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Learning how to fix bow and twist is a mandatory skill for any high-precision manufacturing operation. Even with a perfect setup of your roll forming machine, material variations or thermal changes can introduce annoying defects that lead to rejected batches. In 2026, as Beli RollForming continues to lead with 5 Incredible Advancements, understanding the physics of metal straightness is key to maintaining a competitive edge.
If your profiles are exiting the machine with a curve (bow) or a spiral rotation (twist), don’t panic. This guide reveals the industry’s best-kept secrets to restoring absolute precision to your production line.
Before we dive into how to fix bow and twist, we must define what we are fighting. These defects are caused by unbalanced internal stresses in the metal strip as it is being formed:
The most effective tool in your arsenal for how to fix bow and twist is the Turkish Head (also known as a straightening head). Positioned after the final forming station and before the shear, this device can move in four directions.
To fix bow: Move the Turkish head in the opposite direction of the curve. If the profile bows up, push the head down.
To fix twist: Rotate the Turkish head against the direction of the spiral. Modern 2026 Beli machines feature digital readouts on the Turkish head for sub-millimeter precision.
Twist is often the result of “over-forming” on one side. If your profile is twisting, check the gap between your upper and lower rollers using a feeler gauge. If the drive-side is tighter than the operator-side, the metal will stretch unevenly, inducing a rotation. Ensure the gap is uniform across the entire width of the profile. This is a critical step in Roll Forming Alignment and Calibration.
Bow is frequently caused by the material being forced “up” or “down” as it moves between stations. Ensure that the “pass line” (the bottom of the profile) is perfectly level across all stations. If a middle station is set too low, it creates a “diving” effect that results in a permanent upward bow. Use a laser level to verify that the bottom rollers form a perfectly straight horizontal line.
Sometimes the secret of how to fix bow and twist lies at the very beginning of the line. If your uncoiler or leveler is not applying enough tension, the “coil set” (the natural memory of the metal) will survive the forming process. Increase the pressure on your leveling rollers to ensure the strip enters the first station perfectly dead-flat.
Friction creates heat, and heat causes metal to expand. If your rollers are running hot on only one side, the profile will expand unevenly and twist. Ensure your lubrication system is delivering a consistent volume of coolant to both sides of the tooling. This keeps the material temperature stable, preventing thermal-induced deformation.
If you find yourself constantly adjusting the machine to fix straightness issues, it may be time for a deeper look. Consistent defects are often a sign that it’s time for Amazing Roll Forming Machine Maintenance. Worn bearings or loose stands can cause “play” in the rollers that no amount of Turkish head adjustment can fix.
Knowing how to fix bow and twist transforms a frustrated operator into a master technician. By utilizing the Turkish head, ensuring pressure symmetry, and optimizing your leveling system, you can produce profiles that meet the strictest construction and automotive tolerances. At Beli RollForming, we build our machines with heavy-duty straightening systems to ensure our clients achieve zero-defect production from day one.
If you want to upgrade to a machine that minimizes defects and maximizes output, our 2026 models are the answer.
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