Roll forming

Roll forming, also spelled roll-forming or rollforming, is a

type of rolling involving the continuous bending of a long
strip of sheet metal (typically coiled steel) into a desired
cross-section. The strip passes through sets of rolls mounted
on consecutive stands, each set performing only an
incremental part of the bend, until the desired cross-section
(profile) is obtained. Roll forming is ideal for producing
constant-profile parts with long lengths and in large
quantities.

Bending along rolls

Contents
Overview
Process
Geometric possibilities
Production rates
Other considerations
See also
References
Notes
Bibliography

Overview
A variety of cross-section profiles can be produced, but each
profile requires a carefully crafted set of roll tools. Design of
the rolls starts with a flower pattern, which is the sequence
of profile cross-sections, one profile for each stand of rolls.
The roll contours are then derived from the flower pattern Flower pattern
profiles. Because of the high cost of the roll sets, computer
simulation is often used to develop or validate the roll
designs and optimize the forming process to minimize the number of stands and material
stresses in the final product.

Roll-formed sections may have advantages over extrusions of a similar shapes. Roll formed
parts may be much lighter, with thinner walls possible than in the extrusion process, and
stronger, having been work hardened in a cold state. Parts can be made having a finish or
already painted. In addition, the roll forming process is more rapid and takes less energy than
extrusion.[1][2]

Roll forming machines are available that produce shapes of different sizes and material
thicknesses using the same rolls. Variations in size are achieved by making the distances
between the rolls variable by manual adjustment or computerized controls, allowing for rapid
changeover. These specialized mills are prevalent in the light gauge framing industry where
metal studs and tracks of standardized profiles and thicknesses are used. For example, a single
mill may be able to produce metal studs of different web (e.g. 3-5/8" to 14 inches), flange (e.g.
1-3/8" to 2-1/2") and lip (e.g. 3/8" to 5/8") dimensions, from different gauges (e.g. 20 to 12 GA) of
galvanized steel sheet.

Roll forming lines can be set up with multiple configurations to punch and cut off parts in a
continuous operation. For cutting a part to length, the lines can be set up to use a pre-cut die
where a single blank runs through the roll mill, or a post-cut die where the profile is cutoff
after the roll forming process. Features may be added in a hole, notch, embossment, or shear
form by punching in a roll forming line. These part features can be done in a pre-punch
application (before roll forming starts), in a mid-line punching application (in the middle of a
roll forming line/process) or a post punching application (after roll forming is done). Some roll
forming lines incorporate only one of the above punch or cutoff applications, others
incorporate some or all of the applications in one line.

Process

Roll forming is, among the manufacturing processes, one of

the simplest. It typically begins with a large coil of sheet
metal, between 1 inch (2.5  cm) and 20 inches (51  cm). in
width, and 0.004 inches (0.10 mm) and 0.125 inches (3.2 mm)
thick, supported on an uncoiler. The strip is fed through an
entry guide to properly align the material as it passes
through the rolls of the mill, each set of rolls forming a bend
until the material reaches its desired shape. Roll sets are
Cluster roll set typically mounted one over the other on a pair of horizontal
parallel shafts supported by a stand(s). Side rolls and cluster
rolls may also be used to provide greater precision and
flexibility and to limit stresses on the material. The shaped strips can be cut to length ahead of
a roll forming mill, between mills, or at the end of the roll forming line.

Geometric possibilities

The geometric possibilities can be very broad and even include enclosed shapes as long as the
cross-section is uniform. Typical sheet thicknesses range from 0.004 inches (0.10 mm) to 0.125
inches (3.2 mm), but they can exceed that. Length is almost unaffected by the rolling process.
The part widths typically are not smaller than 1 inch (2.5  cm) however they can exceed 20
inches (51 cm). The primary limitation is profile depth, which is generally limited to less than
4 inches (10  cm) and rarely larger than 6 inches (15  cm) due to roll-imparted stresses and
surface speed differentials that increase with depth.

Tolerances can typically be held within ±0.015 inches (0.38 mm) for the width of the cross-
sectional form, and ±0.060 inches (1.5 mm) for its depth.[3]

Production rates

The production rate depends greatly on the material thickness and the bend radius; it is
however also affected by the number of required stations or steps. For bend radii of 50 times
the material thickness of a low carbon steel 0.7 inches (18 mm) thick can range from 85 feet
per minute (26  m/min) through eight stations to 55 feet per minute (17  m/min) through 12
stations or 50 feet per minute (15 m/min) through 22 stations.
The time for one product to take shape can be represented by a simple function:
t = (L + n⋅d) / V, where L is the length of the piece being formed, n is the number of forming
stands, d is the distance between stands, and V is the velocity of the strip through the rolls.[3]

In general, roll forming lines can run from 5 to 500 feet per minute (1.5 to 152.4  m/min) or
higher, depending on the application. In some cases the limiting factor is the punching or
cutoff applications.

Other considerations

While dealing with manufacturing, Things to consider are, for example, lubrication, the effect
of the process on material properties, cost, and of course safety.

Lubrication provides an essential barrier between the roll dies and the work-piece surface. It
helps reducing the tool wear and allows things to move along faster. This table shows the
different kinds of lubricants, their application, and the ideal metals to use them on.

Work material Roll lubricants Application

Nonferrous Chlorinated oils or waxes, mineral oils Spray, wiping roller
Ferrous Water-soluble oils Wiping, drip, spray
Stainless steels Chlorinated oils or waxes Wiping roller
Polished surfaces Plastic film Calendaring, covering, spraying
Pre-coated materials Film or forced air

The effects of the process on the material's properties are minimal. The physical and chemical
properties virtually don't change, but the process may cause work-hardening, micro-cracks, or
thinning at bends when discussing the mechanical properties of the material.

The cost of roll forming is relatively low. When calculating the cost of the process things such
as setup time, equipment and tool costs, load/unload time, direct labor rate, overhead rate,
and the amortization of equipment and tooling must be considered.
Safety is also a bit of an issue with this process. The main hazards that need to be taken into
consideration are dealing with moving work-pieces (up to 800 feet per minute (240 m/min)),
high pressure rolls, or sharp, sheared metal edges.[3]

See also
Sheet metal
Skin-pass
Structural shape rolling
Tube beading
Roll bending
Drawer slides roll forming machine

References

Notes
 1. Todd, Robert H.; Allen, Dell K.; Alting, Leo (1994), Manufacturing Processes Reference Guide (http
s://books.google.com/books?id=6x1smAf_PAcC), Industrial Press Inc., pp. 300–304, ISBN 0-
8311-3049-0.
2. Groover, Mikell P. (2010). Fundamentals of Modern Manufacturing: Materials, Processes, and
Systems (https://books.google.com/books?id=QU-Qvud3OvoC&dq=roll+bending&source=gbs_nav
links_s). John Wiley & Sons. p. 472.
3. Manufacturing Processes Reference Guide, Industrial Press Inc., 1994.

Bibliography
Halmos, George T. Roll Forming Handbook, CRC Press, 2005. ISBN 0-8247-9563-6
Dobrev, Atanas; George T. Halmos (1993). "Roll forming into the 21st century". Society of
Manufacturing Engineers.
Todd, Robert (1994). Manufacturing Processes Reference Guide. New York: Industrial Press inc.
ISBN 0-8311-3049-0.

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