The Benefits of a Roll Forming Machine
There are several factors that influence the type of machine a business will use for roll forming metals. Some factors include floor space and budget constraints.
The process involves coils of metal that are fed into consecutive forming stations. Each station nudges the metal towards the desired profile. Using this technique, complex and intricate cross sections can be created in a short time.
Roll forming machines work well with a variety of metals including ferrous and non-ferrous alloys, stainless steel, galvanized steel, aluminum and more. It also can shape materials that have been plated, painted, or coated. This makes it a much more cost-effective choice than other processes that can’t work with these kinds of materials.
One of the ways that the use of a roll forming machine reduces costs is that you can often avoid secondary operations such as welding, cutting and punching. These operations take up valuable production time and add to your overall cost. If you plan ahead and choose the right machine for your project, you can minimize these costs and keep the bottom line low.
Another way that you can reduce cost is to get your production line up and running quickly. This can be done by choosing a machine that can handle the volume you need. Some manufacturers offer economic order quantity runs that allow you to purchase your equipment with a lower upfront cost and pay the rest over a long contract period.
Lastly, the tooling for your roll forming machine can also be designed to increase efficiency. Using computer-aided design systems, you can save on setup costs by having your tooling calibrated to the actual thickness of the material being used. This eliminates the black magic that is needed to set a roll form machine and helps it work more efficiently.
Roll forming converts flat sheet metal into a complex profile with consecutive sets roll forming machine of mated rolls. Each set makes only incremental changes to the profile, but the cumulative result is a contoured cross-section. Samson offers tooling for more than 2,000 different shapes in its inventory, including drywall profiles, metal ceilings, tubing and pipe, cable trays, metal furniture, venetian blinds and solar profile metals.
The process can be very fast, but requires a high level of precision. In the past, the only way to achieve this was to use a flying die cut-off machine. Now, manufacturers are able to create metal maze-like structures with a guillotine system that is designed for trouble-free and burr-free cutting made of 60 HRC hard steel.
Many modern machines also come equipped with a programmable logic controller. This internal brain catches any mistakes, minimizing damage and wasted product. It also tightens tolerance levels, ensuring accuracy. To ensure these tools function at their highest potential, they need to be wiped down regularly and have a certain amount of lubrication added. This prevents the rollers from wearing down and helps them reach their maximum potential. With this new technology, it is now possible for businesses to increase productivity by nearly 50%. In addition to this, they can reduce production costs and save money by lowering labor expenses.
Lower Scrap Rates
Because a roll forming machine works with long strips of metal, it has a lower scrap rate than alternative fabrication methods such as stamping or press bending. This is especially true when a part has very close tolerances, such as those used in assembly line manufacturing. Unlike stamping, where parts can be mismatched due to a variety of variables, each roll formed piece will be the same length and shape, helping speed production.
Because of this high efficiency, and the relatively low cost of materials, a roll forming machine is an excellent choice for mass production. This makes it an ideal solution for manufacturers that need large quantities of the same product for a range of applications, such as automotive or appliance trim and housings.
As with any type of machinery, the equipment has a few limiting factors. Most important, the equipment requires skilled operators. These experts are hard to find, and service contractors often don’t have schedules that meet urgent needs.
To avoid these pitfalls, facilities that use roll forming machines can leverage a PLC system to integrate the machine with their ERP systems. Using this technology, a company’s incoming orders can be processed into a data format that the system will automatically send to the machine. This will include the information needed to run specific lengths, hole patterns, and pre-press applications such as shear cuts or slitting.
Roll forming machines, also known as metal roll forming machine or metal sheet forming machine, are best for creating custom shapes roll forming machine and sizes. They work well with a variety of ferrous and nonferrous metals, including stainless steel, aluminum, copper, tin and lead.
The process can run at high speeds, which translates into quick turnaround time for production lines. The rate of production is dependent on the thickness of the material, the amount of bending and the number of stations or steps required. A basic roll forming line begins with a coil of metal that is inserted into the entry section, which then feeds the strip to the station rollers. Once the strip passes through the rollers, it is sheared to the final product length and discharged onto a table.
Some secondary processes such as punching, laser cutting and marking can take place on the same line that does roll forming. This reduces the overall production time and helps to avoid costly mistakes that occur when separate machines are used for different tasks. In addition, CAD/CAM systems help the machines function at their full potential by catching imperfections that may occur during the manufacturing process, minimizing damage to products and waste. This makes them ideal for high-volume production. It is important to note that the tooling on a roll forming machine should be properly lubricated. Otherwise, friction between the tooling and the metal could result in a twist or bow.