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The roll forming process is mainly processed by forming a movement of materials into various shapes of rollers, shafts, valve cores, and special fasteners.

Rolling deformation is a line contact, which is carried out continuously and stepwise, and the required deformation force is small, and one stroke can produce one or several workpieces.

Compared with the cutting and grinding processes, the roll forming process not only has high production efficiency, saves materials, but also has high product strength and stable quality. This process is especially suitable for processing workpieces with long and short machining difficulties, especially for the annual production. Millions of high-volume products are most advantageous with the roll forming process and the most economic benefits.

The rolling process is a cold forging process, and there are many materials for roll forming. Among them, low carbon steel is a commonly used material for roll forming, and nonferrous metal is more suitable for roll forming.
Roll-formed parts are generally obtained by forging a blank piece by a cold heading machine and then rolling it by a thread rolling machine. The equipment for thread rolling and roll forming includes various reciprocating flat wire rolling machines, planetary rolling machines, two cylindrical rolling machines, and three cylindrical rolling machines. The most common type of roll forming is the reciprocating flat wire reeling machine. Therefore, for manufacturers equipped with cold heading machines and thread rolling machines, it is only a problem of designing a rolling forming mold.

 

What Is Roll Forming Process?
The cold roll forming process works by passing the sheet through a series of rollers, each of which adds shape to the metal as it passes. The rollers work together to form the desired cross section. Since the process is consistent and easy to repeat, roller forming offers a great way to produce even very high volumes of metal components. Aluminum profiling can be used to create components for a wide variety of industrial parameters. In addition, we operate over 90 roller machines, with spindle sizes ranging from one inch to three inches. This means that we are able to quickly deal with all of your profiling needs, whatever those needs are. We can create both standard shapes and custom work, both of which are produced at the highest possible quality levels due to their unique roll forming machine design.

What is Roll Forming?

Roll forming is a continuous metal forming process that takes sheet, strip or reel paper and folds or shapes it in a continuous cross section. The process is carried out between successive pairs of rollers which shape it more and more until the desired section is completed. The profiling process can be used to form a wide variety of cross-section profiles. An open profile is most common, but a closed tube shape can also be created. Since the final shape is obtained by a series of elbows, the part does not require a symmetrical section.

Who uses roll forming machinery?

Many industries use roll-formed parts such as the automotive industry, the tool and die industry, the metal furniture industry, construction, railways, and others. There are also several types of roll forming processes such as roll bending, roll forming, flat rolling, sheet rolling, and ring rolling and controlled rolling.

Advantages of Roll Forming

• The roll forming process allows operations such as punching, notching and inline welding. Labor and time costs for secondary operations are reduced or eliminated, reducing parts costs.

• Roll-shaped tools allow great flexibility. A single set of roll-shaped tools will make almost any length of the same cross section. Several tool sets for parts of variable length are not necessary.

• Roll forming machine can provide better dimensional control than other competing metal forming processes.

• Repeatability is inherent in the process, which allows easier assembly of the rolled parts in your finished product and minimizes the problems due to the accumulation of "standard" tolerance.

• Profiling is generally a faster process.

• The roll forming provides customers with a superior surface finish. This makes roll forming an excellent option for decorative stainless steel parts or for parts requiring finishing such as anodizing or powder coating. In addition, the texture or pattern can be wrapped in the surface during forming. Roll forming uses the material more efficiently than other competing processes.

• Roll formed shapes can be developed with thinner walls than competing processes.

Roll Forming Materials

Almost any material that can tolerate bending to a desired radius can be rolled. The more ductile the material, the better it will form. The roller forming process can handle ferrous, non-ferrous, hot rolled, cold rolled, polished, plated or pre-painted metals producing excellent results.
Roll Forming Machine Introduction
Roll forming machine make special configurations from long strips of metal, usually from coiled steel. In most applications, the required section profile of the part is specially designed so that the machine bends the metal if necessary. In addition to roller forming, these machines perform a number of metalworking tasks, including cutting materials and punching rollers.

The roll forming machine can be formed from any type of ferrous and non-ferrous material. MS and aluminum are the most commonly used materials in the roll forming machine process, the rough having to be formed after cutting to a specified size, the latter being the most common. The most productive post-cutting method generally involves a stock rewinder, a profiling machine, a cutting machine and an output table. Average production speeds of 8 to 12 meters per minute.

