Roll Forming Machine Parts

 

Roll forming is a metal working process in which sheet metal is progressively shaped through a series of roller dies until the desired cross-sectional profile is obtained. It is an efficient and cost-effective way to manufacture parts with long profiles and uniform cross-sections.

 

Roll formed parts are used across industries like auto, rail, infrastructure, appliances, furniture, storage, etc. Common examples include roofing panels, door frames, racking systems, highway signage, electronic enclosures and more.

 

This article provides a comprehensive guide on roll forming machine parts, working, configuration options, suppliers, prices, pros/cons and tips for selection.

 

Overview Of Roll Forming Process Parts

 

The main sections of a roll forming machine are:

 

• Material Handling
• Forming Stations
• Cutoff
• Exit Conveyor

 

Table 1: Key Sections of a Roll Forming Machine

 

Section	Components	Function
Material Handling	Uncoiler, Feed Table, Entry Guide	Hold coil stock, straighten sheet, feed into machine at constant speed/tension
Forming Stations	Roller Stands, Rollers, Gears	Progressively cold form sheet metal through series of stands
Cutoff	Shear, hydraulics	Slice formed profile to desired length
Exit Conveyor	Belts, motors, supports	Transport finished parts out of the machine

The forming section is the heart of the machine. It houses a series of roller dies progressions mounted on stands through which the material passes. Each stand incrementally forms the profile closer to the final shape.

 

The number of stands varies based on part complexity – from as few as 3 stands for simple geometries to over 20 stands for complex parts.

 

 

Roll Forming Machine Types

 

Roll forming machines are available in different configurations based on production needs:

 

Table 2: Roll Forming Machine Types

 

Type	Description	Typical Use Cases
In-line	Uncoiler is in-line with forming and cutoff sections	High volume long production runs
Reversable	Sheet reversing mechanism allows return to forming section	Short production runs, requires part flipping
Portable	Compact design on lockable castors	Small batches, on-site production
Custom	Tailored to specific custom part geometry	Low volume proprietary profiles

 

Working Principle

 

The working stages in roll forming from flat sheet to finished part are:

 

Straightening – The unwinding metal strip often has residual stresses and coils set from previous processes. So the first step is to straighten these imperfections using an entry guide and feed rolls.

 

Feeding – The straightened strip enters the forming section at a constant speed and tension regulated by servo feed rolls.

 

Progressive Cold Forming – As the material passes through the series of roller die stands, each stand induces more bending until the final cross-section is obtained.

 

Cutoff – After the profile is fully formed, the cutoff press shears it to the desired finished part length.

 

Exit – The finished part of transferred onto the exit conveyor for bundling and storage.

 

Key Aspects Of Roll Forming Machine Parts

 

Material Feeding

 

The material feeding components handle and prepare the raw coil stock before roll forming:

 

Table 3: Material Handling System Parts

 

Part	Function	Types	Factors
Uncoiler	Hold coil stock, allow unwinding	Decoiler, Hydraulic mandrel, Reel	Coil width, I.D. & O.D
Feed Table	Support strip end, absorb recoil	Flat/Inclined with rollers	Recoil force
Entry Guide	Straighten incoming sheet	Pyramid, Roller straightener	Material thickness
Feed Rolls	Regulate material speed & tension	Knurled, Smooth friction	High friction for thin sheets

Proper sheet alignment and feeding sets the stage for quality roll formed parts.

 

 

Forming Stations

 

The forming section has the series of stands with roller dies that shape the profile:

 

Table 4: Forming Section Parts

 

Component	Role	Design Factors
Stands	House roller dies	Overall length dictates # of stands
Roller Dies	Have machined contours to form shape	Profile complexity, material type
Shafts	Mount dies for rotation	Length, bearing selection
Gearing	Drive synchronized die rotation	Type, ratio, lubrication
Casings	Protect internal parts from dust/debris	Seals, breather valves

The roller die contour design is optimized through advancedSimulation software for the desired part shape. Precision CNC machining translates this into physical tooling. Proper roller surface finishes ensure low friction bending.

 

The casing provides a controlled sealed environment for smooth operation. Gear drives connects the shafts to synchronize die rotations with precision tolerances.

