Roll Forming Handbook

edited by

George T. Halmos
Delta Engineering, Inc. Toronto, Ontario, Canada

Taylor & Francis

Taylor & Francis Group
Boca Raton London New York

A CRC title, part of the Taylor & Francis imprint, a member of the Taylor & Francis Croup, the academic division of T&F Informa pic.

Contents

Introduction to Roll Forming George T. Halmos 1.1 Introduction to Roll Forming

1-1 1-1

Roll Forming Mill George T. Halmos 2.1 General 2.2 Mill Types 2.3 Mill Components References

2-1 2-1 2-1 2-18 2-32

Presses and Die Accelerators George T. Halmos 3.1 General 3.2 Mechanical Presses 3.3 Pneumatic Presses 3.4 Hydraulic Presses 3.5 Information and Dimensions for Press/Die Purchasing and Installation 3.6 Rotary and Other Cutting, Punching Equipment 3.7 Flying Die Accelerators

3-1 3-1 3-6 3-10 3-12 3-15 3-15 3-20

Secondary Operations in the Roll Forming Line

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14

George T. Halmos

4-1
4-2 4-3 4-9 4-14 4-14 4-16 4-19 4-20 4-20 4-22 4-24 4-46 ...4-46 4-46

Secondary Operations Straightening Tight or Loose Line: Cutting Before, In-Between, or After Roll Forming Location of the Secondary Operations Stationary and Flying Dies Punching, Perforating, Notching, and Mitering Piercing and Partial Punching Flanging, Louvering, and Lancing Embossing and Drawing Bending Curving (Sweeping) Marking Swedging (Offsetting) Rotary Dies

Contents
4.15 Mechanical Joining of Different Strips or Parts 4.16 Adhesive Bonding 4.17 Soldering and Brazing 4.18 Resistance Welding 4.19 Painting 4.20 Foaming 4.21 Packaging References 4-56 4-60 4-60 4-60 4-62 4-62 4-62 4-62

Roll Design George T. Halmos 5.1 Roll Design Process 5.2 Cross-Section 5.3 Product Orientation and Other Operations in the Line 5.4 Materials 5.5 Roll Forming Mill 5.6 Other Tool Design Considerations 5.7 Spacers and Shims 5.8 Calculating Strip Width 5.9 Bend Lines 5.10 Number of Passes 5.11 Flower Diagram 5.12 Roll Design 5.13 Calculating Roll Dimensions Manually 5.14 Computer-Aided Roll Design 5.15 Examples 5.16 Roll Marking System 5.17 Roll Orientation 5.18 Setup Charts References

5-1 5-2 5-4 5-13 5-19 5-28 5-40 5-48 5-52 5-55 5-64 5-73 5-78 5-94 5-95 5-100 5-103 5-107 5-107 5-111

Materials George T. Halmos 6.1 Design Considerations 6.2 Mechanical Properties 6.3 Crystalline Structure of Metals 6.4 Forming Metals 6.5 Increasing the Strength of Metals by Cold Working 6.6 Hot Rolling 6.7 H.R. and H.R.P.O. Steels 6.8 Cold Rolled Steel 6.9 Carbon Steel 6.10 Alloyed Steel 6.11 Stainless Steel 6.12 Metallic Coatings 6.13 Nonmetallic Coating and Laminating 6.14 Joining Different Materials in the Roll Forming Process 6.15 Aluminum 6.16 Other Metals and Materials

6-1 6-1 6-2 6-7 6-7 6-10 6-10 6-12 6-12 6-12 6-13 6-15 6-16 6-17 6-18 6-18 6-20

Contents
6.17 Influence of Primary Metal Processes on Roll Forming 6.18 Guideline to Steel Prices References 6-20 6-24 6-24

Lubrication Joseph Ivaska 7.1 Tribology of Lubrication 7.2 Selection of Lubricants 7.3 Surface Properties of Formed Material 7.4 Lubricants for the Secondary Operations 7.5 Application Techniques 7.6 Preparation and Maintenance of Lubricants 7.7 Operating Problems during Production