Its components including roll forming parts, PLC, computer control system, hydraulic pump station system, and automatic cutting system.

The whole unit automatic control system adopts highly integrated network, which makes the automation system more efficient.
Automatic feeding, installation and commissioning with the host, then open air compressor, knife, feeding machine, vacuum pump, pressurized machine, extrusion machine, parking, rest of the first extruder, then shutdown of the rest of the equipment.
The roll forming machine has many parameters to set, defined with the touch screen. Adjust the parameters of the equipment parameters and the adjustment of the user parameters.

Equipment parameters: single pulse length, overshoot, pressure range, pressure time, cutting time, etc. The user parameters are: number, length, first, distal, number, etc.

The roll forming machine should use high pulse input function, high input excellent performance, choose AB phase interference capacity. And by setting interrupt function, ensure accuracy.

The metal forming machine process is classified into - bulk forming and sheet forming process. Bulk forming is further divided into rolling, forging, extruding and drawing wire or rod while sheet forming is divided into bending, deep drawing / cup drawing, shearing.

The market growth of metal forming machine process is likely to spur positively in the upcoming years, particularly, in the manufacturing sector. The manufacturing companies can manage high-quality processes as automation removes the scope for human error and impacts the overall quality of production.

The work of the roll forming machine continues with a special design of the rollers on the amount of support. All the supports roll together and roll the material at the same speed. Roll forming technology came for easier and faster processing on sheet metal to precise demanded profile. Each stand of tooling will make small forming on material and pass it to next stand. As result, we will have required profile shape.

Roll forming machine Design, cold forming is one of the complex forming processes whose product quality is highly dependent on the process parameters.

some roll forming parameters of channel section investigate on the edge longitudinal strain and bow defect of products such as bending angle increment, and strip thickness, and flange width of the section, the width of the section core and the friction in contact with the roller and the strip, also the speed of the roller and the distance between the roller support. It is important to take these parameters into account when designing the profiling process.

Metmac is one of the best roll forming machine manufacturers in China, You can found all you needs on roll forming machinery with affordable prices.
Roll Forming Machine Cost
Roll forming machines are generally equipped to operate at a nominal rate of 100 FPM, but can go to higher or lower speed to meet a specific requirement due to roll forming machine design. At this rate, average daily production is approximately 25,000 to 30,000 feet in the section over an 8 hour period. This takes into account the usual deadlines for loading the coils, threading the crusher, cleaning the finished product and another downtime that could come into the picture. It goes without saying that conversion costs will vary from plant to plant and from project to project. Each work must be analyzed individually; for this reason, general observations have almost no value. However, if a profiling system is highly productive and inexpensive to use, profiling and roll forming of almost all products will result in a lower conversion cost than any other method. The roll forming machines cost is impacted by three main factors: the complexity of the part The dimensions of the part Order volume Greater complexity indicates more passes through the roll former and also requires longer installation times. So what you need to consider when you want to buy a roll forming machine for sale.

1. Setup Time
Setup time refers to the amount of time it takes to put the roll tools into the machine and then take them out. This time will vary based on the complexity of the shapes you’re producing, which relates directly to the number of steps required for tool assembly

2. Materials
The great thing about roll forming is that it produces little scrap – on average, only 0.5% to 3% scrap is produced. So there will not be as much monetary or material waste once you have purchased the materials. Knowing how critical raw material cost is, we suggest a roll forming company constantly watches the world metal markets to ensure it takes the optimal action for any customer’s supply pipeline. Not surprisingly, materials make up the bulk of roll forming machine cost. Raw materials can be anywhere from 40% to 80% of the final cost. The cost of a material depends on its thickness, the cost of the market and the scrap factor. Thin, inexpensive material (such as thin carbon steel) can be 40-50% of the cost. If the material is heavy and expensive (i.e. copper, bronze, stainless steel), it reaches up to 80% of the roll forming machine price.

3. Run Speed
The speed of execution is the speed at which you can pass a strip of metal through the machine. Once the roll dies in place and the steel is loaded, a roll forming machine operates at a constant and rapid rate. The faster it runs, the cheaper the components. There are several different factors that influence run speed:
• Machine speed limitations just like cars, some roll form machines are initially built to run faster than others.
• Number of roll dies in sequence -- If a machine only has 10 roll die stations, each station is taking 1/10 of the work. In that case, each station is doing more work than a machine with 20 stations, which would only take 1/20 of the work. The less work each station has to do, the faster the metal can pass through the machine.

