Cold roll forming process is that when the metal strip passes through several pairs of rollers with holes in sequence, the strip is fed forward as the rollers rotate. At the same time, it is continuously bent to obtain a desired cross-sectional shape. It can be seen that roll bending is a continuous bending method.
Cold roll forming machines are used to form high-strength steel components at room temperature, also known as cold rolling, and are often used to process long lengths of metal to produce a variety of metal products including (lift rails, shelving etc.). The cross-sectional profile of the cold roll forming machinery is usually tailored to the specific needs of the customer. The forming kun is used to control the localised processing of the material to prevent folding and wrinkling during the process. The machine is designed to meet the needs of metal bending.
Cold Roll Forming is a plastic processing method in which the entire length of the strip passes through several different holes in sequence, gradually bending and deforming locally, and the full cross-sectional shape is gradually close to the finished cross-sectional shape, and finally a product with a uniform full-length cross-section is obtained. The pass shape is surrounded by the contours of two or more forming rollers with a certain shape. The cold forming rollers may be horizontal rollers or vertical rollers.
Hole pattern is one of the important factors affecting product quality and productivity. The cold forming roller is installed on the frame. The forming roller responsible for driving the strip forward is driven by the motor through the transmission system. Generally, only the horizontal roller is the active roller, and the vertical roller is often the passive roller. Each machine base is called a cold roll forming machine, each roll forming machine is equipped with two or more forming rollers, and each row of forming unit is composed of more than two forming machines.
In the bending deformation zone of the cross section during the cold roll forming, the outer layer fiber of the bending piece is elongated by the pulling surface, and the inner layer fiber is compressed and shortened. Between the shortening and elongation, there is a layer of fiber with the same length, called the neutral layer, and the arc formed on the cross section is called the neutral line.
As the outer layer is strained to be pulled and compressed, it is easy to cause thinning and deformation. The inner layer is compressive strain, which is not conducive to plastic flow. Besides, the rigid contact of the convex corners of the forming roller makes the metal nowhere to flow, so the neutral layer has to move inward, so the thickness of the bending part is reduced, and the amount of thinning is generally Very small. When determining the thickness and width of the blank, it is considered that the thickness of the strip before and after molding is unchanged, and the sum of the unfolded lengths of the neutral lines in each part (line segment) after molding is equal to the width of the blank.
The material of the corner of the section of the cold-formed steel is cold-work hardened due to the plastic deformation of bending, that is, the strength is increased and the plasticity is decreased. This phenomenon is called the cold-bending effect. If the cold bending effect is used to increase the strength of the component design, 10% to 15% of steel can be saved, and it can also be used as a safety reserve for improving the strength of cold-formed steel components.
Due to the roll forming process, the strip is fed by the active forming roll. Therefore, cold bending forming can be combined with other processes such as welding, perforating, printing, cutting to length, iron wire and paperboard, etc. to form a joint continuous production line.
How Do Roll Forming Machines Work?
Cold rolling machines use multiple stationary rolls to bend metal continuously at room temperature. The advantage of this method is that the steel can be produced without heating, reducing production processes and time.
The fixed rolls are arranged in groups, each group bending the metal more than the previous one. When the sheet enters the roll forming machines, these fixing rolls act as both fixing and bending rolls.
Also known as progressive processing, this method of processing ensures the accuracy of the workpiece and is used at speeds of 30 to 600 feet per minute, often for high volume production and the production of very long parts.
And as more demands are placed on the work of cold roll forming machine for additional machining requirements such as punching, stamping, bending, locking and even in-line welding operations, our cold roll forming machines are upgraded and applied to meet these demands, ensuring that parts are produced in a single pass and ensuring increased productivity. Meeting the need for practicality.
Cold Roll Forming Machine Components?
Infeed Section: This section is mainly used for loading and feeding the material, which is mostly in the form of continuous cut sheets or in continuous coils depending on the final product to be processed.
Roll Forming Section: This section is mainly for the processing of the incoming sheet. It contains a roll forming system with multiple rollers, as well as drives, power systems and infrastructure. The main purpose is to continuously process the profiles that pass through the roll forming section to achieve the desired metal component.
Shearing Section: After the continuous processing of the profile, the profile is cut to the required nominal length according to the specified length.
Exit Section: After the complete processing procedure has been realised, to prevent the finished product from falling, a table is added to carry out the storage of the finished profile.
Control System: A PLC control system is used to achieve a fully automated production mode and to realise the processing accuracy and cutting precision.
Additional Kit: When carrying out production, there may be many additional needs, such as printing logos, straightening, embossing, etc. We offer professional straightening machines, as well as embossing machines. This ensures that the workpiece is formed in a single pass.
What Is The Difference Between Hot-Rolled And Cold-Rolled?
The difference between hot rolling and cold rolling can be seen in the name. Hot rolling refers to the processing of metal materials manufactured in a heated environment, while cold rolling refers to the processing of metal materials at room temperature or close to room temperature, cold roll forming is obviously a more economical and efficient production method in terms of productivity.
Roll Forming Machine Tolerances?
Roll forming machine tolerances are unavoidable, so generally when purchasing a cold roll forming machine, we specify the tolerances on the cross-sectional profile drawing. There are a variety of factors that determine the tolerances of parts produced by this type of machinery, including material type, size, thickness, production wear and tear, etc. This is inherent to the machine, so when we purchase a cold roll forming machine, we must not hesitate because of the presence of tolerances.
The Many Benefits Of Roll Forming Machines
Highly Customisable: different processing moulds can be used and logos can be printed on the surface during the process.
Smooth Processing: the use of progressive processing does not damage the material and reduces the scrap rate.
Long Processing Workpiece: the longest plus length of the profile processing is at 30 metres.
Functional Versatility: equipped with a number of functions such as welding, bending, locking and punching.
High Production Speed: 30-600 feet per minute production speed, extremely high production efficiency.
High Precision: PLC control is used, which greatly improves the machining precision of the parts.
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