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+ 91 - 22 - 67237804
ROLL FORMING MACHINES
Roll Forming is a continuous metal forming process which bends or "forms" sheets, strips or coiled stock into predesigned shapes or profiles by passing the metal between successive pairs of rolls that increasingly (gradually) shape it till the desired cross section is achieved, thereby adding strength and rigidity to light weight metals. Except for a slight thinning of the metal at the bend radius, the metal thickness does not get altered.
Almost any material that can be formed to the desired radius at room temperature can be roll-formed. The more ductile the material, the better it will from. This process can handle ferrous, non-ferrous, hot rolled, cold rolled, polished, plated or pre-painted materials as well. Metal as thin a 0.127 mm and as thick as 19 mm can be roll formed depending on the machinery.
Normally cross sectional tolerances from +/- 0.25mm to +/-0.78mm can be achieved but if better tolerances are required, a material that is amenable to such tolerance should be chosen.
ROLL SHOULD BE DESIGNED FOR A PARTICULAR MACHINE AND INTERCHANGING THEM CAN LEAD TO MALFORMATION OF PROFILES.
TYPICAL TOLERANCES
Angular tolerance +/-10
Twist should be less than 50 in 3 m length of formed section.
Length of leg should be 3 times the material thickness.
Bend radius should be equal to or greater than material thickness.
Springback can be engineered out during tool design by overforming the material beyond its anticipated shape. Endflare can be eliminated or atleast, reduced, by proper tool design.
Almost any material that can be formed to the desired radius at room temperature can be roll-formed. The more ductile the material, the better it will from. This process can handle ferrous, non-ferrous, hot rolled, cold rolled, polished, plated or pre-painted materials as well. Metal as thin a 0.127 mm and as thick as 19 mm can be roll formed depending on the machinery.
Normally cross sectional tolerances from +/- 0.25mm to +/-0.78mm can be achieved but if better tolerances are required, a material that is amenable to such tolerance should be chosen.
ROLL SHOULD BE DESIGNED FOR A PARTICULAR MACHINE AND INTERCHANGING THEM CAN LEAD TO MALFORMATION OF PROFILES.
TYPICAL TOLERANCES
Angular tolerance +/-10
Twist should be less than 50 in 3 m length of formed section.
Length of leg should be 3 times the material thickness.
Bend radius should be equal to or greater than material thickness.
Springback can be engineered out during tool design by overforming the material beyond its anticipated shape. Endflare can be eliminated or atleast, reduced, by proper tool design.
OPERATING PARAMETERS
The variable parameters in the roll forming operation include power requirement, speed, complexity of profile, number of rolling stations etc. These parameters are determined by the type of material, its width, thickness, coating on material if any, and the accuracy required.
Apart from these, auxiliary operations such as prepunching, embossing, curving, coiling, and cut-off also influence the parameters of roll forming operation.
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APPLICATIONS
Automotive
Office Furniture
Bicycle rims
Railways
Trucks & Buses
Home Appliances
Medical Equipment
Heating Ventilation & Airconditioning (HVAC)
Building Construction
Rolling Shutters
Marine Construction
Aircrafts
Highway Construction
Traffic Barriers
Agriculture Equipment
Corrugated Roofings
A ROLL FORMING LINE CONSISTS OF THE FOLLOWING UNITS
REEL CARRIER/DECOILER
This carries the strips in a coil form. Fabricate out of thick steel sections, welded and stress relieved, it can be motor driven as well as dual loading to reduce change over time, for which in-line coil accumulators and strip end joiners can also be provided. Loading platforms for heavy coils with sliding arrangement can be provided.
LOOP CONTROLLERS
Inline accumulation may necessitate loop controllers wherever required. This unit controls the length of accumulation in the loop.
STRIP STRAIGHTENING & FEEDING UNIT
Consisting of guide rolls it straightens the strip in the vertical as well as transverse directions and feeds it into the next unit, which could either be a pre-notching or pre-punching press, or the entry guide of the Roll Forming Machine.
CLEANING TANK
Prior to carrying out any process, sometimes, cleaning and lubricating the strips may be essential hence a cleaning tank of appropriate length with scrubbing or brushing implements can be provided.
SIDE UNIT
This can be mounted in between stations to provide side support and apply force along the horizontal axis to generate profile.