• Roll die diameter
Larger diameters result in faster run speeds. Think tangential velocity.
• Length of final product
Very short pieces take longer to pass through a roller machine. This relates to the time it takes the flying cutoff die carriage to return to the start position before it must accelerate and cut off the next part. Each time it cuts a piece of metal; it must retract and accelerate to punch the next.

• Pre-punch strokes
Since the metal strip must stop momentarily to receive its perforated functions, the more functions that can be perforated by stopping, the faster the parts will execute. Good die designers make sure punched parts stop for the least amount of time. Slack loops in the coil strip between the pre-punching press and the profiling line allows the rolling tools to operate continuously, but the loops cannot take as much slack.
• Unloading time -- If a part is extremely heavy or long, it will require mechanical assistance to move from the machine, meaning the machinist must wait to continue.
Roll Forming Machine Technology In China
Roll forming is evolved from the spin forming method. The difference between rolling and spinning is that the flat sample knife is changed to a rotary rolling head. The advantages of roll forming are high compact body density, large mechanical strength, small deformation, low labor intensity, easy mechanization and automated production, high production efficiency, and easy to form a linked production line with upper and lower processes.

Cold roll forming process is a plastic processing process that continuously rolls metal plates and strips, such as coils and strips, in a multi-pass forming roll arranged in sequence to make specific cross-section profiles. Cold roll forming is a new process and technology of metal sheet material saving, energy saving and high efficiency. By using this process, not only high-quality steel products can be produced, but also the product development cycle can be shortened and production efficiency can be improved, thereby improving the market competitiveness of enterprises.

In China, since the construction of cold-formed units began in the late 1950s, they have undergone a tortuous process of development and adjustment. There were only 6 at the end of the 1970s. China's cold-formed steels developed rapidly in the 1980s, and by 1982 the output was only 16,000 tons. By 1989, more than 20 manufacturers across the country had output of over 300,000 tons and a design capacity of over 600,000 tons, including 14 key plants in the metallurgical system and 45 sets of units. The variety and specifications of cold-formed steel are also increasing. Has reached more than 800 species. Under the favorable form of reform and opening up, national economic construction has put forward new requirements for the variety and quality of steel. The advantages of cold-formed steel have gradually been recognized and accepted, and the production of cold-formed steel has made great progress. So far, it has more than 100 sets of cold-formed units, with an annual production capacity of 1.5 million tons and a total of more than 1,000 varieties and specifications.

(1) The roughing section adopts the combination of common rolls and replacement rolls. When the product specifications are changed, the rolls of some stands need not be replaced, which can save the reserve of some rolls.

(2) The combined rolls for flat rolls are composed of six stands, and the rolls of the vertical roll group are arranged obliquely. The roll volume is small, the weight of the roll is reduced by more than 1/3 than that of the conventional roll forming machine, and the equipment structure is more compact.

(3) The roll profile is simple, it is easy to manufacture and repair, and the rolls have a high rate of repeated utilization. (4) Stable forming, the rolling mill has strong applicability for thin-walled and rear-walled tube forming, and has a wide range of product specifications. So it can be expected that roll forming machine manufacturers will be increasingly needed because cold-formed steel will have a greater development in China.

In recent years, cold-formed steel has been widely used as an important structural component in many industries such as construction, automobile manufacturing, shipbuilding, electronics industry and machinery manufacturing. Its products range from ordinary guide rails, doors and windows and other structural parts to some special profiles made for special purposes, with a wide range of types. The cross-section performance per unit weight of cold-formed steel is better than that of hot-rolled steel products, and has high surface finish and dimensional accuracy. Therefore, replacing cold-rolled steel with hot-rolled steel can achieve the dual effect of saving steel and energy. The development of curved steel has been given great attention. It is users' constant desire for the variety, specifications, and quality of cold-formed steel products that has prompted roll forming machine companies to continuously improve and develop their cold roll forming process.
Roll forming machine Application
Roll forming is a metal forming process in which the metal is shaped by a series of rollers. Profiling produces some of the most widely used metal products.
Roll forming does not involve heat and the rollers do not affect the surface properties of metals. These features make it an ideal choice for shaping polished metals, coated metals, and other metals whose beauty and aesthetic properties need to be maintained.
Profiling is used to bend the sheet metal to produce rounded shapes or frames, called profiled parts. Roll formed parts are popular because they are precise with tight tolerances, and can be made to conform to a variety of shapes, angles and curves.
Roll forming services are utilized by a wide range of industries, including automotive manufacturing, building construction, architecture, carpentry, fences, appliance and utility, and more.
Roll forming machine Application include:

