Roll forming machine use long strips to make specific configuration metals, the most common being coiled steel. In most applications, the cross-sectional profile required to intersect the part is the metal necessary to machine the machine bend. In addition to roll forming, these machines perform a variety of operational metalworking duties, including material cutting and roll forming.
In most cases, the roll forming machine operates in a continuous cycle. The material is fed into the machine where it continually passes through the stages of each operation of the machine to the end of the final product.
A roll forming machine bends metal at room temperature using a number of stations where fixed rollers both guide the metal and make the necessary bends. As the strip of metal travels through the roll forming machine, each set of rollers bend the metal a little more than the previous station of rollers.
This method of progressively roll forming the metal ensures that the correct crossover achieves the cross-sectional configuration of the workpiece while maintaining the cross-sectional area. Typically run at speeds of 8-20 meter per minute, roll forming machines are ideal for high volume production or long parts. And also suitable for creating very few precision parts that are needed, if any, finishing work. In most cases, depending upon the material being shaped, the end product features an excellent finish and very fine detail.
The basic roll forming machine has a line that can be separated into four major parts:
Entry Section, named as uncoiler or decoiler, where the material is loaded. The material is usually inserted in sheet form or fed from a continuous coil.
Station Rollers, known as roll forming rollers. which is the main part of roll forming machine and where the metal shapes as it makes its want through the process. And also are the main driving force of the machine.
Cutoff Unit, where the metal is cut to desired length. Due to the speed at which the machine works and the fact that it is continuously working machine, flying cutoff techniques are not uncommon.
Exit Station, where the finished part exits the machine onto a roller converor or table. Manualy or automatically moved
Today's roll forming machines feature computer-aided tooling designs. By incorporating CAD/CAM systems into the roll forming equation, machines function at their maximum potential. Computer controlled programming provides roll forming machines with an internal "brain" that catches product imperfections, minimizing damage and waste. The famous Roll Forming Machine designed software is COPRA.
Aside from the benefits discussed in the previous section, roll forming machines offer the user some specific advantages. Roll forming machines are energy efficient because they do not expend energy to heat material—the metal shapes at room temperature Roll forming is also an adjustable process and is applicable to projects of varying time duration. Additionally, roll forming results in a precise, uniform part.
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