What Is a Metal Roll Former?

Roll forming is the process of shaping metal into shapes. It is a versatile process that can produce many different products. Metal roofing is one of the most common uses for this technology. It is a powerful fabrication tool that allows roofers to create a custom roof on the spot.

Pre-cut

A metal roll former is a machine that uses a metal coil to produce the shape of a part. It can create shapes with thinner walls than other manufacturing processes. It can also add texture or pattern to the part. It is a great option for projects that require a high-quality finish. It is used for applications such as roofing, which requires a metal sheet that has been formed into a curved shape.

There are many factors to consider when choosing a pre-cut or post-cut metal roll former. The choice will depend on the size and complexity of the job, as well as your production capacity. It is important to choose a machine that has the capability to handle your project’s specific size and requirements. It is also important to consider the type of steel you use for your line, as this will affect the way it performs.

Pre-cut lines are easier to maintain and are able to run multiple profiles on the same line. This can reduce stop time and increase production rates. They can also benefit from having a flat strip shear instead of a profile-specific blade, which saves on costs.

Pre-cut machines tend to have less end flare than post-cut machines because they don’t need the support of the leading and trailing edges. They are also more economical than post-cut machines because they do not require power to drive the upper tooling passes. However, they do require a higher initial investment than post-cut systems.

Post-cut

Roll forming lines can be configured in two ways to produce length-specific formed parts: pre-cut and post-cut. Both have a few advantages and disadvantages, but the best one for your line will depend on a few specific factors. metal roll former For example, the type of product you want to produce and your floor space requirements can help determine which configuration is best for your line.

In a pre-cut operation, the steel is cut before it enters the machine. For example, a metal roof or wall panel line might have a flat shear to cut the sheet or strip of metal into sections before it enters the rolling machinery. This can reduce the cost of expensive shear dies and eliminate the need for shear maintenance.

The main advantage of a post-cut machine is its increased production rate. This is due to the fact that it doesn’t have to wait for the material to reach a certain point before shearing. It is also less prone to shear deformation than a pre-cut machine, and it can be run on heavy gauge or high-strength material.

Another advantage of a post-cut shear is that it can have flat blades, which are typically used on all four sides before they need to be sharpened. This can help reduce tooling wear, which is an important consideration for any roll former.

Pre-formed

A pre-formed metal roll former consists of a series of stations that alter the shape of the work piece as it passes through the machine. Each station performs a different function, such as punching or notching. For example, the first roller might impress four lines of indentations into the steel and then curve the two raised sections. This process is more complex than other methods of forming metal, but it offers several advantages over postcut machines. Pre-formed machines eliminate the need for a cutoff press and die, reducing initial costs and maintenance expenses. They also allow for a more uniform cut and help to prevent end distortion.

During the rolling process, metal is subjected to significant stress. This stress causes the metal to elongate and can cause thinning at bends. This is why it is important to use the right lubricant to reduce friction between the work-piece and the roll dies. Lubrication can also reduce crazing and corrosion of the work-piece surface.

In addition to lubrication, the choice of cooling method can impact the quality of the finished product. Flood cooling extends tooling life, while dry cooling shortens it. Both options have their own disadvantages and advantages, but the final decision depends on the requirements of the project.

Customized

A metal roll former is a piece of equipment that takes standard sheet metal and transforms it into a formed component. This process is highly automated and can produce components at a much faster rate than traditional methods. It can also minimize material waste and save on labor costs, making it an efficient solution for large-scale production. In addition, the precision and consistency of this process can make it an attractive option for manufacturers that require precise, high-quality standards in their products.

During the roll forming process, the metal strip is bent by multiple sets of rollers. Each set is positioned to bend the sheet metal in incremental steps, resulting in a complex profile that can be used to make studs, joists, and trusses. The steel frame roll forming machine curved shapes created by the rollers can help reduce material waste and improve strength, durability, and aesthetics.

Many of the components made in a metal roll forming machine can be customized to fit customer specifications. These custom-made pieces can include features such as a curved roof or tapered sides. This type of system requires a flexible roll former, which uses removable subplates, or “rafts,” to quickly change production settings between two sections without handling individual tools or resetting the gap between each stand. The rafts allow different configurations of inboard and outboard shafts, tooling, and stands, so the machine can be used to make a variety of profiles.