Roll forming Machine > Articles by: RFM

RFM

Roll forming machines are used to manufacture a wide range of steel products. From the building and construction industry where they are used for fabricating steel roofing, steel studs and tracks, purlins, decking, eavestroughing, T-Bars and more. The automotive industry is also a key industry that has utilized rollfromers. Automotive parts such as bumpers, seat rails, window glides and chassis frames are all manufactured using rollforming technologies

Types of roll forming machines for car frames and parts

Car frame roll forming machine

The automotive sector has always been a challenging one.  Drive costs down while increase quality and complexity leaves Tier 1 and 2 suppliers with little room to move.  So how can you leverage roll forming machines for car frame parts manufacturing?  Easy, there are a number of benefits to automating the steel fabrication process used through-out the automotive fabrication process.  Some of the more obvious are quality, speed and at times flexibility.

Why roll former’s fit so well with manufacturing car frames and parts

Lets look at the typical roll forming process and the equipment used to manufacture parts and chassis components.  In almost all installation including those found at Tier 1 parts suppliers to the auot sector you’ll find the following setup and equipment.

Coil handling – Typically a single uncoiler (also known as a decolier) that holds the master coil and feeds the process.  This setup is very critical to the overall quality of the part being milled.  If the master coil is out of alignment  this error will be magnified as the coil is formed through the roll tooling stations.

Straightener –  From the uncoiler the rolled steel requires some pre-flattening prior to entering the roll former.  This step often includes some lubrication as well.  The sheet metal is then fed from the straightener in to the mill.

Roll former mill – Here is where all the action takes place.  The mill consists of a number of stands that support the roll tolling.  An enormous amount of pressure is placed on the base and stand for the roll forming machine and by nature requires some serious engineering to withstand these forces.  Low quality designs often transfer equipment movements through to the tooling and deform the part being manufactured.  Can you imagine if you were manufacturing a car window glide and the mill was moving up and down.  The channel would then pick up this distortion and result in an unusable part.

Cut-off equipment – Once the automotive component or part is manufactured through  the roll forming process it would require some type of cutting.  Typically a cut-off press is used to shear the metal to the required length.  Again, this machine must be designed such that it doesn’t change the profile of the car part being formed. Having a flying or moving cut-off is generally best so that the cutting action continues as the metal is being formed.  This allows for minimal or non production stoppage.

The automotive industry requires high volume low per part costs. This is an ideal combination for industrial rollforming equipment. When purchasing equipment to manufacture car parts, especially frame related items such as chassis components, make sure you do your research.  This is a capital expense and one that can easily make or break your business.  Buying low costs machines is rarely a good idea, even used equipment can be questionable in this application.

For more information on contact us today.

 

How to rollform steel studs and tracks

Industrial roll former used to manufacture stud and trackOne of the most common uses for a roll forming machine is the manufacturing of steel studs and tracks.  Steel framing is commonly used in the commercial high-rise building and construction industry.  Lightweight and easy to assemble this alternative to standard wooden stick framing has gained popularity in the commercial sector.  So how are these common low cost parts manufactured.

7 steps to rollforming studs and tracks

There are 7 basic steps to foll forming studs and track.  Most industrial machines can manufacture all common sizes and profiles used for common drywall construction. The typical configuration for producing high volume parts includes 7 major systems.  Each performs a unique function through the forming process.  From preparation of the metal for bending to cut outs and holes needed for running wires and plumping on the job site.

1) Uncoiler

The uncoiler holds the master coil and feeds in to the line.  Alignment is critical here as any deviation will be amplified through the rolling process causing defects in the final product.

2) Flattener

The flattener add another step to pre-forming quality control.  Having a consistent material thickness as it feeds in to the rollformer is also critical to producing a high quality part.

3) Lubricator

The lubrication unit ensures the metal is easily bent as it passes through each roll stand.  Without this the metal would bind and rip apart as the rolls form the profile of the stud or track.

4) Pre-punch press

Pre-punching is a custom function and is where the holes and notches are made in the stud.  These are located in a common location to allow for wiring and plumping to easily pass through the studs.

5) Mill

The mill is where the forming action takes place.  The roll tooling bends and shapes the sheet metal in to the desired stud or track profile.

7) Cut-off press

The final steps is to cut off to the desired length either a stud or track.  Lengths can vary to fill an order size.

For more information see our stud and track rollforming machine lines.

 

Weather seal rollforming machines

Many products utilize weather seal strips as an integral part of the design.  The difficulty has always been how do you join the weather stripping with the metal framing?

