Roll forming is a continuous operation, typically done at room temperature, in which coiled or sheet metal is permanently formed along the linear axis. Rolling dies, set in pairs (top and bottom), progressively shape the metal until the desired cross section is reached.
Shown above is a roll form "flower diagram". It is utilized to show how the desired cross section is gradually formed. The material starts as a flat coil or blank, and each pair of rolls, or pass, adds some shape.
Why Roll Form?
Roll forming offers an economical and highly repeatable process with close tolerances on part length, width and cross-section detail.
Here are some advantages of roll forming a metal part:
The roll forming process allows operations such as punching, notching, and welding to be performed in-line. Labor cost and time for secondary operations are reduced or eliminated, reducing part cost.
Roll form tooling allows for a high degree of flexibility. A single set of roll form tools will make almost any length of the same cross section. Multiple sets of tools for varying length parts are not required.
Roll forming can provide better dimensional control than other competing metal forming processes.
Repeatability is inherent in the process, allowing easier assembly of roll formed parts into your finished product, and minimizing problems due to "standard" tolerance build up.
Roll forming is typically a higher speed process.
Roll forming offers customers a superior surface finish. This makes roll forming an excellent option for decorative stainless steel parts or for parts requiring a finish such as anodizing or powder coating. Also, a texture or pattern can be rolled into the surface during forming.
Roll forming utilizes material more efficiently than other competing processes.
Roll formed shapes can be developed with thinner walls than competing processes.
Recent Trends in Roll Forming
Pyramid Mouldings is a market leader in custom roll forming.
We utilize the latest technology to minimize cost and improve quality. PLC's, servo-driven feeds, in-line welders, and automated operations are used to save OEM's millions of dollars.
Utilizing Toyota Production System (TPS) philosophies and practices, all Pyramid roll form lines are designed for quick changeover and small quantity runs. No longer are roll formers tied to dedicated machines, long production runs, and large inventories!