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Roll Forming Machine Design, Roll Forming Machine Rollers

roll forming machine design

Roller Design: Profile Drawing Of Steel Profiles

Roll Forming Machine Design

Complexity of profile drawings

The profile drawings of the roll formed profiles is the most signficant factor in roll forming machine design.

There variety of shapes is not limited. And the shapes can be arbitrarily classified as Simple, Open, Closed, Medium Complex, Very Complex and Panels

profile drawings for roll forming machine design

Profile Depth

The depth of the profile is the maximum vertical sizes of the steel section as it exits from the last stands. The depth will influence on the number of roll forming stands. And finally influence the roll froming machine design. With the same cross section, the deeper the section, the more roll forming stands are required for roll forming. 

Width of The Flat Part

The width of the flat part, the nonformed section usually doesn’t influence the number of roll forming stands. However, the wider the flat (not formed part) section and the thinner the material, the higher the possibility that waviness will occur. Regardless of how well-designed the rolls are, they can’t eradicate waviness. In “roll forming machine design”, many ways are advised to reduce or eliminate edge or center waviness.

Wide, flat, nonformed components will create different difficulties throughout roll forming. If just one side of the product is formed and also the rest of the strip could be a wide, flat part, then a small pressure thereon
flat part will make it longer. The longer element can create a camber, twist, or edge waviness.

During roll forming of wide, furrowed panels, the forming sometimes starts at the middle rib. In these cases, additionally to the progressive  modification of the bend angles from pass to pass, a relatively wide flat sections at both sides has to be moved within the same plane sideways closer and closer to the middle . Shifting a thin flat sheet sideways without making large waves is not an easy task.

rollers for corrugated sheets

Cross Section Tolerance

The customer, the cross section designer, and roll forming machine designer much agree on the interpretation of the dimensions and tolerances specified in the profiles drawings before the roll forming machine design commences

The product tolerances will also affect the roller design, the number of roll forming stands. And also the tooling cost. The tighter the tolerance, the more stands are required

Straightness and Flatness Tolerances

Camber, bow, twist, cross-bow, herringbone effects, edge, or center waviness can be caused by the nature of roll forming, as well as imperfections in material, equipment and setup. Tooling has great influence on residual stresses, which create deviation from straightness and flatness. Good roll forming design eliminates or minimizes them; bad design creates or exaggerates these problems.

Believe Industry Company is engaged in design and manufacture roll forming machines for over 10 years. We have an experienced team to design the roll forming machine for specialized cross sections

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