Metal Roll Forming Machine
Metal roll forming machines are crucial in creating many of the things we use on a daily basis without even realizing it. These impressive machines are capable of producing a variety of long, straight shapes and sizes for countless industries.
Using a power feed system, stationary rollers at each station bend the metal bit by bit, creating a desired profile. This process can be done at room temperature, allowing for high volume production.
Rolling
Rolling is a metalworking process in which the workpiece is passed between two or more cylindrical rollers to reduce its thickness or to impart a desired mechanical property. It is one of the most common and economical methods for producing different parts in large quantities as quickly as possible.
Roll forming is an economical way of fulfilling high-volume orders for complex shapes that would be cost-prohibitive with other fabrication methods. Unlike stamping, bending, or press braking, it does not require an expensive die set.
The curved gap between the rolling work rolls is a key to the process’s success. This gap can be made parabolic, flat, or asymmetrical. Forming Machine Some manufacturers utilize continuous varying crown (CVC) in the work rolls, which compensates for roll deformation by allowing the gaps between the work rolls to increase or decrease with lateral shift.
Equipment-supported assembly of edge protection profiles saves time, prevents musculoskeletal disorders, and minimizes staff absences. It is true that this equipment comes at a cost, but its benefits are more than worth the investment. In addition, this device allows employees to mount the profile in a more ergonomic position, which improves worker health and productivity.
Forging
Forging creates complex metal parts in a single process by transforming the geometric shape of the material. Forging creates stronger parts than can be made through casting (metalworking) or machining|machining, resulting in tighter dimensional tolerances.
The forging process takes mill-length steel bars and transforms them into solid or hollow, round or symmetrical metal products. The forging machine works by placing the bar into an open die where it is progressively compressed and formed in a series of steps.
During this process, the internal metal grain redistributes itself to follow the general shape of the part. This redistribution is important because it results in a strong, stable metal with superior mechanical properties. The location of the forging’s parting line also has an impact on its strength. Placing the parting line at the bottom of the forging as in A disrupts the internal metal grain structure, but locating it at the top of the forging as in C does not. This design prevents rupture of the grain structure, providing improved strength.
Extrusion
Extrusion is the process of pushing a material through a specialized shape called a die to create long, continuous sections with fixed cross-sectional profiles. It is a common method for manufacturing products like window frames, metal pipes and tubing.
The raw material used in the extrusion process is referred to as a billet. A conveyor and a screw help to soften the material before it is pushed into a heated die. The die is shaped to match the desired end profile of the product being made.
When the billet has passed through the die, a puller starts pulling it along an extrusion ramp. The resulting new shape is then cooled using water or an air-cooling system. The resulting plastic stock shapes are then ready for machining.
Co-extrusion is another form of extrusion that allows for multiple materials to be mixed during the process and then shaped into the desired final profile. It also includes a cooling chamber that cools the molten mixture uniformly to facilitate solidification. A multi-manifold die is then used to give the resulting molded part its desired shape as it leaves the die.
Tube Drawing
The diameter and wall thickness of tube that has been extruded or formed can be reduced with a drawing process. The drawing is usually done with a mandrel, although it can be done without one depending on the specific drawing process used.
Tube drawing is similar to bar drawing, with the difference that the beginning stock is a tube rather than a rod. The drawing is used to decrease the OD, ID and wall thickness of the tube and improve surface finish. Several factors influence the quality of the finished product: the die angle, the mandrel and the tube lubrication.
A new drawing method, referred to as expansion drawing, has been proposed for producing thin-walled tubes. The forming characteristics and effectiveness of the proposed method were investigated through a series of finite element analysis (FEM) and experiments using carbon steel and aluminum alloy tubes. The results showed that expansion drawing is Forming Machine factory effective in reducing the forming limit, the thickness reduction and the ovality. However, a significant increase in the axial stress sz’ occurs at the chucked region of the tube when the diameter expansion ratio is too large.
Sheet Forming
Sheet metal forming is one of the most common manufacturing processes and is responsible for creating all sorts of everyday products we don’t think about—like fishing rods, wrenches, screwdrivers, etc. Sheet forming can be accomplished through a variety of processes, including shearing, deep drawing, bending, and punching.
When bending, the sheet is gripped along its edges by a form die, or in the case of a horizontal stretch press, by a form plate. This force stretches the sheet, plastically deforming it into the desired shape.
When a part is designed, it’s important to know where the corners will pleat/web during forming. To help understand webbing, it’s helpful to drape a piece of paper over the part and mark where the fold lines would be. This will give you an idea of the maximum amount of bending that can occur, and where a sharp bend may not be possible. This can be particularly beneficial when designing parts that require a high degree of webbing for structural integrity.
