Overview Of Door Frame Roll Forming Machines

 

Door frame roll forming machines are equipment used to automatically bend metal coils into customized door frame profiles. This equipment is versatile, efficient, and delivers quality end products for door frame manufacturing.

 

Roll formed door frames have several benefits compared to traditional fabrication methods:

 

• More uniform profile dimensions
• Higher production rates
• Lower labor requirements
• Consistent quality and precision
• Flexibility to create custom frame designs

 

This guide will cover the working process, types, features, parameters, applications, operation, suppliers, costs, pros/cons, and FAQs about door frame roll forming lines.

 

 

How Door Frame Roll Forming Machines Work

 

The roll forming working principle involves feeding metal coil strips through a series of roller dies to shape the material incrementally into chosen frame cross-sections…

 

Types Of Door Frame Roll Formers

 

There are two main categories of lines for roll forming door frame profiles:

 

Type 1: Automatic Cut-To-Length Roll Forming Lines

 

These systems roll form the metal coil into door frame sections of fixed length as per order requirements. They incorporate a cutting unit to automatically cut profiles to customized sizes.

 

Key Components: Decoiler, guiding rolls, forming stations, cutting unit, PLC control

 

Benefits: High degree of automation, consistency, and efficiency

 

Type 2: Variable Length Roll Forming Machines

 

These roll formers produce frame profiles in continuous lengths rather than fixed sizes. They require manual cutting post-production to cut sections at desired lengths.

 

Key Components: Decoiler, forming stations, pinch rolls, manual cutting post-production

 

Benefits: Flexibility in production planning, lower cost

 

Comparison Of Roll Former Types

 

Parameter	Type 1 Cut-to-Length	Type 2 Variable Length
Automated Cutting	Yes	No, manual post-production cutting needed
Length Flexibility	Low, fixed cut sizes	High, continuous lengths produced
Process Control	High degree via PLC	Medium, manual monitoring required
Productivity	Higher, efficient inline process	Lower, additional processing step
Equipment Costs	Higher due to cutting unit	Lower without built-in cutting

 

Working Process Of Roll Forming Machines

 

The step-by-step working methodology to create door frames on these machines involves:

 

1. Material Feed

 

• Decoiler feeds metal coil strip into roll former
• Guide rolls straighten strip

 

2. Forming

 

• Sheet passes through series of roller dies
• Rollers bend strip incrementally
• Profile is gradually formed across stations

 

3. Door Frame Design and Dimension

 

• Roller dies customize frame design and dimensions
• Various cross-sections like rectangular, round, etc. achieved

 

4. Cutting (for Type 1 machines)

 

• Cutting unit sizes profiles at fixed lengths
• PLC automatically sets cut lengths

 

5. Output

 

• Formed door frames collected at the end
• Manual bundling and storage follows

 

Typical Roll Forming Line Layout

 

The major sub-systems like decoiler, forming stands with roller dies, and cutting unit (if included) are labeled.

 

 

Key Features Of Door Frame Roll Forming Equipment

 

Roll forming machines can be customized with additional capabilities to enhance automation, precision, changeovers, and monitoring.

 

Feature	Details	Benefits
Servo Feeding	Servo motors on decoiler	Accurate speed/tension control
Auto Lubrication	Automated oiling to rollers	Reduced manual maintenance
Quick Die Change	Tool-less die change parts	Faster profile changeovers
Profile Monitoring	Laser or camera inspection	Improved quality control
Touchscreen HMI	User-friendly interface	Enhanced production management
Data Logging	Tracking production metrics	Monitoring efficiency

 

Key Technical Parameters

 

Roll forming equipment have different capacity ratings and capabilities to suit production needs:

 

Parameter	Typical Range
Metal Thickness	0.15 – 1 mm
Strip Width	50 – 200 mm
Production Speed	10 – 25 m/min
Profile Width	50 – 300 mm
Cut Lengths	1000 – 6000 mm

Modern lines have a modular designs for flexibility to create small to large door frame sections by changing components.

 

Application Areas

 

Door frame roll forming technology is widely used across industries requiring metal door frames:

 

• Residential Buildings
• Commercial Spaces
• Industrial Structures
• Infrastructure Projects

 

Common materials used are:

 

• Mild Steel
• Stainless Steel
• Aluminum

 

From small homes to large warehouses, roll formed door frames provide structural integrity.

 

Choosing Right Roll Forming Machine Supplier

 

Selecting an ideal roll forming equipment partner involves:

 

Parameter	Details
Experience	Number of years providing machines
Domain Expertise	Depth of knowledge in technology
Customization	Capability to tailor lines to needs
Cost	Pricing fitting budget
Lead Time	Delivery schedules
Support	Installation, training, maintenance
Reliability	Build quality for uptime
Overall Reputation	Market trust and customer reviews

Analyze above factors thoroughly while shortlisting vendors.

 

Pros And Cons Of Roll Forming Process

 

Pros	Cons
Automated process	High initial capital expenditure
High production rates	Complex maintenance procedures
Dimensional accuracy	Lack of flexibility to profile changes
Excellent surface finish	Limited formability for certain designs
Material savings from coil inputs	Require skilled technicians for operation
Lower long term costs than fabrication	Layout space needed for equipment

 

Cost Analysis

 

Cost Component	Price Range
Equipment Purchase	$10000 – $50000
Spare Parts	$2000 per year
Installation	$1500 upwards
Energy Consumption	~$5 per hour

Total cost for the roll forming line depends on:

 

• Automation extent
• Production capacity
• Additional capabilities

 

Economies of scale apply – higher throughput lines provide lowest cost per door frame.

 

Top Door Frame Roll Forming Machine Manufacturers

 

Company	Location	Contact
Botou Xianfa	China	web: www.rollformingmachine.net
Jingxing Rollforming	China	email: info@jxrollformingmachine.com
Shanghai Metal Corporation	China	phone: +862160882528
SASCO	India	website: sascopvtltd.com
Agile Rollers	UK	phone: +44 07538 799536

The above companies provide customizable roll forming solutions catered to door frame production needs and budgets.

 

Maintenance And Operation

 

Follow standard protocols for operation and maintenance:

 

Activity	Frequency	Details
Machine Inspection	Daily	Check rollers, wires, sensors
Lubrication	Weekly	Grease bearings and pins
Safety Checks	Monthly	Ensure guards and stops working
System Upgrades	Yearly	Update software and hydraulics

Proper maintenance as per schedule improves uptime. Monitor wear on consumables like rollers for timely replacement.

 

 

FAQ

 

Q: What sheet metal thickness can be roll formed?

 

A: Standard machines handle 0.15 mm to 1 mm thickness. Higher rigidity models available for thicker sheets like 1.2 mm.

 

Q: What alloys are compatible for door frames?

 

A: Mild steel, stainless steel 304/316, aluminum 6061 are commonly roll formed alloys.

 

Q: What is the fastest production rate for lines?

 

A: High speed servo motor CNC models output ~25 meters/minute.

 

Q: What profile dimensions are possible?

 

A: 50 mm x 50 mm to 300 mm x 100 mm profiles can be produced.

 

Q: Is surface coating like powder coating possible inline?

 

A: Separate powder coating line needed after roll forming process.

 

Q: What is the lifespan for these machines?

 

A: Approximately 15 years with proper maintenance and part replacements.

 

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