Custom Roll Forming Techniques

The professional roll forming manufacturer who has established himself in this specialist field will always ensure expert advice to customers and deliver well designed products or maintenance services. Such an organization guarantees the most sophisticated tooling system staffed by highly experienced and skilled manpower. Thus most solutions can be found for your new or running installations with minimum of complexity in operations. The advent of superior roll formed profiles has given rise to newer designs and effective performance in comparison with the earlier extruded sections that were rather difficult and more expensive to produce. The main feature of the new technique is maintenance of very close tolerances and better finish of the profile sections that have a better fitting with each other and the environment where they are applied. The roll forming process also gives superior designed products compared to the stamping technique commonly used in the earlier days. Consequently, the roll formed profiles find applications in the electrical installations, cables, furniture and fixtures or fittings, various appliances and automobile or transportation sector, etc. A great deal of information is available at the websites of different roll forming manufacturers.

Roll Forming Machine

In this trade it is common practice to cater to the customized requirements of customers and specific industries. Here the close tolerances that need to be maintained could be a taxing task but the professional companies are fully geared to ensure the highest quality control that will assure the stringent specifications to be met at all times. The equipment for roll forming is rather intricate though convenient to operate. The process therefore can be run at high manufacturing speeds to churn out a great number of parts per hour. There is no compromise in quality and the entire manufacturing line is so operated that the rejections due to quality control are quite minimum. Buffer systems online help in making the downtimes rare between changeovers and the process can truly be termed as a 24/7 schedule manufacture! The most experienced custom rollforming manufacturer can always cater to the client's strict specifications and requirements thereby guaranteeing the best product and accompanying service after sales in the business. The process expertise and customer service professionalism shown by most manufacturers and their sales organizations will undoubtedly keep the customers happy and contented at all times.

Roll Forming Machine

Roll forming machine was applied in large quantities Metal Roll forming is a continuous process.Roll forming is a continuous metal forming process that transforms sheet, strip or coiled metal into shapes with a consistent cross section. The stock is fed through successive pairs of rolls, which progressively shape the metal until the desired cross section is produced. Only progressive roll forming (bending) takes place; the metal thickness is not changed except for a slight thinning at the bend radii. the number of the roll former was different depending on the specification of the product. typical the number can be 8 to 30.the more the roll forming steps. the pressure divided into each one was small, duo to the efficien consideration, there is a balance point we should follow. that is way experience is important in roll forming machine products.

Every active roll forming machine in our plant has been designed, built and maintained by Cardinal Manufacturing employees to stringent specifications.

Roll Forming Machine

This dedicated approach to machine building yields great benefits in both quality and service. Our constant demand for improvement allows us to continually upgrade our machinery whenever innovative technology is introduced.



Furthermore, since every machine is built solely for our use, any breakdown can be quickly repaired without reliance on outside agencies. This self-reliance allows Cardinal Manufacturing to maintain an uninterrupted flow of service to all of our customers.

What you need to know about roll forming

Many companies that form a variety of shapes and have a choice of machines that can be used often switch the rolls from one machine to another. The operator usually has no input in choosing the machine, because its selection is treated as a production/scheduling problem. However, the person who does the scheduling does not know that forming rolls are designed for a machine with a specific horizontal center distance, and running them at any other distance will affect how well they work. This basic principle explains why operators are heard to say: "This set of rolls works on Machine A, but we have problems when running it on Machine B." The term "horizontal center distance" is the most misunderstood phrase in roll forming. It refers to distance from the centerline of one forming station to the next

Roll Forming Machine

Does changing the rolls to a machine with a different horizontal center distance mean they will not work? Not necessarily. However, if the horizontal distance is shortened, it is possible that one or more portions of the metal strip will be stretched going from one forming station to another and be permanently wrinkled. The term for this case is "forming too fast."

If the horizontal distance is increased, there is a chance that the profile will spring open between some passes. Wherever a profile opens, the next station must close it back to its original position in addition to doing its share of the forming. It usually is not possible to close the profile to its original position because of localized work hardening of the metal. This phenomenon is called "losing control of the section."

