Roll Forming Machine Components
In order to form the sheet metal into the desired profile, the designer muct pay attention to the roll forming machine components surrounding the rolls, and to the rolls themselves. A correct manufacturing, setup and in line adjustment of the machine is key to obtaining final products within the desired tolerances.
Below picture will show the main components of a roll forming machine:
Roll Forming Machine Rollers
Rollers is one the main core of roll forming machine compoents. In practical terms, rollers manufacturing must be extremely precise. The deviations of roundness or eccentricities of a very low order will have great implications in part quality. And the surface quality must be extremely high due to contact and lubrication issues. As usual rollers are split into several sections for ease of manufacturing. In fact, there are instances where this is the only possibility and also allows for easier installation.
Between the rollers are spacers, which will reduce the cost of the mill. And easy to adjust to produce different desired profile with splited spacers. View More>>: Roll Forming Machine Part-Spacers and Shims
The shafts is for supporting rolls and connecting them to the roll forming stands, must be very stiff in order to ensure good dimensional stability of the roll gap. The outer diameter of the shafts is from 40 mm to 120mm for different profiles. The shaft will have a keyway through its whole length which will fit with the rolls. The shaft jointed on bearings on both side stands.
On the drive side it will have a section with a larger diameter which rests on the bearing. On the operator side, it is threaded and has a spacer which fits into the bearing and allows the operator to tighten the whole assembly (rolls and spacers) with the nut, independently of the stand and bearings. The threads are usually opposite, the top one is right thread while the bottom one is left thread in order to avoid the unintentional untightening of the nuts during operation. On the drive side, the shaft has a standard shaft end for fitting a flange, cogwheel or chain drive.
Roll Forming Stands
Each side roll forming stand consists of two bearing housings, which are supported by connecting rods, in turn attached to cross bars. Each bearing housing usually has two conical bearings which support the shaft. The height of each shaft is adjusted by screws on the top and bottom crossbars. In order to change the rollers on a roll forming machine, the operator side stand must be removed. This means that positioning on the machine table must be precise and repalceable . If the stands are not correctly mounted, there is the possibility that the shafts are not perpendicular to the direction of travel, which can lead to substantial problems during operation.
There are Several driving methods for connecting the electric motor to the shafts. Chain drives are usual. But universal joint drive shaft which is for connecting the two parts. And which allows for
the independent driving of each roll, which can be useful due to the varying sheet speed through the roll forming machine.
View More information about roll forming machine line.