Roll forming companies have known for many years the many benefits of using the process of roll forming to create complicated and complex metal shapes. Roll forming is often used to manufacture large metal pieces, and it has many benefits over other forms of metal shaping such as pressbreaking. If you are interested in using roll formed metals, consider some of the following advantages:
Lower costs: Roll forming requires less material handling and labor. This creates a continuous production and lowers the cost-per-piece of each metal piece.
Increased consistency: For large orders, roll forming creates pieces that are identical every time. You will find more accuracy, uniformity, and consistency in individual pieces as well as the entire production lot.
Fewer secondary operations: With roll forming, you can add additional extras, often saved for secondary processing, at the same time. During roll forming you can cut, notch, perforate, punch, and otherwise change the metal during the initial production. This also increases the structural integrity of the piece and better parts joining.Rapid delivery and turnaround times: Because roll forming is done mostly with one simple process, parts can get to your sooner. Basically, roll forming is a one-stop shop that allows your metal parts to get to you sooner with greater accuracy and cost savings.
For these reasons and more, if a company has the option of choosing to use roll formed metal, you will not be sorry. Roll formed metal is highly effective and beneficial in a multitude of ways.
Examples of Roll Forming products include angle irons, aluminum angles and steel angles which are used in carpentry and building applications. Metal trim and metal channels are also widely used in construction, but they are also used in the manufacture of industrial, commercial and consumer products. Metal rings are used to embellish buttons on telephones, in elevators and even clothing. They also prevent hoses from disconnecting, street signs from falling and they secure lock hardware in doors. Metal wall panels can improve the appearance of a wall in an office, or it can protect a wall in a factory from flying debris or sparks. All of these roll formed products are produced in stock quantities by metal fabricators because of the constant, high demand for them. However, in the many cases in which a stock roll formed product is not appropriate, custom roll forming provides specialized products in large quantities and of uniform quality. Roll forming is a modular process; roll formers can be configured to produce all manner of metal shapes.Roll formed parts boast a variety of advantages over alternative forming processes; roll formers generate very little scrap material while simultaneously improving the qualities of strength and durability in the metals they process; this makes them very cost-effective compared to other metal shaping processes. Roll forming is a cold forming process, which means that no heat is used to make the metals pliable. Instead, compression and force are used to shape the metals; the compressive stress created by the rollers imparts qualities of strength as they shape the metal. Other metal shaping processes like thermoforming can create larger amounts of scrap, they can be more energy intensive and the machinery can be expensive. Also, roll forming is a continuous process, which means that as long as a roll former is fed with a continuing supply of metal, it can continue producing shaped products. The only major drawback to roll forming as a metal shaping method is the labor intensity of roller configuration; this process requires a trained professional to precisely set roller systems to ensure a flawless finished product. Recent advances in computer control systems have made this process easier, but it can still be costly.
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Roll Formed Part Terms
Piece of equipment that holds metal coil so the roll forming process may
continue uninterrupted while new material is attached to the coil.
- Secondary processes performed in conjunction with roll forming.
- A deviation from a straight line in a roll formed piece.
- Procedure in which heated flat sheet metal is transformed into spiral coils.
- The process of deforming metal at room temperature in order to increase strength and hardness.
- The system responsible for providing the roll forming machines with power and moving the metal coils through the machines.
- The ability of metal to bend or form without fracture.
- The maximum amount of stress a metal can accept without succumbing to permanent deformation.
- Deformation at the end of a roll formed part.
- Piece of equipment that connects two coils to permit the continuance of metal coils into the roll forming machine.
- A metal in which iron makes up a significant component.
- Mechanism that maintains flatness of metal being fed into the roll forming machine.
- A metal that does not contain iron.
- Permanent changes in the shape of a metal that occur after pushing a metal piece past its elastic limit. Deformation is accomplished through the application of stress.
- The process of cleaning steel coils in preparation for metal forming processes, such as roll forming. The coils are subjected to hydrochloric acid that removes impurities, such as rust, from the metal.
- Imperfections in the metal coil.
- The process of changing the rolls on roll forming equipment. This is a long, costly procedure.
- In reference to the edge of sheet or strip metal that results from cutting to width by rotary slitters.
- Deformation in a roll formed part that occurs when the roll forming process fails to stretch a part past its elastic limit.
- Deviation from a straight line in the horizontal plane measured after the part has been formed. Sweep is caused because of incorrect horizontal roll alignment and/or uneven forming pressure.
- The acceptable variation from product specifications, such as cross-sectional dimensions.
- Removing metal scrap from a metal formed part in order to maintain consistency among metal parts.
- Deformation in a roll formed part that resembles a corkscrew. Twists are caused by extreme pressure levels created during the roll forming process.
- The maximum stress which can be applied to a material without lasting deformation of that material.