A roll former is a machine used in metalworking to shape long strips of metal by passing them through a series of rollers. These rollers are typically arranged in a line and each set, or “stand,” performs a small amount of the total bending process. As the metal strip or sheet is fed through the roll former, each stand progressively shapes the metal into the desired profile.
Roll forming, a technique for shaping metal, has its roots in the early 19th century, with the first patented roll forming machine emerging in the 1890s. Its use expanded significantly during the 20th century, especially during World War II when there was a high demand for uniformly mass-produced metal parts. The advent of Computer Numerical Control (CNC) roll formers in the latter half of the 20th century transformed the process, increasing precision, allowing for more complex designs, and enhancing production speed. As of today, roll forming remains integral to various industries like construction and automotive manufacturing, with ongoing advancements in technology and automation promising to sustain its importance.
Popular Types of Roll formers
There are several different types of roll formers or roll forming machines. Some of the more common varieties are:
- Single Duty Roll formers: Single duty roll formers are designed for producing a specific profile or part consistently. They excel in high-volume production environments where the same profile is produced over extended periods. The machine’s components are uniquely tailored to the requirements of the profile, making them less flexible for profile changes but highly efficient at their dedicated task.
- Standardized Roll formers: Standardized roll formers offer greater versatility. They are designed with a standardized base and can accommodate different sets of roll tools, allowing them to produce a variety of profiles. This flexibility makes them a preferred choice for operations that need to produce multiple different parts or profiles, offering a balance between specialization and adaptability.
- Side-By-Side Roll formers: Side-by-side roll formers feature two sets of roll tooling in a single machine, enabling the simultaneous production of two different profiles. This configuration increases productivity and efficiency by allowing the production of two parts without the need for tooling changeovers. It’s beneficial for operations that require the concurrent production of two complementary profiles.
- Double-Headered Roll formers: Double-headered roll formers also possess two sets of roll tooling mounted on a single machine base. However, unlike side-by-side roll formers, each set of tooling forms a different section of the same profile. The sections are subsequently joined together, often through a welding or fastening process. This design is useful when manufacturing complex profiles that require separate forming processes.
- Rafted Roll formers: Rafted roll formers are designed for operations that require frequent profile changes. They feature a replaceable “raft” or sub-plate that houses a complete set of roll tooling. When a profile change is needed, the entire raft, with its attached tooling, is replaced by another raft equipped with the new profile’s tooling. This method significantly reduces downtime associated with tooling changeovers, enhancing productivity in dynamic production environments.
Single Duty vs Standardized vs Side-by-side vs Double-headered vs Rafted
Single Duty Roll formers are custom-built to manufacture a specific part or profile. They are meticulously calibrated for this single purpose, offering high precision and consistency in the end product. The downside is that they lack versatility and cannot be used to produce different profiles.
In contrast, Standardized Roll formers offer more flexibility. They can accommodate various sets of roll tools, allowing them to produce different profiles. This makes them ideal for operations that require regular changes in parts or profiles. However, this flexibility can sometimes lead to a slight compromise in the exactness achieved by single duty roll formers.
Side-By-Side Roll formers have two sets of roll tools mounted parallel to each other on the same machine. This unique configuration allows the machine to produce two distinct profiles at the same time, significantly increasing productivity and minimizing tooling changeover time.
Double-Headered Roll formers, similar to side-by-side roll formers, also have two sets of roll tools on a single machine. However, each set of tooling creates a different section of the same profile. The sections are then joined, typically by welding or fastening, to produce the final product.
Finally, Rafted Roll formers are engineered to facilitate quick changeovers between different profiles. These machines have a ‘raft’ or base plate that holds a complete set of roll tooling. During a profile change, the whole raft, along with its associated tooling, can be swapped out with another raft equipped for the new profile. This feature considerably cuts down on downtime during tooling changeovers, making rafted roll formers very efficient for operations that need regular profile switches.
What to Look for When Buying a Roll former
When considering the purchase of a roll former, there are several factors to consider ensuring it meets your production needs and offers the best value for your investment:
- Manufacturers: Different manufacturers offer various types of roll formers, each with its own unique features and strengths. It’s essential to research manufacturers, considering their reputation, customer reviews, and the quality of customer service they provide.
- Prices: Roll formers can be a significant investment, so price is a crucial consideration. It’s important to balance the cost with the machine’s functionality, durability, and the value it brings to your production process.
- Machine Sizes: The size of the roll former should match your production space and the scale of your operation. Larger machines can handle higher volumes and larger profiles, but they also require more space and power.
- Machine Speed: Speed is a critical factor in determining the production capacity of a roll former. High-speed machines can significantly increase productivity, but they may also require more maintenance and can be more expensive.
- Available Profiles and Sizes: The roll former should be capable of producing the profiles and sizes you need. Some machines offer more flexibility in terms of the range of profiles they can produce.
- Changeover Time: If you need to switch between different profiles frequently, consider a machine with quick changeover capabilities. Rafted roll formers, for instance, are designed for rapid tooling changeovers.
- Warranties: A good warranty can protect your investment and provide peace of mind. Look for warranties that cover parts, labor, and potential defects.
