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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Rollforming high frequency roll tools

Surveying suitability of resistance welding for roll formed parts

December 11, 2007

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Of the many weld processes used, resistance, high frequency and fusion welding are the most likely to be integrated with roll forming. Welding processes that are integrated with roll forming include GTAW, fusion, plasma arc welding, laser welding, resistance welding, and high-frequency welding. The fusion weld processes most successfully integrated with rollforming are those that are fast and don't require a filler metal.

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Roll form tooling design for air bending

April 10, 2007

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Several techniques are used commonly to reduce profile distortion when air bending with a roll former. These include small-radius forming, false bending, vertical side rolls, and angle side rolls.

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Is metal roofing fabrication right for your shop?

April 10, 2007

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When deciding whether to produce roofing panels, you need to determine your ROI, based on if you can use existing equipment or need new equipment, the required panel appearance; possible line configuration; and material handling options.

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Meeting the Standard

January 9, 2007

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Using old roll forming technology is one thing, but it's another to use or buy equipment that does not have essential features that now are considered standard. Learn which five features must be included in roll forming equipment and why they simplify manufacturing.

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Surveying suitability of welding processes for roll formed parts

December 12, 2006

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Of the many weld processes used, resistance, high frequency and fusion welding are the most likely to be integrated with roll forming. Welding processes that are integrated with roll forming include GTAW, fusion, plasma arc welding, laser welding, resistance welding, and high-frequency welding. The fusion weld processes most successfully integrated with rollforming are those that are fast and don't require a filler metal.

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Stud-maker throws church building a curve

September 12, 2006

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Radius Track, a fabricator specializing in its patented curved metal studs, replaced many of the heavy-gauge beams in the a church's dome frame with light-gauge steel studs. As a result, the dome was light enough to be supported without view-obstructing columns.

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Roll forming using spring-loaded top rolls

July 11, 2006

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For certain sheet metal applications, roll forming with spring-loaded top rolls is a practical production method. This article explains the process, describes various machine configurations, and outlines the criteria for suitable applications. It also discusses product requirements that are incompatible with this process.

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Improving roll forming productivity of roofing components

May 9, 2006

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Roll forming of roofing components for the pre-engineered building and component industries presents unique challenges for manufacturers. Tighter profile tolerances, wider product ranges, and compressed lead times present production challenges for producers running older equipment or those contemplating a move into this market. Some developments in equipment and processes that are important to producing secondary structural members include quick-change roll form tooling systems and tooling that can improve the productivity of roofing components- Cee's, Zee's, Eave Struts, Channel, and Base Angle.

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End distortion on roll formed parts

December 13, 2005

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Roll-formed parts are subject to end distortion when the parts are cut at the end of the roll-forming line. Understanding the forces that contribute to end distortion is the first step to balancing the forces and eliminating end distortion.

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In the loop on closed-loop roll forming?

December 13, 2005

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In roll forming, non-stop punching and shear systems have traditionally employed simple open-loop control methods. Closed-loop (also called servo-based) systems can overcome many limitations of the open-loop design and yield higher line speeds, reduce downtime, and reduce scrap.

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A good start makes a difference

March 8, 2005

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Understanding the relationship between the elevation of the entrance guide and the shape of the roll formed strip is crucial to satisfactory roll forming. The entance guide elevation, if improperly set, can cause the strip to bow and twist as it leaves the first forming pass. Setting the elevation properly can help to eliminate additional stress and strain at the strip edges that cause bow and twist.

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Roll forming basics

January 11, 2005

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Roll forming, often called open-section forming, uses successive sets of roller dies to bend a strip of steel progressively until the desired shape is achieved. This process is very similar to traditional tube- and pipemaking, but differs in that it can form more complicated sections.

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Worn out roll forming tooling and no drawings?

March 25, 2004

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You may have found yourself saying, "I need to make an engineering change to my roll form tooling, but I don't have the roll tooling designs or drawings." When you are faced with this situation you will have to start at the beginning, basically, and reverse-engineer the complete set of roll form tooling.

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How important is roll forming lubrication compatibility?

September 25, 2003

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At first glance, it doesn't seem that the compatibility of the lubricant used in the roll forming process needs much attention. You'd better look again. It may surprise you that the chemical and physical properties of the roll forming lubricant leave fingerprints in at least six different areas of the operation.

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Roll formers look for a win

September 25, 2003

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Many systems enable users to download a DXF drawing directly into the roll forming line's computer.Not everyone can be the New York Yankees, or even the roll forming version—especially in today's economic climate.It would be nice, though. The Bronx Bombers have used a fat wallet and keen scouting...

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