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11/09/2007 - Roll forming

Roll forming is a continuous bending process, performed at environment temperature, in which a sheet metal is plastically deformed on its own longitudinal axle. A series of rolls couples (roll stations) create section shape by successive passages, until the desired shape is obtained. Big sheet metal coils are the starting point of the process. This coils are unwound (Figure 1) ant then sent to the forming line (Figure 2), where they are bended until the desired section is obtained. A roll forming manufacturing line is usually subdivided in four sections. The entry section, where material enters production line, is followed by the forming section, where there are the rolls, and the actuation, lubrication and cooling systems. After the last roll, there is usually a straighter, that is used to improve dimensional precision of the product. The third fundamental element is the cutting mechanism, usually of flying die type (that is synchronized with strip motion) that provide to strip cutting. Finally there is the exit section, where material is taken and sent to the next machining phase.
Roll forming is indicated for a large part of metallic materials (or non metallic materials with good bending properties) and is characterized by high production speeds and good dimensional precisions.

Figure 2: Roll forming line – scheme.

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