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The Benefits of Roll Forming
Roll forming is a flexible and price-effective process for shaping metal into custom cross-section profiles. Often called "cold roll forming," because the metal is formed in its hardened state, roll forming is used throughout a wide range of industries to produce parts and parts for everything from metal forming in automobiles to home equipment to airplanes and houses.
For products that may be roll shaped, the process affords a host of benefits and advantages over different approaches.
EFFICIENCY
Most roll forming is done with long strips of metal in coils, so the process is high-speed, with low labor calls for, permitting higher volume production for many products with higher effectivity than with press braking or stamping. Additional processes, comparable to punching or notching, could be incorporated into a roll-forming production line, further reducing labor demands, and outputting accomplished products ready for distribution. Press braking requires separate processes for punching, notching, or perforating, adding time, labor, and expense.
SAVINGS
Roll forming is a no-heat system — reducing energy prices — that gradually bends the metal, in phases, into its remaining shape by passing it by means of a series of customized-designed rollers. Roll forming doesn’t create the tool wear that stamping does, the process eliminates the need for machining, reminiscent of deburring, often required with press braking. Identical parts lower from lengthy strips imply no wasted scrap, and roll-fashioned parts can be of virtually any length, while press braking limits size to the scale of the machine. Roll-fashioned metal parts produced in quantity are almost always more price-efficient than plastic or extruded versions.
FLEXIBILITY
Even complex cross-part profiles which can be a challenge or are unattainable with stamping might be easily created with roll forming, together with spherical, closed, and C-formed profiles. Virtually any metal, ferrous or nonferrous, can be roll-formed, while extrusion is limited to only aluminum or brass. Roll forming additionally permits the shaping of metals already finished with paint, plating, or coating, while extrusion works only with unfinished, unplated stock, and press braking of finished metals requires additional handling and processes, costing time and money.
PRECISION, QUALITY AND CONSISTENCY
Roll forming will be designed to meet very tight tolerances. Products are more uniform and consistent across runs than with press braking, facilitating ease of use in applications akin to assembly line manufacturing, the place components should fit right every time. Roll forming can produce much higher quality products and elements than extrusion.
ADVANCED DESIGN TOOLS
Mills provides inline sweeping and arcing capabilities that may create advanced, sleek curves and bends for aesthetics in products such as automotive or equipment trim.
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