, thickness and material properties. It is important to minimize the number of steps as this reduces the cost of the cold roll forming machine. Then the process can be a competitive alternative also for smaller production volumes. Therefore the knowledge of how high strength steel affects the number of forming steps is important.

Rolled Steel :

Cold Rolled Steel is steel which has been rolled at room temperature, below its recrystallization temperature. This increases its strength and hardness and decreases its ductility. In addition to the improvement of mechanical properties, cold rolling results in more control over the shape and dimensions of the finished product. Cold Rolled steel has an improved surface finish and tighter tolerances compared to hot rolled steel. It is commonly used for parts requiring cold forming, such as crimping, swaging or bending. It can also be used for Shafts, machinery parts, bolts, pinions, gears, as well as in the creation of furniture, appliances and other consumer goods. Cold Rolled Steel can be purchased online and at any Metal Supermarkets location. It can be cut to your exact specifications.

YOU CAN SEE THIS VIDEO FOR ACCESS MORE INFORMATION :

 

 

Roll forming

Roll forming

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