The working principle of roll forming machine
Roll forming machines (or metal forming machines) manufacture specific configurations from long strips of metal, most commonly coil steel. In most applications, the cross-sectional profile required for the workpiece is designed specifically for the machine to bend the metal as needed. In addition to roll forming, these machines perform many metalworking tasks, including material cutting and roll stamping.
In most cases, the roll forming machine operates in a continuous cycle. The material is fed into the machine, where it passes continuously through each stage of operation to complete the final product.
roll forming machines bend the metal at room temperature using multiple stations in which stationary rollers both guide the metal and perform the necessary bending. Each set of rolls bends slightly more metal than the previous one as the strip passes through the roll forming machine. This progressive method of bending the metal ensures that the correct cross-section configuration is obtained while preserving the cross-sectional area of the workpiece. roll forming machines typically run at speeds of 30 to 600 feet per minute and are ideal for manufacturing large numbers of parts or very long parts.
Roll forming machines are also suitable for manufacturing precision parts that require little, if any, finishing work. In most cases, the final product has an excellent finish and very fine detail, depending on the material used to form it.
Roll forming basic knowledge and roll forming process
The basic roller forming machine has a production line that can be divided into four main sections. The first part is the entrance part of loading materials. The material is usually inserted as a sheet or fed from a continuous coil. The next section, the station roll, is where the actual rolling takes place, where the station is located, and where the metal is formed during the whole process. The station roll not only shapes metal but is the main driving force of the machine.
The next part of the basic roller forming machine is the cutting press, which cuts the metal to a predetermined length. Because of the speed at which the machine works and the fact that it is a continuous machine, flying die-cutting is not uncommon. The final section is the exit station, where finished parts leave the machine on the roller conveyor or work table and are then manually moved.
Development of roll forming machines
Today’s rolling machines are designed with computer-aided tools. By integrating the CAD/CAM system into the roll forming equation, the machine can achieve its maximum potential. Computer-controlled programming provides an internal “brain” for the roll forming machine that can catch product defects and minimize damage and waste.
In many modern rolling machines, programmable logic controllers ensure accuracy. This is critical if the part needs multiple holes or needs to be cut to a specific length. The PLC tightens tolerance levels and minimizes accuracy. Some roll formers also have laser or TIG welding capabilities. Including this option on a real machine would result in a loss of energy efficiency, but would remove an entire step in the manufacturing process.
Advantages of roll forming machine
The size of a part manufactured by roll-forming varies depending on the type of material used, the roll-forming equipment, and the practical application. Tolerances may be influenced by changes in metal thickness or width, material rebound during production, tool quality and wear, actual machine conditions, and the experience level of the operator. roll forming machines also offer some specific advantages to users. roll forming machines are energy efficient because they do not consume energy to heat the material — the metal shape at room temperature. roll forming is also an adjustable process, suitable for different time periods of the project. In addition, roll forming produces accurate, uniform parts.
Leading manufacturer of the roll forming machines
Foshan Te Xiang Machinery Co., Ltd is a China leading manufacturer of metallic processing machines, including slitting line, cut to length line, stainless steel polishing line, ERW tube mill line, roll forming machines, embossing line and etc. We grant you the best level of engineering, assembling, and commissioning. If you have any questions about roll forming or are looking for the high performance roll forming machines, please feel free to send an inquiry to contact us. We will do our best to provide you with quality service.
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