Advantages of Sheet Metal Roll Forming Machines

Sheet metal roll forming machines can bend, crimp, and shape sheet metal into the desired cross-section. These machines help manufacturers produce large volumes of complex metal components.

A metal roll forming machine consists of a series of mated rollers that work together to create the final profile. It’s efficient and economical. It also allows for a superior surface finish that can be anodized or powder coated.

Precision

The precision of the rollers that shape the metal in a roll forming machine makes this type of fabrication an excellent option for manufacturing complex parts that require a precise, consistent cross-sectional profile. Other fabrication methods like stamping, bending and press braking are less capable of producing the same exact profile in high volumes.

The process starts with a coil of metal that gets fed through a line of consecutive forming stations, which nudge the material toward the targeted cross-sectional profile. The computer that controls the machine calculates the optimal placement of each station to achieve the desired result.

Lubrication helps reduce friction between the rolls and the metal to prevent tool wear. This allows the forming process to take place faster, which cuts energy costs. sheet metal roll forming machines The resulting smooth surfaces of completed products also eliminate the need for secondary processing steps, such as deburring and trimming flash.

The final step of a typical roll forming line is the shear that cuts the strip to its ordered length. The shear can either be a pre-cut or post-cut type. A pre-cut shear means that the strip is cut BEFORE it passes through the forming stations, which can help increase production rates and eliminates the potential for shear shear dimpling the part’s surface. This style of shear can be enhanced with hydraulic tanks to speed the machine even further for higher production rates.

Flexibility

Roll forming is a highly flexible process that allows metal to be shaped into a wide variety of shapes, even those with intricate bends. This can be done with both ferrous and non-ferrous materials. The flexibility of the machine allows for traditional downstream processes such as punching, embossing, clinching and adding thread inserts to be integrated into the process, eliminating the need for a separate station.

This also means that parts with different lengths can be run on the same line with only minor adjustments to the tooling. This is a big advantage over other processes that require multiple dies for each different length of part.

The speed of the line can be adjusted to match the needs of the project. For example, a high-speed line can be used for production of large quantities of standard parts. Alternatively, it can be run at a slower pace for projects that need to be produced in short runs.

The flexibility of the machine can also be boosted by the addition of automated systems that use CAD/CAM renderings to create new geometries. This will make it easier to produce parts for new applications and reduce the amount of time needed to rework existing parts. This can help reduce waste and increase productivity. These systems can be used to produce a wide range of variations in gauges, flange heights and web widths.

Durability

If you have a roll forming line, you can quickly produce parts without the need for a punch or cut-off machine. That saves labor and allows you to complete more units per day, which can boost sales.

Unlike some metalworking processes, the forming process does not require heating of the material, which saves energy costs. Moreover, the careful control and lubrication of moving components reduces tool wear, which cuts down on maintenance and repair costs.

Roll forming offers a superior surface finish. This makes it ideal for products that need a decorative finish, such as stainless steel. upright roll forming machine The process also reduces the need for secondary operations like sanding and deburring.

The process is not limited by the strength of the metal, which can be bent to a very large radius. However, the production rate of a forming line depends on the material thickness and number of stations or steps. For example, a line that runs metal 0.7 inches (18 mm) thick through eight stations can produce up to 85 feet (26 m) per minute.

When you choose the right equipment, you can minimize problems such as bow, camber, and twist. These problems can result in substandard precision of the later products. It is also important to keep a regular inspection schedule to prevent problems before they become worse.

Economical

It’s difficult to find a more economical way to shape ferrous and non-ferrous metals than the roll forming process. The resulting products are more uniform and consistent than other forms of shaping metal, and tolerances are tighter. These products require less machining and finishing work than other methods, which reduces both labor costs and material waste. Roll forming also produces parts and shapes with more complex and intricate cross sections than other forming processes. This allows for the creation of unique, custom-designed metal components.

Roll forming is an excellent option for high volume production. The process can produce the same part repeatedly, reducing setup time and saving money on materials. Additionally, it is one of the most efficient ways to shape metal in terms of linear footage produced per hour.

Modern roll forming lines can incorporate additional integrated processes, such as punching, cut-off, slitting, embossing, lancing welding, marking stitching and stacking and bundling. This saves even more time and money by allowing the additional steps to be completed in-line rather than using a separate machine.

This makes it easier and faster to meet high-volume demands without sacrificing quality. The ability to complete a wide variety of functions on-demand also reduces the risk of supply chain disruptions that could otherwise delay production and cost your business money. This is especially true if you choose to use a roll former that offers economic order quantity runs, which helps to maximize the value of your tooling investment.