Roll forming machine is a kind of mechanical equipment commonly used in metal material processing. Roll forming machine can process metal materials into the required shape and size by bending and plastic deformation. The main principle of roll forming machine is to use mechanical force to apply bending force to metal materials to make them plastically deformed, so as to obtain the required shape.
In this article, you will learn the following questions about roll forming machine:
1. Definition of roll forming machine
2. Application of roll forming machine
3. Processing technology of roll forming machine
4. How to trial roll forming machine
5. Cost of roll forming machine
1/What Is Roll Forming Machine
The basic structure of the roll forming machine consists of a frame, rollers, transmission device and control system. The frame is the supporting structure of the entire machine and bears the force and pressure generated during the forming process. The rollers are the core components of the roll forming machine. They are driven by the transmission device to apply bending force to the material. The control system is responsible for operating and controlling the machine so that it can be formed according to the predetermined parameters.
The working process of the roll forming machine can be divided into several steps. First, the metal material to be processed is placed in the feeding position of the machine. Then, the rollers are driven by the transmission device to rotate and apply bending force to the material. The grooves and flanges on the rollers can be adjusted as needed to obtain the required forming curve. In the process of the material being bent by the rollers, plastic deformation occurs inside it, so that the material gradually forms the desired shape. Finally, the finished product is taken out from the discharge position after the forming is completed.
The roll forming machine uses mechanical force to bend metal materials. By adjusting the position of the rollers and the shape of the grooves, the bending angle and bending radius of the material can be controlled. Under the action of the wheel, the metal material will be subjected to pressure and tension, thus undergoing plastic deformation and eventually reaching the desired shape.
The cold roll forming machine uses the principle of plastic deformation for forming. Plastic deformation refers to the reversible deformation of the material under the action of external force. During the operation of the cold roll forming machine, the metal material is subjected to the bending force of the roller, causing it to bend and deform. Due to the plastic nature of the metal, the material undergoes reversible plastic deformation, gradually forming the desired shape.
The forming process of the cold roll forming machine needs to be operated and controlled by a control system. The control system can adjust the position of the roller and the shape of the groove according to the predetermined parameters to obtain the desired forming curve. At the same time, the control system can also monitor and adjust the working state of the machine to ensure the stability and accuracy of the forming process.
2/What Is The Application Of Roll Forming Machine
"The products produced by the cold roll forming machine through the deformation and processing of metal raw materials are widely used in the construction and building materials industry, storage equipment industry, cable tray industry, photovoltaic support industry and metal roof tile industry, etc."
The most representative products of cold roll forming machines in the metal ceiling industry include baffle ceiling making machine, open cell ceiling making machine, ceiling t grid making machine, false ceiling channel making machine, stud and track machine, metal ceiling carrier machine and so on.
Through the production process of cold roll forming, metal ceiling production equipment can help solve the vast majority of finished products required in metal ceiling systems, such as various types of metal ceilings and false ceiling channel series products. Cold roll forming machines are widely used in the construction industry. The metal ceiling machine produced by KINGREAL ROLL FORMER can help customers improve production efficiency and obtain long-term production benefits.
Warehouse Storage Shelf System Equipment
Shelving System Equipment can be used to produce complete shelf system products, including metal shelf panel making machine, shelf rack making machine, upright rack making machine and box beam roll forming machine.
Warehouse Storage Shelf System Equipment can adapt to the needs of different industries for shelf products, usually including heavy and light shelf equipment.The CNC system of Warehouse Storage Shelf System Equipment ensures that the dimensional error is ≤0.5mm, which meets the requirements of shelf load-bearing and stability. The mold can be quickly replaced to meet the production needs of different specifications (such as shelf layers, step beams, etc.).
The key components are made of high-strength materials (such as 40Cr steel rollers, GCr15 molds), and the hardness reaches HRC56-62 after heat treatment, which prolongs the life of the equipment.
Cable tray forming machines are designed to produce a rigid structural system for supporting, protecting and managing cables, and are widely used in construction, power, communications and industrial facilities. Cable tray forming machines can produce cable tray covers, cable tray ladders, perforated cable trays, solid bottom cable trays and other components to carry cables, prevent mechanical damage, corrosion or external interference, provide orderly cable paths, facilitate the separation of power cables and communication cables, and improve system safety and maintenance efficiency.
Cable tray forming machines process metal coils into standardized bridge structures through cold bending, punching, shearing and other processes, replacing traditional manual production and significantly improving efficiency and quality
Solar Channel Roll Forming Machine
Photovoltaic bracket forming machine is an automated industrial equipment specially used for the production of solar photovoltaic brackets. It integrates unwinding, leveling, punching, forming, cutting and other processes to achieve continuous and efficient processing. It is controlled by a CNC system, with a dimensional error of ≤0.5mm and a hole position repeatability accuracy of ≤0.15mm, ensuring the stability and adaptability of the bracket.
The applicable scenarios of photovoltaic bracket forming machine include rooftop photovoltaic systems, and lightweight brackets are adapted to the load-bearing requirements of buildings. Ground power stations, large-span steel brackets (span ≤12 meters) are used for long-distance overhead scenes. Industrial environment, anti-corrosion brackets (galvanized or spray-coated) are suitable for chemical, coastal and other high-corrosion areas.
