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Sheet Metal Roll Forming

 
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01/

Our Factory
Locates in Libao town, Hai' an county, Nantong city where close to Shanghai and famous for manufacturing the CNC press brake, shearing machine, plate rolling bending machine, iron worker, etc. sheet metal working machineries.

02/

Our Product
We specialized in the production of Hydraulic press brake, Hydraulic guillotine shearing machines & swing beam shearing machines, Plate rolling bending machine, Profile roll forming machine, roof tile roll forming machine, light steel keel roll forming machine, ironworker, Fiber laser cutting machine, etc.

03/

Production Market
Has cooperated with the professional companies in USA, Germany, France, Australia, Japan, Sweden, Chile, Brazil, etc. more than 70 countries so that develop and perfect the products with superb technology. BRISK currently has representative offices in more than 50 countries and regions through designated distributors.

04/

Our Service
Is not only focus on produce but also in after-sales service. We have established scientific package solution for machines in container transportation, road transportation, train transportation through safety and cost-effective way.

 

What is Sheet Metal Roll Forming？

 

 

Roll forming is a continuous metal forming process taking sheet, strip, or coil stock and bending or forming it to a continuous cross section. The process is performed between successive pairs of rolls that change the shape until the desired section is completed.

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Process of Sheet Metal Roll Forming

 

Uncoiling
Metal coils may become set during storage and have a tendency to stay coiled and become distorted. To correct the problem, the coil is loaded onto the uncoiler, seen below, and fed through a flattener to remove the coil set. The lead end is trimmed to allow for smooth feeding into the pre-press process.

Part of the pre-press operation may be a tapering of the beginning of the feed coil to make it easier for it to slide into the forming rollers.

 

Pre-press Treatment
Before the metal from the coil is fed into the roll forming rollers, it may need applications added as can be seen in the image below, which can involve adding slots, holes, or slits.

 

Roll Forming
At this stage, the material is progressively shaped. A typical roll forming machine can consist of 10 to 24 pairs of roller die stands. The machine is individually or gang driven to force the ribbon of metal through the rollers that gradually shape it to the dimensions of the flower pattern.

 

Cutoff and Discharge
Parts are cut to length as they are in motion, which increases the efficiency and speed of the roll forming process. Once they are cut, they are discharged to a run-out table to be placed for shipment or further processing.

 

Secondary Processes
There are a variety of ways secondary processes can be performed. Some can be completed as the part comes off the cutoff, while others may have to be performed at another station.

 

Lubricant
With any metal forming process, friction plays an important role, which is the resistance produced when two bodies make contact. It is a means of energy dissipating that causes a rise in temperature where two surfaces meet. The temperature is further enhanced by the speed of the process.

Lubrication is used in the roll forming process to reduce friction between the rolls and metal to prevent tool wear. Friction is a necessary part of the rolling process and an important part of shifting the metal forward between the rollers. It should not be eliminated or reduced below an appropriate level. The need for friction has to be considered when choosing a lubricant.

Roll forming uses fluid lubricants with a low viscosity that include paraffin for non-ferrous metals such as aluminum and copper. Lubricants increase the rate of production, which is determined by the thickness of the material, number of roll stations, and the amount of bending. Below is an example of a roll forming process that uses a chlorine free lubricant.

 

How Does a Sheet Metal Roll Forming Work?

 

 

A roll forming machine accomplishes the fabrication process by sending sheet metal—most commonly coiled steel—through a series of fixed rollers, which continuously and incrementally bend the metal into the required form. By progressively bending the metal bit by bit at strategically spaced rollers, manufacturers can customize cross-sectional shapes with exacting precision and uniformity. A typical speed for roll forming machines is anywhere from 30 to 100 feet of metal per minute, ensuring an incredible ongoing output of material.

Typically at room temperature, metal coils or sheets feed into rollers that guide the material to the first of the bending stations. Once there, a roller will precisely bend the metal and then drive it forward through the machine to the next station. Each station will continue to shape the component by bending it a little more, with capabilities for unique and complex part designs. The more contoured the design, the more roller stations the part will pass through.

After the metal makes its way through the rollers, the workpiece enters the cut off press, which cuts the metal to its specified length. Despite the nearly limitless length options, roll forming machines require only one set of tools for generating cuts. This machinery can also offer other in-line services such as welding or punching.

Ultimately, the finished component emerges onto a roller conveyor for a worker to retrieve. This is one of the few stages that may involve manual processing. Added technology can run the machinery, precisely placing the metal for optimal cutting and checking for imperfections while reducing labor costs and material waste.

The formed end product will require minimal finishing work, if any, before packaging or storage. This is due to roll forming’s capabilities for producing finely detailed components with continuous finishes and few seams.

 

 
Benefits and Advantages of Sheet Metal Roll Forming
 
 
Efficiency

The speed of roll forming is due to the long coils of metal it uses that are rapidly fed into the forming machine. Since the machine is self-feeding, there is little need for human monitoring, which lowers the cost of labor. Punching and notching during pre-feeding avoids the need for secondary operations.

