Roll Forming Articles

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.

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Roll former cuts prototyping time

March 31, 2014

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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.

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Roll form and shine bright - TheFabricator.com

Roll form and shine bright

October 9, 2013

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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.

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Rolling, rolling, and rolling complex profiles - TheFabricator.com

Rolling, rolling, and rolling complex profiles

September 3, 2012

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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.

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Roll forming: A sometimes overlooked done-in-one process - TheFabricator.com

Roll forming: A sometimes overlooked done-in-one process

August 3, 2012

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Roll forming isn’t just for simple gutters or panels, but also for custom welded tubes. Components begin as metal coil and are formed in the rolling mill; prenotching adds the desired slots and holes; then, they are finally seam-welded. All this can be accomplished in one production process.

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What's on the horizon for roll forming? - TheFabricator.com

What's on the horizon for roll forming?

August 1, 2011

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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.

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Roll forming: In search of the perfect metal forming application - TheFabricator.com

Roll forming: In search of the perfect metal forming application

September 13, 2010

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Four processes are primarily used to form metal in industry today: extruding, press brake bending, roll forming, and stamping. Roll forming is likely the least used of all of these processes, but given the right applications, it can prove to be the most cost-effective alternative.

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roll forming fully automated adjustments

Roll forming gets flexible

December 2, 2009

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Roll forming technology has adapted to a manufacturing market that demands short runs and quick response.

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Rotary punching revisited

August 6, 2009

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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).

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roll forming multiple gauges

Roll forming multiple gauges with precision

July 8, 2009

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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.

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Magnifying Glass

Continuous improvement for roll forming - Part I

March 10, 2009

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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.

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end forming tools

Putting a few end forming basics to work

March 9, 2009

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Whether maintaining or changing the OD, knowing the basics of end forming—especially friction and lubrication—can help achieve a successful result.

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Roll forming

Continuous improvement for roll forming - Part II

March 9, 2009

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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.

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Flower diagram

Understanding bending, moving material in roll forming

September 30, 2008

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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.

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Edge treatments for roll formed parts

May 13, 2008

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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.

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roll tooling technology

Rolling to market - Part I

March 11, 2008

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For many jobs, the toughest part isn't roll forming the parts themselves—it's getting those parts to the customer. Parts are cut-to-length, then placed on immense wooden frames in such a way that allows the maximum load on a truck. That's a lot of material handling. But what if a shop eliminated the packing altogether by taking the roll forming to the job site itself?

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