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Rolling, rolling, and rolling complex profiles
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
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...
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What's on the horizon for roll forming?
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...
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Roll forming: In search of the perfect metal forming application
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...
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Roll forming gets flexible
Roll forming technology has adapted to a manufacturing market that demands short runs and quick response.
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Rotary punching revisited
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...
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Roll forming multiple gauges with precision
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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Continuous improvement for roll forming - Part I
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...
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Continuous improvement for roll forming - Part II
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...
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Putting a few end forming basics to work
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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Understanding bending, moving material in roll forming
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...
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Edge treatments for roll formed parts
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...
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Rolling to market - Part I
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...
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Surveying suitability of resistance welding for roll formed parts
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,...
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Roll form tooling design for air bending
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?
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
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...
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Surveying suitability of welding processes for roll formed parts
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,...
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Stud-maker throws church building a curve
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...
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Roll forming using spring-loaded top rolls
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...
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Improving roll forming productivity of roofing components
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...
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End distortion on roll formed parts
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?
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,...
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A good start makes a difference
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...
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Roll forming basics
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...
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Worn out roll forming tooling and no drawings?
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,...
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How important is roll forming lubrication compatibility?
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...
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Roll formers look for a win
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,...
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Advanced roll forming troubleshooting
When troubleshooting a roll forming operation, you first need to make sure the roll form tooling is designed and built properly and will produce a quality product when all the conditions are correct.
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Working with your people
If people are your most precious resource, why aren't you spending more money to train them properly?
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Examining roll forming machinery, tooling, and lubrication
Given the problems in your roll forming operation aren't attributable to material, you may want to look into machinery setup and especially your lubrication situation to uncover the real culprit.
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Material—Is it always a problem?
If the problem with your roll forming operation lies in your material, here are some tips in getting to the heart of the problem.
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Exploring the roll forming process
If trying to improve your roll forming operation, look at the four M's -- machine, materials, manpower, and method. Those four areas hold the key to whatever may ail you.
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How important is sheet and plate steel flatness?
This article examines flatness of steel, discussing the outcome of combining temper passing and leveling in the same line. It also provides the outcomes of experimentation on steel that has been leveled, temper passed, and both. Furthermore, it...
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Selecting the right materials for roll forming—Part 2
This is the second part of a two-part article. Read Part I . If you examine the mechanical properties of several materials, including carbon steel, alloyed steel, stainless steel, as they relate to roll forming, you'll gain an understanding of...
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Selecting the right materials for roll forming—Part 1
This is the first part of a two-part article. Read Part II .If you >examine the mechanical properties of several materials, including carbon steel, alloyed steel, stainless steel, as they relate to roll forming, you'll gain an understanding of...
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Mill coolant system design
What kind of coolant system you construct for your tube mill or roll forming operation is just as important as what type of coolant you use.
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