Successful roll forming requires more than a roll forming line and tooling. Robust finite element analysis software, and understanding the material's yield strength and elasticity, are critical. This technology area is full of information on equipment, tooling, and simulation software.
February 1, 2017 | By Tim Heston
Many people call roll forming a black art, but David Rostocil isn’t one of them. If an operator is given the print, follows documented operating procedures, and maintains good records—and has consistent material thickness and properties to work with—the process becomes a science, one that over time can be tweaked and perfected.
October 6, 2016 | By Patrick Kitchen
Tooling is of course a significant cost driver in roll forming. But reducing costs takes more than scrutinizing the number of passes a roll formed cross section requires. It also calls for looking at the big picture and questioning the status quo.
August 25, 2015 | By Tim Heston
A new testing device uncovers the range of yield stresses in specific materials and thus helps roll forming technicians better predict how certain materials will perform.
March 31, 2014 | By Eric Lundin
Prototyping a roll formed profile doesn’t have to be done in the conventional way, with hardened tooling and short runs made from long strips of material (or coil). American Roll Form uses butt-welded strips of steel, fed into a roll former outfitted with soft tooling, to prototype roll-formed sections. It uses a few other strategies that substantially reduce prototyping cost and lead-time.
October 9, 2013 | By Tim Heston
As revenue tumbled nearly 80 percent during the downturn, OMCO’s sales team searched for new markets that could carry them through the tough times and beyond. Ultimately, they found a sector that grew faster than anyone expected. They found solar.
September 3, 2012 | By Sue Roberts
Commercial Roll Formed Products uses a 60-station, modular Dreistern roll forming line to produce highly complex profiles. A focus on producing custom parts has helped the Canadian family-run business grow to include over 30 roll form lines.
August 1, 2011 | By Dan Davis
The roll forming industry is not as straight forward as it used to be. Customers demand more sophisticated shapes and quicker turnarounds. Johnson Bros. Metal Forming, Berkeley, Ill., has rolled with the changes over the past 25 years and now sees an exciting future serving the solar equipment industry.
December 2, 2009 | By Tim Heston
Roll forming technology has adapted to a manufacturing market that demands short runs and quick response.
August 6, 2009 | By Paul Williams
New ways to increase production, reduce labor costs, and maximize floor space may be found by revisiting a 50-year old technology—rotary punching. Many part features and patterns can be punched and formed using pull-through rotary units at up to 300 feet per minute(FPM) in materials as thick as 1/16 inch. In addition, cam technology allows rotary punching and forming of material thicknesses up to 0.105 in. (12 gauge). Servo drives empower line speeds as fast as 650 (FPM).
July 8, 2009 | By George Y. Li
Compensating for gauge changes in precision roll forming doesn't necessarily require significant investment. Spaces, the use of gauge spacers, and other technique can help when roll forming parts of multiple gauges.
March 10, 2009 | By Andy Allman
Continuous improvement and statistical process control are useful, time-tested techniques—they have been used since the 1950s—but their use must be tailored to specific applications. For example, a typical manufacturing metric is parts per minute, but many roll formers should measure feet per minute. This and other tips can help roll formers accurately evaluate their productivity and measure the impact of process improvements.
March 9, 2009 | By Andy Allman
Continuous improvement and statistical process control are useful,time-tested techniques—they have been used since the 1950s—but their use must be tailored to specific applications. For example, atypical manufacturing metric is parts per minute, but many roll formers should measure feet per minute. This and other tips can help roll formers accurately evaluate their productivity and measure the impact of process improvements.
March 9, 2009 | By George Winton
Whether maintaining or changing the OD, knowing the basics of end forming—especially friction and lubrication—can help achieve a successful result.
September 30, 2008 | By Hanhui Li
Roll forming is a matter of two processes: shaping material using localized deformation with a large amount of material movement (in other words, bending and moving the material). Localized deformation (bending) is a permanent bend with a slight thickness reduction at the bending line. Material movement is a matter of relocating or rotating a section, either formed or unformed, without changing its shape. Although roll forming engineers often address these processes at the same time, it can be helpful to consider forming and movement separately.
May 13, 2008 | By Hanhui Li
According to OSHA and BLS data, safety in metal manufacturing has been improving. Workplace injuries and injury severity fell from 2000 to 2006. The biggest improvements have been in severe injuries, so minor injuries have gotten more attention lately. One such minor injury is cutting. Roll formers can do their part to prevent workplace cuts by focusing on deburring.