Eaching Machinery Equipment Limited is a leader in professional roll forming solutions. Specializing in customized roll forming machinery, parts, and accessories. Working with a team of professional engineers we work together to provide the best service to our customers. Roll forming involves a continuous process by which the metal sheet is fed into sets of mated rollers, each of which makes only incremental variations in the form. The product of these incremental variations forms a complex profile. Rollers are thoroughly arranged using a flower pattern, which recognizes the consecutive changes to the metal sheet. The shape of each roller is generated from the individual sections of the flower pattern.
Why Roll Forming: Benefits and Advantages
1. Efficiency
Due to technology innovation and modernization, most of the roll forming machines are self-feeding, and the need for human monitoring is minimized, and the cost of labor is lowered. Pre-press treatment, during the pre-feeding, limits the need for secondary operations. Normally, the speed of roll forming is caused by the long coils of metal directly coupled and fed into a forming machine.
2. Quality
Products created have extremely precise dimensions. They have an acceptable tolerance, clean curves, forms, and edges are maintained with the absence of deformities. In conclusion, products are uniform and precise in a complete run.
3. Flexibility
In manufacturing complicated and complex cross-sections, ferrous and non-ferrous metals are being used. Painted or other types of coating alterations are not possible in some roll forming process. However, roll forming is capable of shaping them regardless of the type of finish.
4. Length of parts
In roll forming machines, any desired length can be attained or produced using the same tooling for any part.
5. Minimal Part scrappages
Minimal part scrappage is produced in the roll forming process. In each production run, only 1- 3% of scrappages are produced, which is far less than any other metalworking process. In this case, it lowers the cost of working with expensive materials.
6. Cost-effective
The roll forming process does not require a heating process, which drastically lowers power consumption. Regular monitoring and proper maintenance of all the machine components reduce machine wear and the cost of machine part replacement. In some of the roll forming processes, finished products are already smooth, and the need for secondary processes such as deburring and trimming is unnecessary.
7. Process repeatability
In bending metals, there are many complications manufacturers have to face, especially residual stress, which negatively affects the repeatability process. The quick process of roll forming helps metals keep their residual stress.
Roll forming Machinery Technical advances
Computer-Aided Design
In designing roll forming patterns, the process requires three engineering concepts: Geometry, Length, and the type of material to be used. The designs generated in CAD/CAM can be simply transferred to CNC programming.
Geometry – Several roll forming designs are too complex; CAD can reduce the complexity and convert parts into a sole structure. Some simple components can be merged to form a single complex shape.
Length – Roll forming is very suitable for long length with high production runs. Stamped and press brake parts can be easily converted to roll forming using CAD programming, making the whole process easier.
Type of Material – CAD can detect metal appropriateness without having to make a production run or prototype.
Computer Numerically control
They are commonly known as “CNC,” where the design from a computer (using software, CAMs) is attached to the CNC machine. The computer converts the design into numerical code that controls how the CNC machine cuts and shapes the material.
CNC is capable of controlling automatic tools, equipment, and rollers. They are responsible for machine operations and can be programmed with specific patterns with high precision.
CNC roll forming machines can be adjusted without the alteration of tools. Measurements can continuously be changed, including irregular or non-symmetrical ones as well as sheet thickness changes.
Automation and Programmable logic control
Just like in CNC, PLC also uses a computer. PLCs are specialized computing systems used to control machines and their processes. It uses programmable memory to store procedures, instructions, and functions that include on/Off Control, timing, and other necessary functions. In PLCs, the more complex the required process, the more command input will be programmed, especially in the press treatment process.
TIG welding and lasers
Tungsten inert gas welding uses a non-consumable tungsten electrode to create a weld in a roll-formed shape. As the roll-formed exits from the machine rollers, and before the cutting process, roll-formed automatically welded by either a laser or TIG welder. The radii of the roll-formed must be precise.
