Roll Forming and Production Costs

Production Rate and Conversion Cost Standard roll forming machines are usually equipped for operation at a nominal rate of 100 FPM, but may easily be designed for a higher or lower speed to meet a specific requirement.  At that rate,...

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Planning for Machine Setup Time

Operators need to plan ahead and devote time to stripping, cleaning and storing one set of rolls, then and loading and adjusting another set. The intensity and length of time dedicated to machine setup can vary based on the...

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The Roll Forming Operator: Who Runs the Machine?

Will You Need a Team? For lines of average proportions, usually a single roll forming operator is sufficient. Depending on the number of machines in the plant, however, this single operator may or may not be capable of making a roll setup. As lines...

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The Complete Roll Forming Line

The complete roll forming line can take one of two approaches to the processing of a particular part. It can be arranged to produce that part from: Precut lengths Coiled strip Some parts demand the cut length approach; however, the most efficient, productive, consistent,...

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When to Split or Combine Your Tooling

Split Rolls and Combination Tooling Rolls are split where necessary to facilitate machining, grinding or for other changes, and also to allow for easy replacement of a roll piece that might be subject to extreme wear. In general, no roll pieces exceed...

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Tips for Positioning Your Shape

Accessory Tooling It is sometimes necessary to mount rolls on vertical axes, between driven roll stages, to exert side pressure to a shape when it is needed for forming or guiding. Likewise, when cut-to-length strips are fed through a roll forming...

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Roll Form Tooling: Selecting Roll Stages

Tooling in a roll forming machine predominately consists of the driven forming rolls, together with the spacers that hold them laterally in alignment on the spindles.  The importance of proper roll design, materials and manufacture cannot be emphasized enough. ...

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Forming Machine Drives

The OEM will determine the correct amount of horsepower required to form the section.  The horsepower takes into account four critical items.  They are: Material Thickness Total number of forming stands Desired line speed Yield strength of material With these items in mind the...

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Machine Effects on a Formed Section

The capability of any given machine with regard to height or depth of the section is measured mainly by the vertical distance available between spindles.  This, together with the distance from the centerline of the bottom spindle to the...

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Choosing Your Roll Forming Machine

The roll forming machine is the instrument needed to convert strip to a finished cross-section.  Common to all makes is a fabricated base, roll spindles, spindle support housings and a drive. Integral Drive Type The most popular forming machine is the...

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