From the earliest days of civilization, metals have been used to create weapons, tools, body armor, structures, vehicles, jewelry, and art. Due to its strength and malleability, metal in one form or another has almost endless uses for any imaginable application. Though processes for handling, forming, and manipulating metals has improved over the early forges and blacksmithing techniques, in many ways the only changes are in industrial automation and speed.
One such automated process in forming metal into a desired, functional shape is roll forming. Also commonly referred to as a single word, i.e. rollforming, it is a process that utilizes a series of rolls, or stands, that are set up consecutively, with each bending the metal incrementally, progressing through additional rolls until the final desired shape is attained. It typically begins with coiled steel that is held by a dispenser from which it is unrolled and fed into the cutting attachment and from there into the shaping roll mills. It is a very efficient process for large quantities and shapes requiring long length.
Roll forming allows more than just the bending of metal in progressive steps. It can also include holes or notches by punching, and embossing, or forming a pattern on the metal such as wood grain simulation. It can be used with most any type of metal, including as high strength or low alloy steel and aluminum. It is a very precise system, often employing computer simulation in order to optimize the process using the minimum number of rolls to achieve the desired final shape.
Because roll forming is done without heat, with the metal remaining in a cold, hardened state, it has advantages over extrusion methods. It doesn't affect the metal's chemical or physical properties in order to achieve the final shape. Cold roll forming results in parts that are typically stronger and lighter than extruded counterparts. It can also be painted and finished during the same process. It is also less labor intensive, resulting in a less expensive process and product.
Roll forming processes are very versatile with numerous applications. A good example of roll formed metal is metal shelving that is precisely bent and notched. The process is used in the automotive industry to create parts including chassis sections and impact bars. It is used in the building construction industry for a variety of applications. Resulting parts can be simple or highly complex, requiring a close collaboration between the user and manufacturer for a successful result.
Author Resource:-
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