 

Cutoff System

 

The cutoff press slices the continuously formed profile into set lengths as per the batch requirement:

 

Table 5: Cutoff System Parts

 

Part	Description	Control Modes
Cutoff Press	Mounted downstream of final stand	Hydraulic, Servo Electric
Upper/Lower Blades	Slice through material	Carbide inserts for wear resistance
Scrap Chute	Collect cutoff scraps	Roller conveyor discharge
Length Control	Regulate slice cycles	On-the-fly, Fixed increment

Precise blade control and optimal shear angles give superior edge finish and perpendicular cuts. The scrap chute handles remnants efficiently.

 

Exit Conveyor

 

Once formed and cut, the finished parts are collected and bundled through exit handling equipment:

 

Table 6: Exit Conveyor Parts

 

Part	Function	Types
Belt Conveyor	Transport cut parts	Flat belt, Roller bed, Bucket
Stacking Tables	Align/bundle pieces	Manual, Automated
Baling Press	Wrap bundles with straps/film	Horizontal, Vertical

Efficient exit handling ensures finished roll formed parts are moved without damage for storage and shipping.

 

Roll Forming Machine Accessories

 

Beyond the main modules, roll formers can be equipped with additional components as per production needs:

 

• Decoilers – Alternative unwinding systems for coil stock handling
• Loopers – Create slack loops in material flow before cutoff
• Embossing – Coining stations to emboss logos/text
• Punches – Hole punching units for bolt holes etc.
• Ink Markers – Inkjet systems to print date stamps etc.
• Safety Enclosures – Mesh or sheet metal enclosures for safe operation
• Conveyors – Extend part flow handling upstream and downstream
• Sensors – Measurement instrumentation for automation
• IoT Modules – Connectivity hardware for data capture

 

These accessories enhance capability for secondary operations or monitoring.

 

Roll Forming Machine Design Factors

 

Key aspects that drive roll former configuration:

 

Table 7: Roll Forming Machine Design Factors

 

Parameter	Details	Effect
Production Rate	Parts needed per hr/shift	Machine speed, indexing control
Part Length	Distance between cutoff slices	Machine length, conveyor size
Material Width	Coil stock strip width	Die lengths, frame width
Material Type	Steel, aluminum etc. grain orientation	Force calculations, surface finish
Part Shape	Profile complexity, number of bends	Number of stands, die contours
Precision Needs	Dimensional and bend tolerance	Roller surface finish, guides
Secondary Operations	Hole punch, emboss etc.	Additional stations, space
Automation Level	Manual/auto material feed, stack/bundle	Labor requirement, sensors, handling

 

Roll Forming Machine Suppliers

 

There are many established manufacturers of roll forming equipment across geographies:

 

Table 8: Roll Forming Machine Brands

 

Brand	Location	Typical Models	Price Range
Dimeco	USA	Helios, TFX Elite	$150,000 – $500,000
Formtek	Canada	Orion, Maxima	$100,000 – $800,000
Bradbury	USA	EasyForm, SelectRoll	$100,000 – $600,000
Gasparini	Italy	FlexyRoll, FastRoll	$200,000 – $1 Million+
Samco	India	Mach 2, Concept	$50,000 – $250,000

Both local and international vendors offer machines across output levels, automation needs and budget. Lead time is ~3-6 months.

 

Roll Forming Machine Pricing

 

Cost depends on factors like:

 

• Production rate
• Overall machine length
• Level of automation
• Additional secondary operation stations
• Software and IoT capabilities

 

Figure 1: Typical price range for various roll former configurations

 

• Basic machines start around $100k
• High end automated lines are $500k+
• Custom one-off profile machines can cost $1 Million+

 

Request detailed quotes from shortlisted suppliers based on specific needs.

 

Roll Forming Machine Installation

 

Key aspects of roll former installation:

 

Table 9: Roll Forming Machine Installation

 

Activity	Details
Site Readiness	Level flat floors for stands, provision power/air utilities
Lifting & Positioning	Use fork trucks, cranes etc. Safety critical
Securing	Bolt stands to foundation, true verticals
Alignment	Precision align roller dies and knife blades
Trial Runs	Validate feeds, performance before production
Documentation	Supplier provides manuals for operation, maintenance & safety

Proper groundwork and precise installation provides a robust foundation for smooth functioning.