Roll forming machine for construction and building: Roll-formed sheet metal is widely used in the construction sector, and metal is increasingly replacing other building materials, whether for narrow sections for beams, columns or reinforcement bars, wide sections for roofs and walls, special sections such as those used for partition walls or panoramic windows, or enclosure sections such as sectors or doors, both industrial and domestic.

Roll forming machine for motor industrial: For Automotive Roll Forming Machines We understand the requirements of the industry, deliver tough automotive quality and reliability requirements, and meet the latest automotive industry standards, such as TS, ISO, AIAG and reliability standards and specific OEM quality. Metmac has the ability to create fully integrated automotive profiling solutions with in-line pre-punching, in-line welding, in-line scanning units and flywheel cutting systems

Roll forming machine for ship building: they are used to bend metal plates and platform components such as those for oil extraction or foundations for wind turbines. Manufacturers in the sector need machines capable of bending metal plates of great thickness and hardness, guaranteeing maximum structural strength. Depending on the required productivity and capacities, supplies 4HEL series 4-roll bending rolls or HAV series 3-roll bending rolls able to fabricate plates with thickness greater than 200 mm. These machines are equipped with instruments for measuring, calibrating and handling rolled parts.
• Roll forming machine for road safety guard and defence: The safety barrier is a barrier on a road designed to prevent vehicles from leaving the roadway in order to improve road safety. The fully automatic roller forming machine can produce 2 and 3 wave railings according to customer requirements.

• Roll forming machine for infrastructure field: these machines have the combined the advantages of three roll pyramid type, three roll initial pinch type and four roll pinch type machines. A pre-pinch error can be corrected even after the shell is finished and, therefore, the highest degree of pre-flex can be easily reached. Without removing the plate from the machine, bending works can occur, after the first insertion of the plate, the pre-pinching and rolling operation can be properly performed.

Roll forming machine for steel and iron metal working business

Roll forming machine for electricity power supply
Roll Forming Advantages And Disadvantages
Roll forming machine has many advantages over braking and extrusion. Compared to braking forming, roll profiling can produce more parts with greater uniformity and consistency over the entire length of the part. Roll forming also eliminates multi-step operations, cutting up scrap and slitting burrs. The advantages of profiling compared to extrusion methods are as follows: practically all metals can be formed by rolling using sheet metal roll forming machines, not just aluminum. In addition, roller forming can eliminate secondary operations - multi-step operations such as notching, punching and post-painting - by combining them in the roll forming machinery. As we all know roll forming machines design are strong, stable, simple, and fit in the requirements of a majority of architectural applications.

Assembly

Two separate parts can be assembled to form a single unit.

Clad Shapes

Two different materials can be formed simultaneously to produce a plated shape in one operation.

Energy Efficiency

Roll forming is an energy efficient process, generally requiring no process heat to add.

Finish Roll

Forming can produce superior surface finishes. Sharp, clean contours can be maintained. The absence of marking dies on the material often eliminates the need for additional finishing.

Hole and Slot

Patterns pre-punching allow you to include holes or slots which cannot be made as a secondary operation due to their location or the characteristics of the part. Hollow Shapes Hollow or semi-hollow shapes can be produced with thinner walls than allowable processes.

Lengths

Almost unlimited lengths can be roll formed. The only limitations are due to the handling equipment, space constraints and shipping capacity.

Material

Almost any bendable material can be roll formed. Production The rapid and continuous nature of profiling lends itself to economical production of large volumes of parts.

Secondary Operations

Many additional operations, such as punching, notching, welding and bending, which would otherwise have to be performed as secondary operations can be integrated into the profiling process, thereby reducing handling and processing costs, Even the labels giving installation instructions can be applied to the form as an online process.

Structural Applications

Roll forming machine materials generally have a strength advantage over competing processes in structural stiffness applications.