 
Cost savings

Metals do not need to be heated for roll forming, which significantly lowers energy costs. The careful control and lubrication of moving parts reduces tool wear and the cost of component replacement. The smooth finishes of completed parts removes the need for secondary processes such as deburring or trimming of flash. Parts are produced in large quantities reducing the cost of the final product.

 
Flexibility

Complex and intricate cross sections can easily be produced using ferrous and non-ferrous metals. In some processes, it is not possible to shape a metal that has been painted, plated, or coated. Roll forming can easily shape them regardless of the type of finish.

 
Quality

Products are more uniform and consistent across a complete run. Tolerances are very tight with extremely precise dimensions. Sharp, clean contours are maintained with the absence of die marks or deformities.

 
Length of Parts

Since the metal is fed into the machine, any length can be produced using the same tooling for any part.

 
Less scrap

Roll forming produces one to three percent scrap for each production run, which is far less than any other metal working process. The lower amount of scrap lowers the cost of working with expensive metals.

 
Repeatability

A major problem with bending metal is residual stress, which negatively affects repeatability. The rapid processing of roll forming helps metals retain their residual stress as well as any loss of weld seam control.

 
Versatility

Roll forming can perform profile bending for sheets of ferrous or nonferrous metals with different thickness levels. There is flexibility in part design as components can consist of a single bend or an intricate pattern of geometric shapes, all with a high degree of precision and uniformity. The process is ideal for producing U-channels, C-channels, round and closed shapes as well.

 
Part Dimension Capabilities

The roll forming process and its machinery reduce the need for seams by allowing you to shape longer metal components, and in varying lengths, all with one tool set. Stud and track machinery, for instance, can generate framing as long as is required. Brake pressing and stamping operations cannot accommodate the lengths of material that roll forming equipment can.

 

 

The Versatility Of Sheet Metal Roll Forming Applications
In The Automotive Industry

The automotive industry is one of the most significant beneficiaries of roll-forming technology. It is used extensively for manufacturing various components, such as:
Bumpers: Roll formed steel channels are commonly used for automotive bumpers. The process allows for creating precise shapes and contours, enhancing aesthetics and functionality.
Door Frames: Door frames made through roll forming are lightweight yet sturdy, providing structural integrity while minimizing vehicle weight. This helps improve fuel efficiency and overall performance.

Roof Rails: Roof rails on cars are often produced using roll forming. They must be durable and weather-resistant, making roll-formed profiles an ideal choice.
Chassis Components: Steel sections with roll forming are used to construct vehicle chassis, contributing to rigidity and safety.

In Construction

The construction industry relies heavily on roll forming for various structural and architectural elements. Some key applications include:

Metal Roofing and Siding: Roll forming creates corrugated and standing seam metal roofing and siding panels. These materials are durable, weather-resistant, and easy to install.
Studs and Tracks: Roll forming stainless steel studs and tracks are essential in framing interior walls. Roll-formed sections provide the necessary strength and dimensional stability.
Purlins and Girts: In metal building construction, roll-formed purlins and girts are favored components. They combine cost-efficiency with impressive load-bearing capacity, contributing to the structural integrity of such buildings.
Flashings and Trim: Customized flashings and trim components are roll-formed to fit specific architectural designs, providing functionality and aesthetics.

Aerospace Applications

In the aerospace industry, precision is paramount, and roll forming meets this demand exceptionally well. Some applications include:

Aircraft Frames: Roll forming produces lightweight yet strong profiles for aircraft frames, reducing fuel consumption and enhancing performance.
Seat Tracks: Seat tracks made with roll forming provide adjustability and strength for passenger and crew seats in aircraft.
Aerospace Tubing: Roll-formed tubing is used to construct hydraulic and fuel lines, ensuring reliable performance under extreme conditions.

Consumer Goods And Appliances

Roll forming extends its reach to consumer goods and appliances, where it plays a vital role in shaping components for various products, including:

Shelving Systems: Metal shelves made from roll-forming processes are commonly used in retail and warehouse settings due to their durability and adjustability.
Garage Doors: Roll forming stainless steel creates the tracks and panels for garage doors, ensuring smooth operation and longevity.
HVAC Components: Ductwork, brackets, and other HVAC components are often roll-formed, providing efficiency and reliability.

 
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Our Factory
 

 

BRISK locates in Libao town, Hai' an county, Nantong city where close to Shanghai and famous for manufacturing the CNC press brake, shearing machine, plate rolling bending machine, iron worker, etc. sheet metal working machineries. The company' s registered capital is around USD 150,000.00 and invested 6000 Square Meter Manufactory and 5000 Square meter exhibition showroom in Jiangsu Province.

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FAQ
 

 

Q: What is the rolling process in sheet metal?

A: In metalworking, rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness, to make the thickness uniform, and/or to impart a desired mechanical property. The concept is similar to the rolling of dough.