 

Roll Former Operation

 

Day-to-day operation involves:

 

Table 10: Roll Forming Machine Operation

 

Activity	Guidelines
Material Loading	Position coil on mandrel securely
Jog Mode	Initial slow speed test run
Parameter Input	Enter batch size details
Cycle Initiation	Start automatic forming cycle
Monitoring	Observe process for any issues
Safety	Follow lockout procedures during maintenance

The operator mainly loads raw material, enters dimensions and removes finished goods. Automatic modes simplifies the workflow.

 

Roll Former Maintenance

 

Regular upkeep activities:

 

Table 11: Roll Forming Machine Maintenance

 

Task	Frequency	Tools Needed
Inspection	Daily	Flashlight, measuring tools
Bolt/fastener check	Monthly	Wrenches, torque meter
Roll/shaft lubrication	3-6 months	Grease gun, lubricants
Blade sharpening	As needed	Sharpening tools
Gearbox oil change	Yearly	Funnel, oil container
Sensor/wiring check	As needed	Multimeter, circuit tester

Daily inspections coupled with periodic preventive tasks reduce breakdowns. Maintain fastener torque specs.

 

Choosing Your Roll Forming Machine Partner

 

Important considerations when selecting roll forming suppliers:

 

Table 12: Roll Forming Machine Selection Criteria

 

Parameter	Guideline
Experience	Number of years in business, client testimonials
Domain Expertise	Understands specifics of your product needs
Quality & Support	ISO certified, trained service engineers
Delivery	On-time record, installed base in region
Technology Use	Leverages simulation, sensors, data analytics
Customization Skills	Flexibility to tailor for special needs
Pricing and Value	Price commensurate with performance capability

Evaluate multiple competent vendors on these aspects before choosing the right system.

 

Pros And Cons Of Roll Forming

 

Table 13: Roll Forming Process Pros and Cons

 

Advantages	Limitations
Fast, continuous production	Initial tooling cost investment
Uniform high quality cross-sections	Complex shapes need multi-pass forming
Ideal for long straight profiles	Short etch parts not optimal
Efficient material utilization vs machining	Specialized operators needed
Low tooling maintenance	Horizontal floor space intensive
Adaptable automation options	Longer lead time vs other processes

When used for suitable applications focused on linear profiles, roll forming delivers productivity and quality at economical cost. Understand that it has limitations with short complex bends.

 

 

FAQs

 

Q: What materials can be roll formed?

 

A: Most ductile materials like low carbon steel, stainless steel, aluminum are commonly roll formed. With proper tooling adjustments high strength steel, copper and even plastic sheets can go through the process.

 

Q: What tolerances are held in roll forming?

 

A: Roll formed parts typically achieve profile tolerances of +/- 0.5mm in modern machining. Closer tolerances are possible but reduce productivity. Standard bend radii are around 1 to 1.5 times material thickness.

 

Q: How to calculate roll forming cost per piece?

 

A: Total cost = machine depreciation + material coil cost + labor. Calculate per piece rate based on annual production volume. As volumes scale cost goes down significantly.

 

Q: What safety measures are must in roll forming?

 

A: Require personnel to wear cut protective gear, gloves when handling coils or sharp profiles. Fully enclose nip points. Interlock guards with electrical power cutoff for entry. Install safety mats.

 

Q: How to reduce roll formed part rejects?

 

A: Monitor feeds, speeds and guide adjustments. Ensure precise 90 degree cutoffs. Improve operator training for visual inspection of cuts/bends. Perform regular machine maintenance.

 

Q: What are the finish options for roll formed products?

 

A: Common secondary finishing steps include powder coating for corrosion resistance and aesthetics, rubber lined interiors for noise insulation, perforations for air flow and adhesive foam inserts for thermal breaks.

 

Conclusion

 

Roll formed sections offer excellent technical and commercial value for long straight profile requirements across a diverse range of applications in infrastructure, buildings, equipment, appliances and more.

 

When you partner with a dependable roll forming machine supplier and implement proper operational discipline, it results in a flexible, efficient and profitable manufacturing system with low cost of entry.

 

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