Our latest rollforming advancements now mechanically crimp the weather strip with the profile.  With the introduction of the vinyl weather stripping in to the process of roll forming you can now mechanically fasten the two together.  By combining these two processes in to one machine you now have a superior mechanical bond in an uninterrupted continuous profile.   Your production capacity, efficiency and overall quality have now increased.

Benefits of a weather seal rollformer

  • Single process
  • High strength mechanical fastening
  • Endless lengths
  • Increased productivity
  • Custom design and profiles

Common applications

Some of the most common uses for inline weather seals can be found in garage doors, windows, automotive doors, hotel and office revolving doors and large utility and maintenance doorways.

For more information contact us today.

Uncoiler

Uncoiler or decoiler for master coil handlingEvery rollforming line requires some method of feeding sheet metal to the rolling mill.  The uncoiler (also known as the decoiler) is the most common auxiliary piece of equipment purchased when buying a roll former.  Our uncoilers are available both in standard designs and custom configurations.  Engineered to meet rigorous use within all industries including, stud and track, automotive, shelving and racking, appliance and all metal parts manufacturing industries.  Competitively priced our uncoilers meet the demands of global fabricators.

Engineered for your industry; reliable and durable uncoliers

A complete line of uncoilers designed and engineered to meet the demands of your industry.  Optional coil cars combinations are available to help increase production work flow.  Integrated hold down arms and braking systems offer an increased level of security and operational performance.   Built to last these reliable uncoiling systems make easy work when handling large master coils.

Reduce downtime with dual and multihead designs

Having the ability to pre-load a coil in order to minimize change over time is critical for many operations.  The dual head and multihead designs do just that.  Now you can load up to 5 coils of any width and material type to keep your production flowing smoothly.

Capabilities

  • Traversing base designs up to 14″
  • Powered feed rewind and unwind
  • Single and double end coil stations
  • Capacity range 2,000 lb up to 45,000 lb
  • Coil safety hold downs
  • Rotating base and expanding hydraulic design

Options

  • Powered – power feed
  • Hydraulic braking
  • Hold down arm
  • Multihead design

Contact us today for more information on uncoiler equipment for your steel material handling needs.

 

Machines for manufacturing metal products

Rollforming machineOne of the most common places you will find a rollforming machine is in the fabrication of building and construction materials.  A wide range of common building materials are manufactured through the roll forming process.  The machinery is generally single function in nature producing one specific profile or small variations with in it.

Standard configuration of a rollforming line

Most metal forming machinery setups use a common line configuration.  At the start of the process uncolier (also known as decoliers) hold the master coil and fed the line.  Depending on the profile requirements and the quality of the steel coil a flattener may be need to bring material thickness consistency to the mill.  Lubrication is also added at this stage to reduce friction through the bending process.  When forming a more complex or heavy gauge material lubrication can be added at critical locations within each stand.

Many manufacturers of steel products can benefit from quick change over tooling. One of the most common ways to achieve this is through rafting or cassette roll tolling.  This second set mounted on a base plate can be easily removed and ‘changed over’ in order to manufacture a new steel profile.

Cold forming machine

Once the continuous steel sheet enters the rolling mill powered tooling pulls the sheet in and progressively forms and bends the steel in to the desired shape and profile.  The number of stands needs for any roll former is dependent on the  complexity of the shape.  The forming of metal places large stresses on the overall design and construction of a mill.  Careful consideration and engineering is required in order to construct a long lasting machine.

Once the sheet metal leaves the mill it is often in its final shape.  Now presses are used to cut to length continuous strips of metal specific to customers orders.  The best roll forming machines offer a range of punch and cut off dies and designs allow for an endless combination.

For more information about our full line of rollforming machines contact us today.

Roll forming machines

Range of roll forming machines for the fabrication of steel productsManufacturing a broad range of roll formers and serving a wide range of industrial applications, our unique approach integrates innovation, customization and value. Our capabilities are truly global with manufacturing and service operations worldwide. Shipping complete rollforming lines or forming components anywhere you are.

Duplex roll forming mills

Rapid change over design the Duplex rollformer is a laterally powered split tooling configuration. These mills provide fast and responsive profile width change overs.

Learn more about duplex roll forming and the stud and track mill.

Universal Rolling Mill

Individual gear boxes for each roll stand offer versatility and flexibility in metal forming. This mill is engineered for quick change over of drafting and cassette tooling.

Learn more about our universal mills and roofing machines.

Toggle Forming Mills

Built to withstand heavy daily workloads this powerhouse delivers. With a large vertical capacity and quick-disconnect shafts this mill is designed to perform.