Each metal has a different set of formability characteristics, which includes springback. A set of roll tooling that is designed for a low carbon steel might not work on one of the stainless steels or any metal that has more springback. As a guideline, the only way to determine how much lengthening or shortening the horizontal machine center will affect the performance of a set of forming rolls is to try the rolls at different horizontal distances using the metal in question.



The trend in rollforming is to reduce the thickness of the metal in the part, and maybe change the metal. As a result, the formability of the metal changes. The Purchasing Department orders the new raw stock, and the Sales Department notifies their customers of the availability of an improved product. The Production Department receives notification, so it can plan for a change in volumes for its products.

The operators, however, are not told of the change to the product. Thinner material, with different formability, is brought to the roll forming line, and the operator is expected to produce parts at least as good as the ones they have been making. None of the people involved in making the change is aware that a change in metal thickness affects the performance of the roll tooling.

What you need to know about roll forming

Roll forming is a metal bending operation. This is the fundamental principle of the roll forming process. A common mistake that is made when running a rollforming machine is to roughly adjust the first forming passes to get an approximate shape, and then use the last several stations to force the metal into the final shape. An approach like this combines coining, stretching and extruding, and results in a part that is full of internal stresses. If the metal is thin, the part becomes "alive." A test to check if a light gauge profile was formed too fast in the last several rollforming stations is to hold a long piece of the profile by one end and slowly rotate it. If it is alive, it can suddenly snap into a twist along its length.

Roll Forming Machine

Internal stresses within a live section are not consistent, causing problems in secondary operations, like curving or bending. Two pieces that are roll formed by different operators using the same set of tools can look the same, but behave differently. One person adjusted all the forming passes so each pair of rolls did its share of the work, while the other used the last passes to crunch the metal into shape.



Although a rare exception, sometimes the operator cannot obtain a good cross-section without excessive pressure in the last driven passes because of a poor roll design. In other words, the rolls are not capable of forming the product. An experienced operator can determine the capability of a set of roll tooling by setting the roll gaps to do pure bending, and closing them slightly to compensate for the springing apart of the roll spindles under load. The set of tools will have a different capability for each material and material thickness combination that is processed. If the correct shape must be forced into the profile at the end of the forming machine, then part consistency will be difficult to maintain, and will show up in statistical checks or secondary operations.

Application of roll forming machine

Our c purlin roll forming machine z purlin roll forming machine and quick interchangeable z c purlin roll forming machine Can be used to produce Light Weight Portal Framed Buildings. The roll forming machines have the added advantage of being able to produce any office accommodation that may be required and integrating it into the structure of the building. The portal frame designing offers a whole angle building solution that is ideal for small to medium sized buildings

1. Portal frame design is drawn as per vertex example.

Roll Forming Machine

2. The Intermediate joists and purlins are also designed using the framing removing the need to outsource components.

3. The components are then formed by the roll forming machine. And can be
delivered to site as completed frames, semi assembled components or flat packed for on site assembly. (flat pack is perfect for sites where access is limited.)

4. Once the frames are assembled the portals and end walls are stood and connected with the joining lattice frames. Giving the main structure of the building.

Benefits of the Howick System.
- Swaged to fit studs with location dimples and recessed screw holes giving flush walls with no steps of protruding screw heads.

- Components finished ready to assemble.

- No cutting or waste on site.

- Lipped top and bottom track add rigidity to the frame.

- Door and window opening are accurately sized.

- Panels can be made on a Just In Time basis.

- Reduced On Site labour and skill requirements.

- Holes can be pre punched in position for services removing the need to manually



create the holes on site.
- Light weight frames reduce foundation requirements.

- Entire Building constructed from a single section.

- Frames are galvanised requiring no further treatments.

5. The wall panels are then positioned adding strength to the structure.

6. The roof panels are then secured to complete the structure ready for cladding and finishing.

7. Office space can easily be constructed as stand alone or structurally attached using the same framing. Allowing the entire unit to be produced with a single roll forming Machine.