7-1 7-1 7-5 7-8 7-10 7-11 7-12 7-18

Coil Processing, Material Handling, and Plant Layout

George T. Halmos and Joseph Horvath 8.1 Flow of Material 8.2 Coil Handling and Storage 8.3 Sheet Handling and Storage 8.4 In-Line Coil Handling 8.5 Coil End Welding 8.6 Strip (Coil) Accumulators 8.7 Flattening and Leveling 8.8 In-Line Sheet Handling 8.9 Finished Product Handling 8.10 Finished Product Storage 8.11 Material Handling Equipment 8.12 Material Handling Accessories 8.13 Crane Controls 8.14 Plant Layout References 8-1 8-2 8-3 8-6 8-9 8-14 8-16 8-19 8-22 8-23 8-31 8-34 8-38 8-40 8-41 8-43

Designing Products for Roll Forming

George T. Halmos
9-1 9-2 9-10 9-20 9-22 9-22 9-29

9-1

9.1 Developing Light Gage Products 9.2 Design Considerations 9.3 Secondary Operations 9.4 Profiles Manufactured in Different Sizes 9.5 Design of Specific Products 9.6 Dimensioning and Tolerancing References

10

Equipment Installation, Roll Setup, Maintenance, and Troubleshooting

George T. Halmos 10.1 Installation of Roll Forming Lines 10.2 Roll Installation and Setup 10.3 Maintenance and Spare Parts 10.4 Troubleshooting and Trouble Prevention 10-1 10-1 10-8 10-14 10-32

xii

Contents

11

Behavior of Metal Strip during Roll Forming Manabu Kiuchi 11.1 Various Types of Deformations 11.2 Causes of Redundant Deformations 11.3 Effects of Redundant Deformations on Product Defects 11.4 Mathematical Simulation of the Deformation of a Metal Strip 11.5 Computerized Design System for Roll Profiles 11.6 CAEfor Roll Forming
t

11-1 11-1 11-3 11-6 11-19 11-29 11-34 12-1 12-1 12-2 12-3 12-4 12-7 12-7 12-7 12-7 12-11 12-11 13-1 13-1 13-2 13-2 13-3 13-3 13-8 13-9 13-13 13-13 13-14 13-14 13-14 13-15 13-16 George T. Halmos 14-1 14-1 14-2 14-3 14-4 14-10 14-10 15-1 15-2 15-2

12

Acquiring Roll Forming Lines, Education, and Training 12.1 Why Roll Form Products? 12.2 Different Paths to Start Roll Forming 12.3 Evaluating the Product 12.4 Selecting Line Components 12.5 Procuring Roll Forming Tooling 12.6 Equipment and Tool Specifications 12.7 Acceptance Test 12.8 Education and Training 12.9 Motivation References Safety AshokShah 13.1 Safety 13.2 Common Safety-Related Definitions 13.3 Safety Design Procedure 13.4 Determining Limits of the Machinery or System 13.5 Determining Hazards/Risk Estimation 13.6 Risk Reduction by Design 13.7 Safeguarding 13.8 Selection of Guards and Protective Devices 13.9 Required Characteristics of Guards and Protection Devices 13.10 Signals and Warning Devices 13.11 Personal Protective Equipment 13.12 Training 13.13 Summary References

George T. Halmos

13

14

Increasing Efficiency of Roll Forming Lines and Case Studies 14.1 Output, Productivity, and Efficiency 14.2 Line Utilization 14.3 Improving Productivity 14.4 Case Studies 14.5 Preliminary Tool and Equipment Cost Analysis 14.6 Preliminary Cost Analysis Unusual, New, and Future Roll Forming Technologies 15.1 The Last 100 Years 15.2 The Future of Roll Forming

15

George T. Halmos

Contents 15.3 Pull-Through Mills: Nondriven Rolls 15.4 Tension Roll Forming 15.5 Combining Roll Forming and Cold Drawing 15.6 Developing New Roll Forming Methods 15.7 Roll Forming Tools 15.8 Reducing the Thickness of the Starting Material 15.9 Forming at Elevated Temperature 15.10 Hot Roll Forming Variable Cross-Sections 15.11 Hot Thickness Reduction along the Length of the Strip 15.12 Welding Hot Roll Formed Sections 15.13 Other "Hot" Processes 15.14 In-Line Soldering, Brazing, and Heat Treating 15.15 Equipment and Tooling Requirements for Hot Roll Forming 15.16 Press Tooling for Conventional Roll Forming Lines 15.17 Computer-Controlled Roll Forming Lines References

xiii 15-5 15-6 15-7 15-7 15-9 15-10 15-11 15-11 15-12 15-12 15-13 15-13 15-14 15-16 15-16 15-17

Appendices References Index

A-l R-l 1-1