Roll forming or rollforming is an uninterrupted bending process, typically done at room temperature, in which a long strip of metal sheet or coiled steel is passed through the sets of rolls mounted on repeated stands. Each set performs an incremental part of the bend, until the required cross-section profile is achieved. Roll forming is the perfect way of generating constant-profile parts with long lengths and in large quantities. Bicycle rims, precipitator panels, door frames, fence posts, fenders, step-beam members, auto bumpers and auto trim are few example of roll formed products. Due to the heavy prices of the roll sets, computer simulation is often used to develop or validate the roll designs. Computer simulation also helps to optimize the forming process to minimize the number of stands and material anxiety in the final product. Normally, it takes about 75,000 pieces of a given part per year to validate a roll former. However, some applications can be validated with 3,000 pieces of a particular part per year.
Roll forming is quite economical and highly repeatable procedure with close tolerances on part length, width and cross-section detail. These are somebenefits of roll forming a metal part:
The processof roll forming allows the operations like punching, notching and welding to be executed in order. Manual labor cost and time for secondary operationsare decreased or eliminated. Roll form tools offer a high level of flexibility. A single set of roll form tools can make almost any length of the same cross section. Multiple sets of roll form tools for different length parts are not needed.
The process of roll forming can provide better dimensional than any other opposing metal forming processes. Repeatability is intrinsic in this procedure which allows easier gathering of roll formed parts into your finished product, and reducing the problems because of standard tolerance build up.
The process of roll forming is typically a higher speed process. Roll forming procedure provides a superior surface finish to the customers. Due to this, roll forming has become an excellent option for decorative stainless steel parts or for parts requiring a finish such as anodizing or powder coating. Also, a pattern or texture can be rolled into the surface during forming.
In compare to other competing processes, roll formed shapes can be generated with thinner walls. In compare to other competing processes, roll forming utilizes the material more efficiently.
Roll forming is quite economical and highly repeatable procedure with close tolerances on part length, width and cross-section detail. These are somebenefits of roll forming a metal part:
The processof roll forming allows the operations like punching, notching and welding to be executed in order. Manual labor cost and time for secondary operationsare decreased or eliminated. Roll form tools offer a high level of flexibility. A single set of roll form tools can make almost any length of the same cross section. Multiple sets of roll form tools for different length parts are not needed.
The process of roll forming can provide better dimensional than any other opposing metal forming processes. Repeatability is intrinsic in this procedure which allows easier gathering of roll formed parts into your finished product, and reducing the problems because of standard tolerance build up.
The process of roll forming is typically a higher speed process. Roll forming procedure provides a superior surface finish to the customers. Due to this, roll forming has become an excellent option for decorative stainless steel parts or for parts requiring a finish such as anodizing or powder coating. Also, a pattern or texture can be rolled into the surface during forming.
In compare to other competing processes, roll formed shapes can be generated with thinner walls. In compare to other competing processes, roll forming utilizes the material more efficiently.
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