Roll forming machine is a continuous forming operation in which a long stripe of sheet metal is passed through sets of roll tools mount on following stands, each set performing only an incremental part of the forming, until the preferred cross-section profile is obtained. Roll forming machine is perfect for manufacturing Different kind of profile like (roofing type, c to z type, ceiling channel type, u type and much more ) with long lengths and in large quantity.
Roll formed Machine may have compensation over extrusions of a similar profiles. Roll forming machine parts may be much lighter, with thinner walls possible than in the extrusion forming process, and stronger, having been work hardened in a cold state
Roll Forming Machine Parts
Roll forming Machine can be set up with multiple configurations to punch and cut off parts in a constant operation. For cutting a part to length, the forming lines can be set up to use a pre-cut die where a single blank runs through the roll mill, or a post-cut die where the profile is stop after the roll forming machine process. Features may be added in a hole, cut, embossment, or shearing form by punch in a roll forming machine. These part features can be done in a pre-punch application (before roll forming starts), in a mid-line punching application (in the middle of a roll forming line/process) or a post punching purpose (after roll forming is done). Some roll forming machine incorporate only one of the above punch or cutoff application, other.
Roll Forming Machine Process
The process of roll forming is one of the simpler industrialized processes. It typically begins with a large coil of sheet metal, between 1 in. and 20in. in width, and 0.004 in. and 0.125 in. thick, supported on a Decoiler. The strip is fed during an entry guide to properly align the material as it passes through the rolls of the mill, each set of rolls forming machine a bending until the material reach its preferred shape. Roll tools are normally mounted one over the other on a pair of horizontal shafts supported by a Roll Forming structure. Side roll tool and cluster roll tools may also be used to provide greater accuracy and flexibility and to limit stress on the material. The shaped strips can be cut to length line ahead of a roll forming machine, between mills, or at the end of the roll forming machine.
The manufacture rate depends greatly on the material width and the bending radius; it is also affected by the number of stations or steps required. For bend radii of 50 times the material thickness of a low carbon steel .07 in thick can range from 85 feet per minute through 8 roll forming machine stations to 55 feet per minute through 12 roll forming machine stations or 50 feet per minute through 22 roll forming machine stations.