ROLL FORMING
The process of continuous
bending
MIKE, SALOUA
The process of rolling involving
the continuous bending of a long
strip of sheet metal to end up with
a desired cross-section, Is known
as roll forming.
This type of manufacturing
process involving sheet metals is
for mass production because
bending of shorter pieces
separately will not be time and
economically wise.
Hence the fabrication of a long
and defined shape then cut into
various length is the best option.
The fundamental
concepts behind roll
forming go back to
Leonardo da Vinci. The
first continuous roll
forming lines can be
traced back to the
1910s. Yet even after
all this time, many still
don’t know what roll
forming really is. It’s a
staple in certain
sectors like
automotive, aerospace,
and the metal building
industries, but to many
PRINCIPL
ES
Roll forming lines incorporate a
variety of rolls, of course, but they
also have at least one but often
several kinds of dies. Every
continuous line has a cutoff die that
cuts the final roll formed piece to
desired length if needed.
Material emerges from a coil or blank
through a precision leveler (if the
application requires it), and then into
the first stand of a roll forming line.
The upper and lower roll tools on
every stand perform a certain
amount of forming that together
The metal forms as it squeezes through the
first set of rolls, then relaxes slightly (thanks
to springback) before entering the next roll
set or forming pass. That next station forms
the piece to the next “petal” of the flower
pattern, accounting for previous springback
from the prior pass. And so the process
continues until it reaches a straightening
station, or sweep block, which eliminates or
induces camber, before being completed or
cut to length at the end of the line. The
resulting parts can be straight, curved, or
even formed into a helix pattern.
ADVANTAGES DISADVANTAGES
Due to the more gradual forming sequence, roll
forming provides tight tolerances and an Not every part or product is right
attractive finish. for roll forming. For limited runs
Roll forming is a flexible and cost-effective
and prototyping other processes
process for shaping metal into custom cross- might be suitable.
section profiles. Often called “cold roll forming,”
because the metal is shaped in its hardened Tooling can be expensive
state.
Produces end flare due to linear
Roll forming is a no-heat system — reducing
stresses on products
energy costs — that gradually bends the metal,
in stages, into its final shape by passing it Small orders are more expensive
through a series of custom-designed rollers.
Roll forming can produce much higher quality
products with tight tolerance and components
than extrusion.
Products are more uniform and consistent
STEPS OF THE ROLL FORMING PROCESS:
1. Uncoiling:
is an equipment for
unrolling the steel coils
2. Pre-press treatment:
Before the roll forming some
applications can be take place.
3. Roll forming:
the material is progressively shaped
using a roll forming machine.
4. Cutoff and discharge:
Parts are cut to length and
placed for shipment or further
processing.
THANK YOU