Learn more about our toffle rollformer and C/Z purlin machines.

Gear Mill

Looking for high tolerance specifications? Manufactured to meet demanding tolerance specifications the gear mill is widely used for high spec applications. Commonly built with smaller tooling setups metal fabricators rely on this machine to deliver repeatable part quality.

Learn more about our gear mills and automotive parts rollforming lines.

Purlin

One of the more common building and construction materials manufactured by cold forming steel is the purlin or girt.  This structural steel (versatile) component is an essential part of any building project.   the roll forming machine is a perfect match for purlin production.

Production line considerations for making purlins

C/Z Purlin roll formerBy their very nature purlins are straight uniform designs.  The common profiles include C, Z and Sigma and include common hole and notch placement.  As with many sheet metal materials used in the building industry having this type of uniformity and consistency allows manufacturers to produce high volume low cost products.

Considerations for roll forming purlins

The cold forming of any heavy gauge material such as that used in the fabrication of purlins requires specific machinery.  The rollformer is no exception.  As sheet metal material thickness and hardness increases so do the requirements of all components and auxiliary equipment attached to the forming mill.

Design considerations

  1. Uncoiler design
  2. Uncoiler bracking
  3. In-feed guide system
  4. Mill base and support system
  5. Roll tolling
  6. Tooling stands
  7. Hole punching systems
  8. Cut-off press

Each of these areas within the forming process is critical when manufacturing C/Z purlins.   Minimizing the quality of any of these will result in poor quality product and high re-work costs.

For more information on our purlin roll formers contact us today.

 

 

Duplex mill offers more than increased speed for panel lines

One simple way to increase the output of your roll forming line is to add a second mill.  This ‘duplexing‘ is a common practice for many production process however, there is more options than throughput for a rollformer panel line.

Sheet metal panel roll forming equipment line.

Duplex roll forming machine

Duplex roll forming equipment

With two cold forming mills installed next to each other a number of efficiencies begin to appear.  With a few changes to the infeed steel coil handling equipment (uncoilers) and the roll tooling assemblies or rafted / cassette tooling a manufacturer can service a wide range of clients.

Benefits to having a duplex roll forming machine for panel production

  1. Increased production rates
  2. Panel profile (shape) flexibility
  3. Reduced labor split over 2 lines
  4. One material handling system (uncoiler) on infeed
  5. Easier sheet metal panel stacking equipment

There are numerous ways to increase your bottom line with a duplex rollforming machine.  For more information on these special metal forming lines contact us today.

Custom builders of roll forming machinery and equipment

RFM provides custom roll forming machinery for manufacturing steel framing products such as stud and track, structural steel, purlins and roofing products.

Quality design and engineering

Every roll-forming machine and line starts in our engineering department. Our team works with you from the start to design to your custom profile needs. Utilizing the latest CAD/CAM technologies and roll tooling software we optimize our tooling designs for your product.

Innovation in rollforming

Custom roll forming equipment for sheet metal coils A diverse customer base has exposed us to a wide range of profile shapes and material types. This exposure and continued focus on innovation impacts every line we manufacture. Our research and development team is engaged with other automation and process communities so that they can incorporate leading edge technologies in our roll forming lines.

Specialty equipment for metal forming

With every custom roll form application specialized auxiliary equipment is required. From in-line welding to flying cut-off presses we have you covered. Complex designs often require completely new material handling equipment and packaging lines.

For more information on our custom roll forming services contact ustoday.

New roll forming machine option increases panel production

Manufacturers of corrugated roofing panels Corrugated sheet roll forming machineneed to push the product out fast.  This commodity based product is all about speed and quality.

New roll forming machine palletizer optimizes throughput

One of the most common problems with any rollforming line is the material handling at the discharge end.  Great that the forming mil is capable of high speed forming but can you handle the output?

Our new multi-direction stacker can increase your production throughput by 200%.

Benefits of a multi-directional rollformer stacker

  1. Dual loading stations
  2. Split load production stacking
  3. Single high speed roll former
  4. Lower per piece cost
  5. Lower labor costs

This revolutionary advancement in sheet metal roll forming can be applied to a wide range of applications and products.  For more information on how you can realize these benefits on a new roll former or used roll forming machine contact us today.


Leadership

Manufacturing leading rollforming machinery for the steel fabrication industries around the world

Innovation

Developing new technologies and automation focused on delivering leading edge metal forming equipment

Design

Designing equipment to automate and process steel formed products more effectively and preciously