Roller Die-Forming Process
Roller die-forming is a formwork process in which sheet metal is pressed between rollers and upper and lower dies which form the sheet into the desired shape. The sheet metal is usually heated for improved malleability during the forming. Roller die-forming is a popular forming method for many industries, including automotive, HVAC, aluminum extrusions, tanks, fasteners, and consumer products.
The roller die-forming process begins with the design of the formed components. A custom die set is then created for the component, based on the application and desired dimensions of the component. The design of the die set includes both an upper and lower die, as well as a series of rollers. The upper and lower dies are made from hardened steel, and then machined to the desired shape. The die set must be tuned to the material being formed and the desired component shape in order to avoid excessive strain and wear on the dies.
The next step in the process is to set up the roller die-forming machine. The rollers, upper and lower dies, and sheet metal are then placed into the machine. The rollers are adjustable, and must be carefully adjusted to ensure that the rollers do not damage the material being formed. The rollers must also be adjusted to properly form the component to the desired shape.
Once the machine is set up and the rollers are adjusted, the sheet metal is fed into the machine. As the sheet enters the machine, the rollers gradually compress the material inward towards the lower die, forming it into the desired shape. The roller die-forming process can be used for thin gauge materials as well as thick gauge materials and several different shapes.
To complete the process, the component is then removed from the machine and put through a cool-down process. This is done to ensure that the component retains its shape and to prevent warping or deforming.
Roller die-forming is an extremely cost-effective forming process and provides numerous advantages over traditional forming processes. It is less labor-intensive and requires minimal tooling, which makes it ideal for large production runs of components. For these reasons, it has become a popular choice for many industries. Additionally, roller die-forming offers repeatable and accurate results, making it an ideal choice for components that require strict tolerances or complex shapes.
