••••••>The Benefits of Roll Forming

Roll forming is a process in which strips of metal, usually in coil form, is continuously passed through a series of roller dies and progressively formed to the desired shape. In many cases roll forming eliminates multiple stage production, sub-assembly and finishing operations. Any number of subassembly operations can be continuously combined in the operation. Like all cold forming processes, roll forming work hardens the part (increases the tensile strength) by producing a grain structure that follows the contour of the part and does not produce scrap.

Even though thread rolling is the most common type of roll form, other applications include forming of knurls, grooves, chamfers, pointing, radii, etc. In these rolling processes however, generally the displaced material is restricted and/or elongated while holding the original blank diameter.

The cost and product advantages of this process are numerous. It permits consistent adherence to close tolerances, producing shapes and dimensions to fit your application. By eliminating the need for secondary operations such as notching and deburring, production speed is increased and assembly costs are reduced. Roll-formed material generally has a structural strength advantage over other processes. Hollow or semi-hollow shapes can be produced with thinner walls than competing processes. Material cost savings, improved part strength, consistent quality and reduced manufacturing costs are supplemental to the benefits already derived on the cold formed blank.

Roll forming is the most economical choice for many companies that look to streamline their production and reduce overall cost. The high-speed continuous nature of roll forming is especially beneficial for large volumes. An experienced custom roll former will incorporate a number of secondary operations in one line. Savings are realized through the need for fewer component parts, fewer post-production operations and reduced manufacturing cost.

An experienced roll former can guide you through the early planning stages providing the benefit of years of experience in design and engineering. Several stages of redesign may occur in order to trim costs and simplify production and assembly. A custom roll former can deliver finished shapes, cut to exact length for assembly in your production. This frees up valuable manufacturing space in your plant and completely eliminates scrap loss. By eliminating secondary operations, labor costs are also greatly reduced.

••••••>Roll forming

The use of metal has changed our lives. Stronger homes, heavy machinery, tools and many household objects use metal for its durability and strength. It can be molded to almost any shape and size according to temperature. Rolling is a necessary part of metalworking and is also classified according to the temperature used. If the metal is above the recrystallization temperature, then the rolling process is called hot rolling and if it is below, then it is termed cold rolling.

One of the processes of rolling is called roll forming wherein strips of metal sheets are passed through sets of rolls. This is done to create a desired cross section profile. The resultant product is used in many areas like general engineering, automobile manufacture, pollution control and construction. The procedure allows other operations like punching, notching and welding to be performed in succession which reduces labor cost and time.

Material is also utilized more efficiently through roll forming, reducing wastage and the need to use vast quantities of substances. While similar to pipe and tube making, the process allows for a better ability of forming complicated sections. Also, you can produce finished parts or have them painted during the process.

If you’re looking for a roll forming manufacturer in the United States, you won’t have to search far. Most companies use the latest equipment to produce fine rolls at lower costs. They can fix holes and dimples in metal to bring out smooth and even material using advanced computer software. Others use machines whose accuracy is fine tuned to a very precise 00.01mm.

Inline welding capabilities like TIG and laser welding and induction ensure that the products conform to quality standards to guarantee customer satisfaction. Along with roll forming, many also offer other services like routing, miter cutting, robotic welding, artificial aging and solution heat treatment.

When searching for a roll forming manufacturer, compare services offered by different companies. Which offers you the best at a reasonable cost? Of course, this doesn’t mean compromising on quality over cost. It just means that there are manufacturers who do offer a lot at a lesser cost and the trick is to scout well to find one.