SPEED CONTROLLER
This unit controls the speed of decoiling and can be varied continuously over the range, with inching option.
PUNCHING PRESS
These can notch or punch holes in strips prior to forming which would be difficult or impossible to punch after forming.
ROLL FORMING STATIONS
This is the heart of this line and consists of various stations depending on the length and complexity of the desired shape. A box type table made of thick steel plates, welded and stress relieved, forms the base, that is ground to house the various stations and their mechanisms such as motors, gearboxes, shafts, roll forming dies, lubricating systems etc.
PROFILE STRAIGHTENING MECHANISM
This mechanism is used to straighten the profile after it has been formed.
CURVATURE UNIT
Where a particular curvature has to be given to the formed length, this unit has adjustable rollers that can be set to curve the lengths to the desired radius.
CUTOFF UNIT
This is a precision engineered fly-cut off which cuts the profiles to desired lengths while they are moving and the forming process need not be stopped to cut the pieces.
HYDRAULIC CUTTING UNIT
Hydraulic Cutting Unit to suit a particular profile.
RUN-OFF-TABLE
After the formed lengths are cut, they are stacked on this run-off table for further processing or packing.
ROLL FORMING TOOLS
These are the most critical parts of the machine which finally ensure the correctness and quality of the formed profile.
These rolls are designed through computer aided design (CAD) process by generating FLOWER DIAGRAMS that depict the anticipated, progressive flow of the strip, through the dies.
These dies are made of tool steel oil hardened and tempered (H & T) upto HRc 57-60.
The rolls can be chrome plated to sustain highly polished finish, or prevent painted surfaces from being damaged.
These rolls are designed through computer aided design (CAD) process by generating FLOWER DIAGRAMS that depict the anticipated, progressive flow of the strip, through the dies.
These dies are made of tool steel oil hardened and tempered (H & T) upto HRc 57-60.
The rolls can be chrome plated to sustain highly polished finish, or prevent painted surfaces from being damaged.
CONTROL PANEL
A stand alone panel which houses all the MCBs, variable speed drives alongwith switches and indicators.
A mobile panel which can either be mounted on a trolley or an overhead rail so that it can be moved to the place along the machine, where required. This houses the main control switches including INCHING & EMERGENCY SWITCH OFF as well.
A mobile panel which can either be mounted on a trolley or an overhead rail so that it can be moved to the place along the machine, where required. This houses the main control switches including INCHING & EMERGENCY SWITCH OFF as well.
To ensure proper alignment, the beds are ground on Mattison (USA) make large surface grinders
MODELS
RF 36
RF 310
RF 516
RF 720
RF 1645
Sheet Thickness mm
0.30-0.60
0.30-1.00
0.50-1.60
0.70-2.00
1.60-4.50
Sheet Width mm
50,100,150
50,125,200
50,125,200
75,150,250
150,250,400
KW
1.10-5.50
3.70-11.00
5.50-15.00
5.50-22.00
11.00-55.00
Depending on complexity of cross sectional profile and forming speed the machine parameters are defined.
COMPLEXITY
B
B
NUMBER OF
STATIONS
STATIONS
4
8
6
12
8
16
10
20
12
24
B = No of Bends in a Profile.
Suffixes to Model No.
F = Fixed width
A = Adjustable width
FX = Fixed width exchangeable table.
AX = Adjustable width with Exchangeable table.
FC = Fixed width Cantilever type
FDC = Fixed width Double Cantilever type
EXAMPLE:
Model No. RF 516 AX means machine to form sheet thicknesses from 0.5 mm to 1.6 mm with adjustable width and exchangeable table.
Amolik Precision Machines
50, Bindal Industrial Estate, Lathia Rubber Lane, Saki Naka, Andheri (E), Mumbai-400 072. India.
< Tel. : 91-22-28516201 > < Fax : 91-22-67237804 >
E-mail : amolikmachines@gmail.com
Website : www.amolik.com
50, Bindal Industrial Estate, Lathia Rubber Lane, Saki Naka, Andheri (E), Mumbai-400 072. India.
< Tel. : 91-22-28516201 > < Fax : 91-22-67237804 >
E-mail : amolikmachines@gmail.com
Website : www.amolik.com
© 2011 AMOLIK PRECISION MACHINES . All Rights Reserved
