Roll Forming Machine (Design & Build Guide)
Roll Forming Machine is a processing machine that passes rolled steel or other long strips of metal through a series of Hardened Steel Rollers, which are controlled using a pre-set PLC code, to achieve a specific processing operation on the sheet metal at each station to produce a specific metal part. It is characterised by high progress, high speed, low scrap and one-off forming. It is therefore a very economical way of processing and is often used for the processing of large quantities of parts.
Note: The Roller, also known as a station, is a mechanical component used to process sheet metal, which is gradually bent as the sheet metal is processed between the roller, in conjunction with multiple rollers operating in steps to obtain the required shape of part.
Design guide for roller forming machines
As mentioned above, the Roll Forming Machine process involves feeding the sheet metal into the forming machine and forming the sheet by means of hardened steel rollers. In the case of coil production, the Sheet Metal Decoiler series is required to assist with the loading, straightening and cutting operations to increase the efficiency of the forming machine. For different customised requirements such as additional functions such as punching, slotting, notching and labelling, then we recommend adding a punching machine or other equipment. Therefore, we have compiled a list of relevant factors that influence the design of the machine for different needs, to help you choose the most reasonable Roll Forming Machine.
1. Material thickness
Generally speaking, the thickness of the material used varies and so does the diameter of the rollers, so we need to adjust the diameter and spacing of the rollers according to the thickness of the material. We can accommodate material thicknesses in the range of 0.012″ to 0.200″.
2. Material type
Roll Forming Machines are generally used to machine mild steel. However, there are some special parts that require the use of higher strength materials (stainless steel, structural steel, HSLA steel, etc.) for the processing of parts. These materials are often stronger and harder and therefore require more machining steps and higher cutting forces at the end.
3. Component size
The size of the component is also an important factor for the Roll Forming Machine to be able to process properly. Generally speaking, as the size of the component increases, so does the number of rollers required to carry out the construction process.
4. How complex are the components?
The most complex part of Roll Forming is the bending of the sheet, which is generally done at 90° or 180°. As the number of bends and angles increases, so does the number of Roll Forming operations and the number of rollers required, which is an important factor directly related to your costs.
Roll Forming Machine General Applications
The roller forming machine processes sheet metal in multiple stations to form open or closed metal parts. It is an operating mode that is often used to machine basic parts. It is therefore used in a wide range of industries: aerospace, marine, automotive, commercial construction, road construction and many others. It is by far the most economical mode of machining parts.
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