Advantages of Metal Roll Forming Systems
When it comes to creating components with a set profile throughout their length, few processes are more cost-effective than roll forming. The process shapes coiled sheet metal by continuously running it through a series of dies to create the desired shape.
The resulting part is then sheared to its ordered length. Further, a number of secondary operations can be done on the line like punching, embossing, clinching and labeling.
Cost-Effective
Roll forming is a highly scalable manufacturing process. It can handle a wide range of sizes and shapes and is often more cost-effective than other metal forming processes, particularly when high volumes are required. This makes it ideal for applications like manufacturing drywall profiles, roof trim, curtain wall systems, cable tray supports and more.
In addition to reducing operational costs, the gradual deformation of the metal during the roll forming process minimizes material waste. Compared to other processes, which can leave behind scrap that requires additional processing, this is a major savings.
Traditional downstream processes like punching, embossing and clinching can be integrated into the roll-forming process, which saves tooling costs. The ability to add these features in-line also reduces labor costs because the machine does not have to stop and restart for every profile it produces.
Choosing the right roll forming supplier is also essential to minimizing your manufacturing costs. Consider selecting a company that offers economic order quantity runs, which minimizes up-front costs while ensuring you have enough inventory to fulfill orders quickly and efficiently. Many suppliers will even hold on to your tools and provide you with a discount if you need more than one run of the same part. This helps reduce downtime and miscommunication, which can add up to unnecessary costs. You can also keep track of your inventory with an ERP system to minimize wasted production time.
High Precision
Metal roll forming can produce shapes metal roll forming systems and features that would be impossible or expensive to achieve in any other way. This is especially true with high-strength materials where the tensile strength increases with every incremental bend.
The heart of a metal roll forming line is the roll forming mill, a series of carefully designed rollers that gradually shape and nudge flat strip metal into its final contoured cross-sectional profile. This process can also include a sequence of shears that cut the final part to the desired length.
Modern metal roll forming lines have closed-loop control of the precutting, punching and shearing to help ensure the finished product meets its ordered specifications. This allows manufacturers to run the line at higher speeds than was possible with older technology, while maintaining tight feature tolerances and accurate parts.
The accuracy of the system is based on the precision of the rolls, which can be either a set of dies or powered drive rollers. The newest roll forming systems are engineered to use a smaller number of larger-diameter rollers than their predecessors, which helps improve accuracy and reduce costs.
The design of the rollers can be customized to accommodate specific work material properties, such as tensile strength, ductility and hardness. Different work materials react differently to the stresses of the bending process, and softer material often requires fewer bending stations than harder material. A roll forming line can be configured to accept a variety of profiles, so fabricators don’t have to make manual changes in the machine’s tools between each production run.
Faster Production
With fewer cut-offs, seams, and rejected parts, the cost per unit of your finished product drops dramatically with roll forming. This lower cost reflects increased precision and consistency that eliminates costly mistakes.
The process of metal roll forming transforms coils of flat sheet into complex, contoured cross-sectional profiles using consecutive rollers. Each of these forming stations “nudges” the metal toward the targeted profile. Depending on the target shape and the material thickness, you can achieve very high production rates. For example, a low-carbon steel 0.7 inches (18 mm) thick can be formed at up to 85 feet per minute (26 m/min) through eight stations.
This enables you to increase production and improve efficiency, making it easier to meet your customer’s delivery schedule. In addition to reducing production time, metal forming also cuts production costs by eliminating secondary operations. Actions like punching, notching, clinching, and adding thread inserts can all be completed within the forming process.
To further maximize efficiency, you can choose to have the incoming strip sheared either before or after each forming station. This helps you to shorten your production times, particularly if you have to wait for the coils to change over between orders. Another production-increasing option is to upgrade to a networkable control system. This can upload orders from your office ERP or design software directly to the machine and reduce operator error.
Reduced Material Waste
A key advantage of metal roll forming is that it creates significantly less waste than other production processes. The process uses incremental changes to shape the desired cross-section, which enables high precision and eliminates scrap. This allows manufacturers to use large volumes of material and save money by avoiding wasteful cuts, seams, or rejected parts.
In addition, the durable products produced through metal roll forming have long lifespans and contribute to sustainable consumption patterns. They reduce the need for replacements, which lowers demand for resources and energy. Moreover, many of the materials used in metal roll forming are recycled and can be reused. This translates into reduced environmental impact and reduced greenhouse gas emissions compared to primary raw material production.
The metal forming industry is committed to sustainable production. Companies invest in research and development to shutter making machine improve efficiency, reduce waste, and minimize environmental impact. They also focus on collaborating with customers to provide solutions that align with broader sustainability goals.
For example, they are able to help you produce lightweight and fuel-efficient components for cars, reducing vehicle emissions and contributing to a cleaner environment. They can also create components for renewable energy systems like wind turbines, solar panels, and building frames. The long-lasting durability of these parts enables greater energy efficiency, which reduces the need for resources and lowers carbon dioxide emissions.