3/ Processing Technology Of Roll Forming Machine
"The cold roll forming machine is generally composed of a multi-pass horizontal roller frame and a straightening roller frame. Different auxiliary deformation rollers and vertical rollers are configured according to the requirements of profile forming. The horizontal roller is a transmission frame and undertakes the main task of deformation. The auxiliary roller is passive and is set between two horizontal rollers or in groups. Its main function is to deform the blind corners that cannot be compacted by the flat roller and reduce the pass of the horizontal roller. The vertical roller is set in the same plane of the horizontal roller hole type and is used for the edge forming of the last few passes. For the closed street surface of the bite, cores, pull rods, bite indentation and other components are also set.
The pressing form of the rolling mill can be divided into spiral mechanical pressing and hydraulic pressing. Mechanical pressing has a lower cost, and hydraulic pressing is easy to operate. The transmission method is a universal shaft type, and the upper and lower horizontal rollers can have a large adjustment range to adapt to the production of multiple types of profiles. To facilitate the replacement of rollers, the outer frame and the bottom plate are mostly connected by flip-over hinges. The transmission between roller groups mostly adopts chain transmission to ensure the synchronization of transmission."
Decoiler
The unwinding device is a key component of the forming machine. It is mainly used to unwind the metal coil and provide a continuous and stable material supply for subsequent roll forming, punching, shearing and other processes. Its core function is to ensure that the material enters the processing flow flat and with controllable tension, which directly affects the production efficiency and the quality of the finished product.
The unwinding machine fixes and unwinds the metal coil through the expansion and contraction reel to prevent the material from unwinding or deflecting. Adjust the unwinding speed and tension of the coil to prevent the material from stretching, deformation or relaxation. The material position is monitored in real time through the induction rack or photoelectric sensor to achieve automatic start and stop.
Roll Forming Machine
Forming Rollers gradually bend the sheet into a preset cross-sectional shape through continuous rolling of multiple sets of rollers (horizontal rollers, vertical rollers, and auxiliary rollers). Horizontal rollers are responsible for the main deformation task, and vertical rollers are used for edge forming or correction of complex angles.
Forming machine components are the core modules that realize plastic deformation of metal sheets or coils and ultimately form target profiles. They are made of high-strength alloy steel (such as Cr12MoV), with a quenched surface (hardness HRC58-62), a wear-resistant life of more than 1 million times, a multi-roller layout, active rollers driven by motors, and auxiliary support by driven rollers to reduce stress concentration.
Cutting System
The cutting equipment in the cold roll forming machine is a key component used to cut the continuously formed metal profiles to the preset length. Its accuracy, efficiency and cutting quality directly affect the qualified rate of finished products and production costs. The profile displacement is tracked by encoders or sensors, and the profile is accurately cut according to the preset length (error ≤±0.5mm) to ensure that the cutting surface is flat and burr-free, reducing the subsequent grinding process.
The cutting equipment of the cold roll forming machine can choose flying shears, flying saws, lasers or hydraulic shears according to the material characteristics (thickness, hardness), product accuracy requirements and cost budget.
4/How To Trial The Roll Forming Machine
Roll forming machine trial refers to the operation of machine operation test and parameter trial after the assembly of the roll forming machine is completed to ensure that the performance, accuracy and other indicators of the machine meet the requirements. The following is an explanation of the specific steps of roll forming machine debugging.
1. Preliminary preparation of the machine: including the installation of the machine, adjustment of the base, positioning of the machine and other operations
2. Electrical debugging: Electrical work debugging is an indispensable debugging process, including the debugging of electrical control systems and other auxiliary motors.
3. Power debugging of the machine: The power debugging of the machine is mainly to check whether the control command of the electrical control system is reasonable and whether the auxiliary motor is working normally.
4. Cutter die debugging: Cutter die debugging is one of the most important debugging processes of the roll forming machine. Its purpose is to check whether the machine can complete the work of roll forming.
5. Curling wheel group debugging: The curling wheel group is an important part of the machine. Its debugging is to enable the curling wheel group to accurately control the shape of the material curling.
6. Speed and displacement debugging: Speed and displacement debugging is to control the running speed and displacement of the machine to ensure the accuracy and performance of the machine operation.
7. Punching and cutting debugging of cold roll forming machine: Punching and cutting debugging is the last debugging process of the machine, and its purpose is to ensure that the machine can complete cold roll forming and punching work normally.
5/Cost of roll forming machine
The price of cold roll forming machines is affected by many factors, and the prices of equipment with different configurations, functions and brands vary greatly.
1. Product complexity and profile size
If you need to produce complex profiles such as corrugated plates and special-shaped sections, you need to customize more roller sets, usually 20-30 sets, which will extend the debugging cycle and significantly increase the price.
Large profiles require larger rollers and transmission systems, which will increase the amount of steel and processing costs, and the price of equipment will increase accordingly.
2. Automation and integration level
It only contains cold roll forming and manual cutting functions, and the price is relatively low.
Integrated modules such as unwinding, leveling, punching, forming, cutting, etc., and equipped with a PLC control system, the price can reach 500,000-1 million yuan/unit.
3. Precision and surface treatment requirements
If the profile tolerance is required to be ≤±0.5mm or surface polishing/chrome plating, a higher precision roller processing technology is required, and the cost increases by 30%-50%.
4. After-sales service costs
Complex equipment requires a higher after-sales budget (such as debugging and maintenance), and manufacturers usually include service costs in the quotation.
KINGREAL ROLL FORMER is one of the professional roll forming machine manufacturer, we are looking forward to establishing long-term and stable cooperation with customers all over the world.