Tolerances

Roll forming can reach tighter tolerances than those possible with most competitive processes.

Tooling

The same tool can be used to roll a shape from different materials.

Uniformity

Profiling produces symmetrical parts with uniform dimensions which ensure precision adjustments, simplify production, speed up assembly and minimize rejection. Disadvantages of a roll forming machine: Strips must butt-up without damaging leading edges, normally requiring additional forming stations

• The front and rear ends of the pre-cut strips are not supported against adjacent roll passes, which causes straightening problems
• Auxiliary guides may be required to control the material as it transitions from one pass to the next
• Tooling is generally subject to more abuse and wear from the entry edge of the profile
• The end of the flare at the outlet and the entry edge may be more visible on the precut parts
• Torsion, end flare and arc are more difficult to minimize when forming pre-cut parts, especially asymmetrical profiles
• Material can jam or double in production and damage the roller gauge and tooling
• Production of shorter parts has limits - the profile must be engaged in three forming stations at all times
• If floor space is a problem, longer pieces require a material conveyor between the pre-notch press and the gauge, equal to or greater than the longest part
Materials Suitable For Roll Forming Machines?
Roll forming is a process in which a strip or sheet of metal, such as steel that can proceed using a specific roll forming machine for coiled steel, is passed through a continual set of stands (rolls) until the desired cross-section profile is achieved. The sheet or strip is plastically deformed along a linear axis in a room temperature environment. Typically used to create long pieces, profiling is also useful for making large quantities of a specific shape.
Each stand in the roll forming machine has a specific job in the fabrication of the piece, and every stage involves minor changes in the configuration of the metal. The size of the stands used depends on the metal’s type, thickness, and formability.
Once you’ve chosen roll forming, you’ll need to understand what the materials suitable of the process offer before you can begin considering your roll forming machine design:

Ferrous Metals

Ferrous metals are any metals that feature a bivalent iron compound. Some examples of ferrous metals include:
• Steel: made up primarily of iron and malleable below its melting point by at least one temperature range without requiring special heat treatment. Rolling steel is generally free from slag and between 0.05 and 2% of its weight is carbon. Steel can also contain small amounts of silicon and manganese, as well as trace quantities of sulfur and phosphorus. And this material have many types of machines such as steel cold roll forming machine, sheet metal roll forming machines, steel sheet cold roll forming machine, steel profile roll forming and making machine
• Stainless Steel: contains a high percentage of chromium, which lends it high staining and corrosion resistance. This form of steel is resistant to weak mineral acids, organic acids oxidation, and other caustic materials.
• Galvannealed: sheet steel which has is similar to other galvanized steels. It is perhaps more similar to hot dip galvanizing. In order to create Galvannealed steel, the material is passed through a liquid zinc alloy bath.

Non-Ferrous Metals

Non-ferrous metals do not contain iron in their chemical composition. Some of the more common non-ferrous metals used in roll forming machinery include:
• Aluminum: a soft, malleable and light metal with excellent corrosion resistance. When exposed to air, it forms a thin layer of aluminum oxide to protect it from wear.
• Brass: an alloy of copper and zinc with a brilliant gold-like color and high corrosion resistance. There are several types of brass, including bronze, an alloy of copper and tin. Brass is very malleable and is used in a variety of applications.
• Copper: a ductile metal known for its electrical conductivity. It also features prominently in building materials and as a primary component in other non-ferrous alloys.
• Lead: used in many types of building supplies such as roofing metal, flashing, gutters, gutter joints, and others.
• Composites: materials engineered from two or more materials with chemical or physical differences.

Examples of Roll Formed Materials Corrugated metal, or corrugated galvanized iron (CGI), is formed into sheets coated with metal as it passes through a set of engineered rollers. These sheets are commonly used in the roofing of rural and military buildings, as well as for water tanks and sheds. The final product is lightweight and the grooves in the sheet result in improved bending strength. Although it is still referred to as corrugated galvanized iron, CGI is actually composed of steel.
Other examples of roll formed materials include angles, angle irons, and V-shapes. These components are used for frames, rails, posts, flanges, brackets, collars, reinforcements and other applications. Roll formed materials can also be made into rims, rings, clamps, coating, louvers, blades, slats, bars, wire and much more. In fact, most bendable metal can be roll formed, and the shape and use of the roll formed material can be as simple or as complex as the machinery allows.
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