The Benefits of Roll Forming

Roll forming is a versatile and price-efficient process for shaping metal into custom cross-part profiles. Often called “cold roll forming,” because the metal is formed in its hardened state, roll forming is used across a wide range of industries to produce parts and parts for everything from metal forming in automobiles to appliances to airplanes and houses.

For products that may be roll formed, the process presents a host of benefits and advantages over various approaches.

EFFICIENCY

Most roll forming is finished with long strips of metal in coils, so the process is high-speed, with low labor demands, allowing higher quantity production for many products with higher effectivity than with press braking or stamping. Additional processes, such as punching or notching, could be incorporated into a roll-forming production line, additional reducing labor demands, and outputting completed products ready for distribution. Press braking requires separate processes for punching, notching, or perforating, adding time, labor, and expense.

SAVINGS

Roll forming is a no-heat system — reducing energy prices — that gradually bends the metal, in levels, into its final form by passing it through a series of customized-designed rollers. Roll forming doesn’t create the tool wear that stamping does, the process eliminates the necessity for machining, corresponding to deburring, typically required with press braking. Equivalent parts lower from long strips mean no wasted scrap, and roll-formed parts might be of almost any length, while press braking limits size to the dimensions of the machine. Roll-fashioned metal parts produced in quantity are nearly always more value-effective than plastic or extruded versions.

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FLEXIBILITY

Even complex cross-section profiles which might be a problem or are not possible with stamping may be easily created with roll forming, together with round, closed, and C-shaped profiles. Almost any metal, ferrous or nonferrous, might be roll-fashioned, while extrusion is limited to only aluminum or brass. Roll forming additionally allows the shaping of metals already finished with paint, plating, or coating, while extrusion works only with unfinished, unplated stock, and press braking of completed metals requires additional dealing with and processes, costing time and money.

PRECISION, QUALITY AND CONSISTENCY

Roll forming may be designed to fulfill very tight tolerances. Products are more uniform and consistent across runs than with press braking, facilitating ease of use in applications akin to assembly line manufacturing, the place elements should fit proper each time. Roll forming can produce a lot higher quality products and components than extrusion.

ADVANCED DESIGN TOOLS

Mills gives inline sweeping and arcing capabilities that can create advanced, graceful curves and bends for aesthetics in products equivalent to automotive or appliance trim.

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