Development of Roll Forming Machines:
The roll forming machine is designed with computer aided tools. Machines can reach their maximum potential by integrating CAD/CAM systems into the roll forming equation. Computer-controlled programming provides the roll former with an internal”brain”that captures product defects and minimizes damage and waste.
In many modern roll forming machines, programmable logic controllers ensure precision. This is critical if the part requires multiple holes or needs to be cut to a specific length. Programmable logic controllers tighten tolerance levels and minimize accuracy.
Roll forming process:
The basic roll forming machine has a line that can be divided into 4 main sections. The first part is the inlet part of the loaded material. The material is usually inserted in sheet form or fed from a continuous roll.
The next part, the station rolls, is where the actual roll forming takes place, where the stations are, and where the metal is formed throughout the process, Station rolls not only shape the metal, but are the main driving force of the machine.
The next part of a basic roll forming machine is the cut-of press, which cuts the metal into predetermined lengths. Due to the speed at which the machine works and it is a continuous machine, fly cutting technology is not uncommon. The last part is the exit station, where the finished parts leave the machine to a roller conveyor or table, where they are moved manually.
Application range of roll forming machine:
Compared to other forming processes, the roll forming process makes it easier to manufacture lighter steel parts because the wall thickness can be determined according to the structural needs of the part.
Parts can be rolled even if a finish or paint has been applied. While nonperforming can produce similarly complex profiles, roll forming is a room temperature process. As a result, it avoids the warping risks associated with nonperforming while being more energy efficient.
With these many advantages, it’s no surprise that roll forming has applications in many industries, including automotive, appliances, construction, agriculture, solar, and shelving.