Roll forming is a versatile and cost-efficient process for shaping metal into custom cross-section profiles. Usually called “cold roll forming,” because the metal is formed in its hardened state, roll forming is used throughout a wide range of industries to produce parts and components for everything from metal forming in automobiles to home equipment to airplanes and houses.
For products that may be roll formed, the process affords a host of benefits and advantages over various approaches.
Most roll forming is completed with long strips of metal in coils, so the process is high-speed, with low labor calls for, permitting higher volume production for most products with higher effectivity than with press braking or stamping. Additional processes, corresponding to punching or notching, could be incorporated into a roll-forming production line, additional reducing labor calls for, and outputting accomplished products ready for distribution. Press braking requires separate processes for punching, notching, or perforating, adding time, labor, and expense.
Roll forming is a no-heat system — reducing energy prices — that gradually bends the metal, in levels, into its closing shape by passing it by a series of custom-designed rollers. Roll forming doesn’t create the tool wear that stamping does, the process eliminates the need for machining, akin to deburring, usually required with press braking. An identical parts cut from long strips mean no wasted scrap, and roll-fashioned parts will be of just about any size, while press braking limits size to the dimensions of the machine. Roll-fashioned metal parts produced in quantity are nearly always more value-efficient than plastic or extruded versions.
Even advanced cross-section profiles that are a challenge or are unattainable with stamping can be simply created with roll forming, together with round, closed, and C-formed profiles. Virtually any metal, ferrous or nonferrous, could be roll-shaped, while extrusion is limited to only aluminum or brass. Roll forming additionally permits 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 can be designed to meet very tight tolerances. Products are more uniform and constant across runs than with press braking, facilitating ease of use in applications resembling assembly line manufacturing, the place parts must fit right every time. Roll forming can produce much higher quality products and parts than extrusion.
ADVANCED DESIGN TOOLS
Mills gives inline sweeping and arcing capabilities that can create advanced, graceful curves and bends for aesthetics in products similar to automotive or appliance trim.
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