Roll forming, sometimes spelled roll-forming or rollforming, is a metalworking process by which sheet metal is gradually plastically deformed using consecutive sets of roller dies. The process has evolved from the manual art of metal forming into highly-automated systems able to perform complex procedures with high efficiency and precision.
Roll forming first begins with flat, which is a flat metal sheet that is typically painted or galvanized as needed. The sheet metal is then fed into the in-feed end of the roll forming machine, where it is securely held by sets of rollers. As the sheet metal unwinds through the roll forming machine, the sets of roller dies gradually shape the metal into its intended form. Along the way, any additional features, such as bends, notches, and pierced holes, are created with special machines. Finally, the metal is rolled to its final shape and size. This process has several advantages, including a reduction in manufacturing costs, longer product life-cycles, and less winding strain.
Roll forming can be used for almost any kind of metal, including carbon steel, stainless steel, aluminum, and copper. For each metal, the specific roll forming machine and settings must be altered accordingly. The process can be used to create a variety of products, including angle irons, low-profile roof trusses, steel frames for doors and windows, and automotive panels. The most common application for roll forming is in the construction industry, where various parts such as girders, floor joists, and roof trusses are created on a mass scale.
The cost of roll forming is highly dependent on the type of output desired, as well as the quality of the metal being used. Equipment setup costs, labor fees, and the complexity of the design can also vary depending on the project. Most roll forming operations can be performed on a wide variety of equipment, including CNC-operated machines, free-standing machines, or machines that can be attached to welding cells.
Roll forming is an efficient and cost-effective way to create complex structural components and shapes. With the right formulation and design, roll forming can create tight-tolerance parts and products with exceptional strength, while reducing labor and material costs associated with traditional metal fabrication. Relying on the expertise and guidance of experienced professionals, manufacturers are able to create components that are both high quality and cost effective.
Roll forming is a valuable asset for any sheet metal manufacturing plant, providing the means for producing high quality parts and components quickly and efficiently. In addition to the initial cost savings, roll forming also helps reduce overall manufacturing costs by eliminating extra labor, expediting production time, and reducing machinery and tooling costs. Furthermore, because the process does not require extensive heat treatment, rolled components can be built faster and at a lower cost than those produced using traditional manufacturing methods. This method of metal fabrication is a worthwhile investment for many industries, allowing them to realize the savings and quality benefits associated with roll forming.
