Advantages of Roll Forming :
- The roll forming process allows operations such as punching, notching, and welding to be performed in-line. Labor cost and time for secondary operations are reduced or eliminated, reducing part costs.
- Roll form tooling allows for a high degree of flexibility. A single set of roll form tools will make almost any length of the same cross-section. Multiple sets of tools for varying length parts are not required.
- Roll forming can provide better dimensional control than other competing metal forming processes.
- Repeatability is inherent in the process, allowing easier assembly of roll formed parts into your finished product, and minimizing problems due to “standard” tolerance build up.
Roll Forming Process
Roll forming steel is essentially a continuous bending operation performed on metal strip at room temperature. Tandem sets of rolls progressively shape the metal until the desired cross-sectional profile is achieved.
Roll forming is ideal for producing parts with long lengths or in large quantities. It can also produce parts of multiple lengths from the same tooling. Virtually any material that can be formed using sheet forming techniques can also be roll formed. Roll forming may also be an excellent solution whenever the consistency of the cross-sectional profile is critical.
Benefits of Roll Forming
High productivity rate as compared to other manufacturing processes
Able to combine multiple manufacturing operations in-line with the roll forming stations greatly reducing total manufacturing costs
Reduces handling, packaging and shipping costs
Produces parts of various lengths from the same roll sets
Able to produce parts with different hole patterns from the same roll sets
Capable of eliminating supplemental operations (e.g. cutting-to-length, drilling, splicing, etc.)