Tube Mills & Quick-Change: Timing is Everything

Part 3 It’s time now to examine the overall pros and cons of climbing on board rafting as a tube mill quick-change design compared with the still-popular conventional method for producing brand new tube shapes and sizes. For a tube mill,...

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Tube Mills & Quick-Change: Rafts & Drive Shafts

Part 2 Moving into “rafting” is an important upgrade for ambitious tube mills aiming for expansion and efficiency in a highly-competitive field where the ability to “quick-change” is a key enabler of performance. The moveable subplates of rafts, unlike the traditional...

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Tube Mills & Quick-Change: One Step At A Time

Part 1 For many tube mills faced with the constant challenge of adjusting or exchanging tooling for making tubes with different dimensions, a frequent question concerns the existing changeover equipment. Should the mill be upgraded with new tooling, i.e. rolls...

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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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Identifying Appropriate Roll Materials

Roll Materials and Roll Life Rolls are usually made from tool steel, the grade being dependent on the expected production and finish of the piece part.  For general duty applications where a smooth finish strip is to be formed or...

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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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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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Distortions: Springback & End Flare

There are two main elastic distortion phenomena that both the shape and tool designer must be aware of when forming: "springback" and "end flare". Let's break them down one at a time, explaining what they are and how they...

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Roll Forming Design Considerations: Part 2 of 2

This post is a continuation of "Roll Forming Design Considerations: Part 1 of 2", where we discussed process limitations to consider when developing successful continuous production habits. Tolerances a. Tolerances on part dimensions are largely dependent on the tolerances of the...

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Roll Forming Design Considerations: Part 1 of 2

For the most part end product design dictates shape configuration, but at the same time familiarity with the processing limitations goes a long way toward designing for manufacturing simplicity and thereby successful, continuous production of uniform piece parts. Some...

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