roll forming presentation
TRANSCRIPT
4630 CR 209 S.Green Cove Springs, FL 32043
904-284-5611www.rollerdie.com
Roll Forming – Stamping – Press Brake – Powder Coating – Polishing – Welding - Assembly
Roller Die - Company Profile
Key Statistics
Revenue: $59 million (FYE 9-30-13)
Employees: 300
Corporate Headquarters: Louisville, KY
Plants: Louisville & Frankfort, KY
Green Cove Springs (Jacksonville), FL
Rossville, Ga. (Chattanooga, TN)
Queretaro, MX
Stockton, CA
Founded in 1928
ISO 9001:2000 Certified
Privately Held
Lean (TPS) Culture
Press Brake
Light Gauge Stamping
Assembly,Finishing
Roll Forming
What is ROLL FORMING? Roll forming is a
continuous forming process taking sheet or coil stock and bending or forming it to a desired cross section.
The process is performed between successive pairs of rolls that increasingly shape the metal until the desired cross section is achieved.
Materials
Almost any material that can tolerate bending to a desired radius can be roll formed.
The more ductile a material is, the better it will roll form.
The roll forming process can handle ferrous, nonferrous, hot rolled, cold rolled, polished, plated, or pre-painted metals producing excellent results.
Materials
Materials as thin as 0.005" and as thick as 0.750" can be roll formed, depending upon the size of the roll form machine spindles.
Material pieces as narrow as 1/8" and as wide as 72", or more, can be roll formed, depending on machine size.
Design Considerations Bend Radii:
Best practice is a one-metal-thickness inside radius.
May need slightly larger in high-strength steels
Sharper corners CAN be obtained at the expense of tool life
Scoring the inside of the strip can help make sharper corners in some cases.
Design Considerations Deep sections:
Require more passes, larger machines, larger rolls and dies
Risk overstressing the edges of the material
Typical machines – 100 mm max. height of part
Short Legs: Three times metal thickness is a good
minimum leg length
Design Considerations
Wide sections Apply ribs or offsets to wide panels Helps prevent wrinkles, “oil-canning” Often wide material has appearance
issues
Design Considerations
Cross Section Tolerances Typically +/- .25 mm to +/- .75 mm Tighter tolerances are achievable:
Different approach to tooling Special quality materials
Angular Tolerances Typically +/- 1º
Design Considerations Length Tolerance
Influenced by many factors: Length of part Speed of rollformer Measuring system Cutoff system Material properties
Commonly available: +/- 0.8 mm Special equipment and tooling: +/- 0.25
mm Long parts (3 M or more): +/- 3.0 mm
and up
Design Considerations Straightness:
Bow (up or down) or Curve (side to side) – 1.0 mm per Meter
Twist - 1 degree per Meter Flare:
Typically avoid measuring the cross section within 50 mm of ends.
Flare can be controlled with special attention
Roll Forming vs. Other Processes Volume is key versus tooling costs Typically see 25,000 LF of part to justify cost of custom
shape; BUT, if can use standard shape, much less Extrusions – aluminum – 3 x galvanized cost;
inexpensive tools, expensive part Press brake – good for low volume; inexpensive tools,
expensive part (labor), limit to length of part by brake bed
Stamping – good for single part; if multiple lengths in family, tooling very expensive; if done in multiple steps, expensive (labor)
Roll form lines allow piercing, features to be done in-line, no secondary operation.
Roller Die
Why we should be Your Roll Form Source: Long-time experience
Both Decorative and Structural Parts Technical Expertise
Available to Assist in Design Multiple Facilities, including Mexico Lean Manufacturing Systems Fully integrated engineering department
overseeing our custom tool & die shop on site Large library of standard shapes/stock tools