Key Points to Consider in a Channel Roll Forming Machine Design

Key Points to Consider in a Channel Roll Forming Machine Design

Roll forming is one of the most efficient ways to shape metal.channel roll forming machine It is a process that involves several stages, from the strip to the finished product. Many complex profiles are formed using this method, including strut channels, cladding, solar frames and more. However, the complexity of these shapes creates a multitude of variables that can be challenging to manage, even for experienced designers. Despite this, there are a few key points that should be considered in every channel roll forming machine design to ensure success.

The first point to consider is the material that is going to be used. Different materials have different elongation and yield strengths. For example, low-yield steels with a high tensile strength (up to 160 KSI) can be shaped at a relatively high degree of accuracy, while higher-yielding materials may require a much lower "k" factor in order to maintain a good dimensional tolerance.

Another consideration is the amount of forming torque that will be applied to the profile during each pass. This is often a function of the forming angle, but can also be affected by the lubrication used in the forming process. Using the proper lubricant will help to minimize friction and reduce the amount of force applied to the profile.

In addition to the forming torque, the amount of material being fed through each pass is a crucial aspect in the channel roll forming process. If too much material is being fed at a given time, it can lead to a number of problems, such as excessive forming torque, marking or scuffing, a twist with asymmetrical profiles and camber or bow.

A servo feeder is a device that can be added to the end of the machine's roll forming line to increase the feed rate and improve efficiency. This can be a great benefit for manufacturers who produce a lot of exposed fastener systems or other profile that requires frequent cutting. The main disadvantage of a servo feeder is that it can add to the overall cost of the system, but it can be a worthwhile investment for companies that need the ability to meet production deadlines.

During the design stage, it is essential to consider the channel's end use as well as the mill specifications/tolerances. It is also important to look at the design of the tooling, incorporating fixtures, guides and side rolls. Side rolls can be helpful with light- or heavy-gage materials, as they can provide a smoother transition into the main forming passes. This can also help to reduce scuffing on the flanges of the profile.

Lastly, a careful assessment of the "k" factor will need to be made. With higher-yielding materials, a "k" factor of around 35-40% may be sufficient. For lower-yielding materials, a k factor in the range of 20-55% is common. This will be dependent on the forming angles and inside bend radius of the profile, so it is important to get this right before moving forward with a new design.

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