FOCUS ON ROLL FORMING
sheet steel are similar to what is seen in extruded aluminium .
“ The roll-forming process makes the creation of lighter-weight steel parts easier compared to other shaping processes , since the wall thickness can be targeted based on the structural needs of the component . Parts can be rolled , even if a finish or paint has been applied ,” added NMC .
Roll forming has applications in many industries including automotive ; appliances ; construction / architectural design ; agriculture ; HVAC ; solar and racking . It is also used extensively for the production of filter frames , fire dampers , modular constructions and LSF ( Light Steel Framing ).
Rollforming Z profiles ( image : STAM ).
The roll-forming line can bend metal ; form metal into tubes ; create metal maze-like structures and punch the metal with holes during the process
In the roll-forming process , a coil or long individual strips are fed through a roll-forming line which converts the flat sheet to a contoured cross-sectional profile .
“ The unique aspect of this approach is the use of consecutive forming stations , each of which nudges the metal towards the desired shape . Based on the targeted profile , a computer calculates the optimal placing and shape of the rollers for maximum efficiency and designs the track . The more advanced the desired shape , the more rollers the material goes through . The roll-forming line can bend metal ; form metal into tubes ; create metal maze-like structures and punch the metal with holes during the process ,” it continued .
It takes a deep knowledge of engineering to determine the order in which each bend should happen ; what needs to be underbent / overbent to account for springback and where any holes need to be punched ( so that they end up in the right place on the final profile ).
The rollers are precision-contoured metal dies that shape the incoming sheet metal . In most cases , they are also the powered drive rolls that pull the strip through the roll-forming unit . These rollers can be as simple as the cylindrical rollers used to roll luggage through airport scanners , or they can take on more intricate shapes . After the final forming station , the strip is sheared to the ordered product length . Typically , no additional work is needed before shipment since the final form has been achieved .
Additional services a roll former may offer include protective finishes , such as pre-painted or galvanized steel . This saves a secondary step in the production process .
Venetian blinds from roll-formed material ( image : DALLAN ).
Roll-formed purlin ( VLB Group ).
Roll-forming benefits
There are a variety of advantages to rollforming . Because of the “ assembly line ” efficiency of roll forming , long lengths of metal can be produced and cut in large quantities which reduces cost . Secondary processes ( such as punching or even welding ) can be integrated into a single production line . The profiles that can be produced using roll-formed
Roll-formed products for material handling
Custom roll-formed products offer a range of applications for the material handling industry , enabling the optimisation of equipment and processes for increased efficiency , durability and performance .
“ Roll forming allows for the production of complex geometries and profiles , providing the material handling industry with the design flexibility necessary to create innovative and efficient equipment and systems . By using pre-cut strips and coils , roll-forming processes reduce waste and maximise material utilisation , offering cost-effective production methods and increased sustainability ,” outlined Roller Die + Forming , a supplier of customer roll-formed products .
“ Custom roll forming is also scalable , enabling manufacturers to quickly adjust production quantities in response to changes in market demand , maintaining cost efficiency and responsiveness . Roll- forming technology also ensures tight tolerances and exceptional component quality , resulting in optimal performance and a strong return on investment for material-handling manufacturers ,” it continued .
Application examples include :
■ Racking and shelving systems : Custom roll-formed components provide the structural support and strength required for efficient and space-saving racking and shelving solutions , designed to accommodate diverse storage requirements and maximise warehouse utilisation .
■ Conveyor systems : Roll-formed components are essential to the design and function of conveyor systems , offering lightweight and durable solutions for roller tracks , support frames and guide rails . They ensure efficient movement of goods throughout the material-handling process .
ISMR December 2023 / January 2024 | ismr . net | 45