What to Look For in a Roll Forming Machine

If you want to buy a roll forming machine, there are a few important aspects to look for. These include high-speed, precision, and cost. These factors are essential for a successful business. Read on to learn more. A roll forming machine will help you create the perfect products in the shortest time. Its capabilities include forming and re-forming plastic and other materials. It can also be used to create complex shapes.

High-speed

A high-speed roll forming machine has a variety of features. It can produce various shapes, such as trapezoidal and similar profiles. It can work with coil widths of up to 1.500 mm. During the process, the steel sheet is fed into the rolls and formed. Once formed, the products are fed out. In the end, they are finished products. High-speed roll forming machines are used for the production of a variety of parts.

The HVM series high-speed roll forming machine is developed on the basis of the HV series forming machine. It incorporates hydraulic, electrical and mechanical equipment to ensure high-speed operation. It has received 2 patents for utility model and invention. The HVM series high-speed roll forming machine can produce panels of different shapes and sizes. Its various parts include sheet guiding equipment, hydraulic system, automatic stacker, and automatic control system.

The High-speed roll forming machine consists of a forming frame made of cast iron with a tempered finish. The roll shaft material is 40Cr with a hardness of HB280 after quenching. The forming mold is made of Cr12MoV and is HRC 56-62 degC. The transmission structure is gearbox. The machine has a light steel keel machine. Its cutting off part consists of a receiving table. The machine’s electrical control system controls the process.

Continuous

The Continuous roll forming machine produces thin to wide sheets of material, up to 72 inches in length. Its production rate depends on the material thickness and the number of stations required. The production rate for low carbon steel with 50-times bend radius can range from 85 feet per minute through eight stations to 55 feet per minute through twelve stations. The speed can be adjusted based on punching applications. The following is a description of the various roll forming machines available.

The Accessory System is a system that offers a variety of options for roll forming. A number of pre-loaded pass stations enable fabricators to produce a variety of metal construction accessories. The machines can operate without the operator, which is a major advantage. With the Accessory System, the fabricator does not need to change tooling for multiple passes. Additionally, this feature makes it much easier for fabricators to adjust gap settings.

The High-strength steels make roll forming an ideal choice for high-volume batches. It produces parts that do not require extensive finishing processes, which reduces costs. The high-strength steels also require higher overbends, which can make the end product harder to control quality. The Continuous roll forming machine also minimizes secondary processes. If you’re looking for a high-quality and low-cost metal forming machine, a Continuous roll forming machine may be the right choice.

Precision

A Precision roll forming machine is a perfect tool for the production of intricate parts. The material can be either ferrous or non-ferrous and can have a wide variety of cross-sections. It can also produce parts with a great degree of detail and finish. Precision roll forming machines are ideal for the production of intricate parts with a small number of minor adjustments. They can be used for both small and large scale production.

The process of roll forming begins with a large coil of sheet metal ranging from one inch to thirty inches in width. Depending on the configuration of the machine, this coil can be as thin as 0.012 inches or as thick as 0.2 inches. The coils must be cut and prepared before the forming process can begin. The process is described in a diagram, which shows each step of the process, including discharge and cutoff.

The global High Precision Roll Forming Machine market is expected to reach US$ million by 2028, increasing at a CAGR of %. North America and Europe are expected to have the largest share of this market through 2028. Japan and India are among the fastest growing markets and are projected to experience the highest growth rates over the forecast period. The High Precision Roll Forming Machine market is expected to grow at a CAGR of % from 2018 to 2028, which is a significant amount.

Cost

The cost of a roll forming machine varies depending on the type and complexity of the process. Typical in-house systems can produce a single profile, while a forming line can produce up to 1.5 million linear feet a year in single shift operation. The higher the volume, the higher the ROI. A roll forming machine can be a good investment for your business, but you need to know the cost.

The first step is to understand the process of roll forming. Roll forming produces about 3% scrap and if the tolerances are too tight, tool wear and stress cracking will result. To prevent such problems, you should design the tool to fit the machine’s travel range. A pre-cut line is slower than a post-cut line, but it has lower equipment expenses and simpler cut off dies. For high-speed applications, flying die systems are often used. They can achieve accuracy of 0.032″ or better.

Another important factor to consider is the number of passes necessary to form a section. This can be an obvious choice, but in some cases, it may be necessary to add extra passes or modify adjacent passes. This can add to the cost of a roll forming machine. In addition to the amount of punching and forming, it is important to consider the number of repeatable features and how much the process will cost. Once you have your desired profile, you’ll be able to choose the right tooling and machine setup for your business.

Safety

Having a proper Roll Forming Machine Safe Operating Procedure is crucial to prevent injury from working with this equipment. These procedures outline the steps to be taken to ensure the machine is safe to operate. These procedures can be instantly delivered via email and can help you train your workers on the correct use of the machine. They also include a training quiz for workers, which consists of questions that are either multiple choice or true or false. Safety is a top priority, so safety measures should start from the design phase and continue through the production process.

When operating a roll former, make sure that the area surrounding the machine is clear of debris. Dust and other metal materials can gather in this area, compromising the aesthetics of rolled products. Likewise, the presence of water can cause the drive rollers to wear down or rust. When cleaning a roll forming machine, make sure to follow the manufacturer’s cleaning guidelines. By following these tips, you can increase the life of your roll forming machine and make it safer for your workers.

In order to minimize the risk of injury during a roll forming operation, you must pay close attention to the tolerances of the tooling. For instance, it is vital to monitor the gap between the steel sheet and the metal part. Imperfections may occur at any point in the process. Changing the tooling manually can be hazardous and could result in accidents. In addition, a misaligned entry guide can cause an uneven result.

Types

There are many different types of roll forming machines available on the market. The primary differences between them are speed and precision. Double-headed machines feature two separate sets of rolling shafts and housings that are adjustable for different widths. Rafted machines have common rolling tools mounted on a raft. The advantages of forming metal in this way include less material waste and faster production. Another advantage is that roll forming machines require minimal tool wear and maintenance.

There are many applications for roll forming machines. Parts produced by these machines include panels, tracks, and shelving. These parts are commonly used in commercial and industrial buildings, and for lighting and HVAC applications. A typical roll formed part is about one inch wide. The maximum width is twenty inches. The depth is typically limited to four inches because the roll-imparted stress increases with depth. Depending on the material used, the type of roll forming machine is needed to accommodate the part’s thickness.

The speed of roll forming machines varies by application. The rate depends on the material thickness, the bend radius, and the number of stations required. For example, a 50-foot-radius low carbon steel forming machine can produce a steel tube at a speed of 85 feet per minute through eight stations, or a 60-foot-per-minute output through 22 stations. The production rate may be up to 500 feet per minute, depending on the application.