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.
April 10, 2007 | By Hanhui Li
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.
December 13, 2005 | By Hanhui Li
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.