Q: How does sheet metal forming differ from rolling?

A: It is the process by which pieces of sheet metal are altered and reformed without removing any of the original material—rolling as well as forging and extrusion work differently because they apply forces to the material to pressure it into flowing into a new shape.

Q: What does a roll forming machine do?

A: Roll form machines are designed to make sheet metal into straight formed shapes. The roll forming process takes a continuous flat sheet of metal and power feeds it through a successive series of Hardened Steel Rollers, which station by station shape the metal into a finished shape as it passes through them.

Q: What is the sheet metal forming process?

A: Traditional metal manufacturing techniques include forming, casting, molding, joining, and machining. Sheet metal forming involves various processes where force is applied to a piece of sheet metal to plastically deform the material into the desired shape, modifying its geometry rather than removing any material.

Q: What is roll forming in sheet metal?

A: Roll forming is a continuous process which converts sheet metal into an engineered shape using consecutive sets of mated rolls, each of which makes only incremental changes in the form. The sum of these small changes in form is a complex profile.

Q: How is sheet metal rolled?

A: The roll of flat sheet metal is hung on a spindle and then fed through the roll line. Roll forming works when the flat metal goes through a series of rollers that slowly bend the flat metal into the finished cross section.

Q: How thick is roll forming?

A: Roll forming is, among the manufacturing processes, one of the simplest. It typically begins with a large coil of sheet metal, between 1 inch (2.5 cm) and 20 inches (51 cm) in width, and 0.004 inches (0.10 mm) and 0.125 inches (3.2 mm) thick, supported on an uncoiler.

Q: What are the three metal forming processes?

A: Examples of massive forming processes are extrusion, forging, rolling and drawing.

Q: What is the process of sheet forming?

A: Sheet forming is used to produce curved panels for large structures such as the fuselage. The process involves clamping the ends of rolled metal sheet (usually thinner than 6 mm) and then stretching over a forming block to the desired shape.

Q: What is roll forming process in sheet metal?

A: Roll forming is a unique metal forming process that starts with a long strip of metal, usually in coil form. The roll forming machine forces the material through a series of mated tool dies to achieve a uniform shape. Each step of the operation bends the workpiece little by little until it reaches the desired shape.

Q:  What is the rolling process?

A: Rolling is a process used to shape metal into a thin long layer by passing it through a gap of two rollers rotating in different directions (clockwise and anti-clockwise) [5]. The gap between the two rollers is supposed to be smaller than the thickness of the working piece of material to be formed.

Q:  What materials are used in roll forming rollers?

A: There are many materials that can be used for rolling forming, such as low-carbon steel, stainless steel, galvanized sheet, aluminum, etc. Among them, low-carbon steel is commonly used for rolling forming, and non-ferrous metals are more suitable for rolling forming.

Q:  What is ironing in metal forming?

A: Ironing is a sheet metal forming process that uniformly thins the workpiece in a specific area. This is a very useful process when employed in combination with deep drawing to produce a uniform wall thickness part with greater height-to-diameter ratio.

Q: Is rolling a sheet metal forming process?

A: The process of rolling is a specialized form of metal forming for shaping large bulk material into more detailed parts and large length cross sectional materials, as well.

Q: What are the different types of sheet metal forming?

A: The main processes of sheet metal forming are the stretch forming, deep drawing, or in general a combination of both. During stretch forming, the sheet material will be shaped by the punch but squeezed between the drawing die and the blank holder. The material flows under a biaxial stress and strain condition.

Q: How is metal formed in rolling?

A: In metalworking, rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness, to make the thickness uniform, and/or to impart a desired mechanical property.

Q: What is the fundamental concept of metal rolling?

A: 1) The arc of contact between the rolls and the metal is a part of a circle. 2) The coefficient of friction, µ, is constant in theory, but in reality µ varies along the arc of contact. 3) The metal is considered to deform plastically during rolling. 4) The volume of metal is constant before and after rolling.

Q: What is the best metal for sheet metal forming?

A: Mild steel is by far the most commonly used material for sheet metal fabrication. The relative strength it has, combined with the ease of fabrication and relatively low cost compared to stainless steel or aluminum, means that it's suitable in plenty of applications.

Q:  What is the thinnest sheet metal you can get?

A: Sheet metal thickness typically ranges from about 0.005 inches to about 0.125 inches. The minimum thickness that is practical for most applications is about 0.005 inches, while the maximum thickness that is practical for most applications is about 0.062 inches.

Q: What is the least expensive sheet metal?

A: Mild/Low Carbon Steel
Due to its low carbon content, mild steel is very easy to fabricate. Additionally, mild steel is more malleable than stainless and very easy to weld. Mild steel is also much cheaper than stainless and typically cheaper than aluminum as well.

As one of the leading sheet metal roll forming manufacturers and suppliers in China, we warmly welcome you to buy high-grade sheet metal roll forming for sale here from our factory. All our products are with high quality and low price.

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