- Power Requirements: Check the roll former’s power requirements to ensure they match your facility’s capacity. High-power machines may require a three-phase power supply.
- Automated Functionality: Automation can increase efficiency, improve precision, and reduce labor costs. Some roll formers offer automated features like computerized controls for speed, length, and quantity, and automatic loading and unloading systems.
Applications & Uses
Roll formers are versatile and widely used in a variety of industries, including:
Construction & Roofing
- Flooring: Roll formers are used to shape metal or steel into floor decking panels. These panels are corrugated to increase their strength and rigidity, making them an ideal choice for flooring in industrial and commercial buildings. The roll forming process ensures uniformity and precision, leading to quality output and efficient installation.
- Window and Door Framing: In the construction of windows and doors, roll formers are used to shape metal into framing components. The roll forming process provides the ability to produce complex profiles and cross-sectional shapes that are typically needed for window and door frames. This leads to the production of frames that are not only strong and durable but also aesthetically pleasing.
- Purlins: Purlins are horizontal beams along the length of a roof, resting on principals and used to support the weight of the roof deck. Roll formers are used to shape metal sheets into purlins with the required thickness and dimensions. This process results in purlins that have consistent quality, strength, and are ready for quick installation.
- Roof Trusses: Roll formers are used to shape metal sheets into the components needed for roof trusses. The high precision and repeatability of the roll forming process allow for the production of truss components that fit together perfectly, ensuring the structural integrity of the roof.
Automotive
- Car Bumpers: Roll formers are used to shape sheets of metal into the specific form of a car’s bumper. The roll forming process ensures uniformity and strength, both of which are crucial for bumpers as they serve as the first line of defense in collisions.
- Flooring for Vehicles: The floors of vehicles, particularly in commercial and industrial vehicles, often need to be extremely durable. Roll formers are used to create corrugated metal flooring, offering strength and rigidity to withstand heavy loads and frequent use.
- Safety Doors: Safety is paramount in the automotive industry. Roll formers are used to create the metal framework of vehicle doors, which must be strong to protect passengers in the event of a collision. The precision of roll forming ensures each door frame is consistent and meets safety standards.
- Framing Parts for a Wide Variety of Vehicles: Roll formers are versatile tools that can be used to create frames and other parts for a wide range of vehicles, from cars to trucks to RVs. The ability to create complex, custom shapes makes roll forming a popular choice in vehicle manufacturing.
- Drip Rails: Drip rails are the metal pieces that run along the side of a car’s roof to divert water away from the windows and doors. Roll formers create these pieces to have a specific profile that effectively channels water while fitting seamlessly into the vehicle’s design.
Pipe/Tube Mills
- Standard Pipes: Roll formers are used to create standard pipes, which are commonly used in plumbing, heating, and fluid transportation. The roll forming process ensures uniformity in the pipe’s diameter, thickness, and overall quality.
- Mechanical Tubing: This type of tubing is often used in applications like machinery parts, bearings, and cylinders. Roll formers help create tubes with specific shapes, diameters, and wall thicknesses to fit the desired mechanical application.
- Energy Pipes: In the energy sector, pipes are used for oil and gas transmission, among other uses. Roll forming can be used to manufacture these pipes, ensuring they are durable enough to handle high-pressure and harsh environments.
- Structural Tubing: Structural tubes, often square or rectangular, are used in construction and engineering projects for their strength and versatility. Roll formers help create these tubes, allowing for precise dimensions and consistent quality.
- Automotive Tubing: Roll formers are also crucial in creating tubes used in the automotive industry. These tubes are used in various parts of a vehicle, including the chassis, exhaust systems, and suspension systems. The ability of roll formers to create complex, custom shapes makes them invaluable in this sector.
Accessories for Roll formers
There are several accessories that can be used with roll formers to enhance their functionality, increase production speed, and improve the quality of the finished product. Some of these accessories include:
- Decoilers or Uncoilers: These are used to unwind and feed the coil stock into the roll former. They ensure a smooth, consistent feed into the machine.
- Coil Handling Equipment: This equipment helps to safely and efficiently move and position heavy coils of metal in preparation for roll forming.
- Feeding and Straightening Devices: These are used to accurately feed and straighten the material before it enters the roll forming machine. This can help improve the quality of the finished product.
- Punching and Cutting Dies: These are used to punch holes or cut the formed material to specific lengths. They can be integrated into the roll forming line or used as separate, standalone machines.
- Press Brakes and Folders: These can be used to make additional bends or folds in the formed material after it exits the roll former.
- Stackers or Collectors: These collect and stack the finished products as they exit the machine, facilitating easier handling and packaging.
- Control Systems: Sophisticated control systems can be used to automate the roll forming process, allowing for more accurate and efficient operation.
Tips & Tricks
You won’t have much trouble finding a specific type of roll former on Surplus Record. At the top of all the pages on our website, you’ll see a search bar. Type the phrase “roll former” into it, click on the category that drops down, and examine the options we have available.
Featured manufacturers include Tishken, Yoder, Lockformer, Bradbury and Dahlstrom.
We also work with a variety of dealers who specialize in roll formers. You can also find dealers in your area or by name who specialize in roll formers.