How to become a successful roll forming manufacturer?

Industries related to heavy metal perform roll forming, because these metals need to be shaped in different shapes and sizes, pierced and drilled for particular purposes and are cut in accurate measures for industrial needs.Genrally roll forming is required for heavy gauge companies but it can be required in small scale industries too.

A manufacturer of roll forming is not easy sometimes, when some of the same shape to be produced in heavy industry to measure and then completed by a roll forming operation is to strengthen the metal. It strengthens the metal and make them stronger. Metal has to be reformed from the original as it can not be used directly for production. So, for the process of reform and shape them to the fold, and even the brake pump. So how better to gain success in the business of forming rolls is to perform these actions with care to preserve its reputation in the industry.

How to become a successful roll forming manufacturer

The length of the heavy gauge metals is too much and they need to be handled carefully for making then uniform and consistent. Some time the manufacturing process of roll forming desires closer and narrow tolerances to be handled in varied ways. So the industries which perform roll forming should be able to handle these kinds of dense or closer tolerances. Roll forming related industries perform high volume and even fast speed actions, the surface ready should be properly finished and of superior quality. No doubt, it wholly depends on their craftsman ship and their team member’s skillfulness and the management of Roll forming manufacturer.



As modern era is the era of cutthroat competitions, so industries engrossed in the roll forming process needs to be competitive in the terms of prices. There are variety of industries which offer competitive prices and better quality services. One needs to be very particular about providing on time and proper services, so that they may get success in the terms of satisfied customers. Word of mouth is a great way to get success in any business and that is true with the metallic roll farm business too.

Overall, good terms are the back bone of each and every business. If the companies work ethically, provide better services then only they can be successful in any of the business. Metallic Roll form business has a bright future ahead, so if you are competitive enough then success is certain.

Roll forming machine application

Roll forming machine was applied in large quantities of parts with constant complex cross-sectional shapes. Parts often are of long length. As with extrusions, however, short parts can be made by cutting the formed strip to certain length.

Sheet thickness can be 0.13 mm to 25 mm was processed. However, except for heavy-wall welded steel pipe and structural members made by this process, normal commercial limits are 0.25 to 4 mm Processible widths range from 25 mm to 21/2 m (1 to 100 in). however, 1 m(40 in) is a common commercial maximum, and 400 mm (16 in) is the thinest processible on the most commonly available roll forming machines. Deep forms are difficult; 100 mm (4 in)is a practical depth limit for easily made cross-sectional shapes.

Roll Forming Machine Process

Roll forming Machine components have many applications, especially when mass production is involved. In the building industry, components manufactured by this process include roof and siding panels, purlins, joists and studs, window frames, door-trim ridge rolls, downspouts, architectural trim, and copper electrical conductors.

Appliance parts made by roll forming include panels for stoves, refrigerators, and other appliances, particularly when wraparound forms are involved, refrigerator shelves, and lighting-fixture parts. Curtain rods and tracks for sliding doors and draperies, drawer handles, and metal picture-frame members are also made by roll forming. When curling (longitudinal-bending) equipment is included in the roll forming line, such parts as bicycle fenders and wheels, quonset-hut frames and roofing, barrel hoops, drum rings, and bezels are formed.

Roll forming can be carried out with planted, galvanized, lithographed, vinyl-coated, and painted stock (if the paint is baked and the roll forming is not too severe or if a bendable-paint formulation is used ). Dual-layered components also can be made at one time. These may include bimetallic parts such as those made when a thin stain-less-steel facing sheet and a carbon steel support sheet are roll forming together or when fiber, paper, asbestos, or rubber inserts are places in a metallic form.

Long pieces such as railroad-car and truck-trailer trim members can be made with this roll forming process. The maximum length of parts is dictated only by application requirements and handling conditions. Figure illustrates some typical cross sections that can be produced by this roll forming process.