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COLD ROLL FORMING Process

For 100+ years, cold roll forming process has provided strong parts — quickly and cost-effectively — for numerous industries.

What is Cold Roll Forming?

Cold roll forming is a kind of cold bending processing, also called profile sheet bending, is a reliable, proven approach to metal shaping, and is an efficient, effective shaping that delivers tight tolerances on complex profiles, which is ideal for modern applications.

Cold roll forming is the process of gradually bending a flat strip or coil of metal into a longitudinal, uniform profile. the cold roll forming process uses a continuous bending operation where long metal strips, typically coiled steel, are passed through consecutive sets of rolls at room temperature. Each set of rolls performs incremental parts of the bend to produce the desired cross-section profile. Cold roll forming is a cold-forming process that doesn’t require heating up the metal. High-temperature, specialized equipment isn’t necessary to produce cold-rolled shapes.

Unlike other metal shaping methods, the cold roll forming process is inherently flexible. Secondary processes can also be integrated into a single production line.

What can cold roll forming do?

Cold roll forming can be used to shape galvanized steel, non-galvanized steel, stainless steel and copper. It is the production of a profile from the metal strip in a continuous process, where material passes along a series of stations on the production line through sets of rollers, manipulating it to the required form.

What are the raw materials for cold roll forming?

Raw material can be either flat or coiled sheets. It’s possible to use hot rolled steel in sheet form as the raw material in cold roll forming. 

What is cold roll forming capability?

Typical cold roll forming mills can accommodate material gauges ranging from .010″ up to 0. 250″ thick. The bend radius is largely determined by the ductility of the metal. However, 180-degree bends are commonly achieved with the right material. Roll forming easily accommodates the integration of secondary operations such as welding, punching and precision laser cutting to optimize production efficiency.

Advantages

  • Rollforming is optimal for profiles with long lengths and large quantities
  • Delivers consistent and accurate results
  • It’s suitable for a variety of metals
  • It is environmentally friendly
  • Ideal for custom product design and manufacture
  • Curvature radius corresponds to the thickness of the metal strip.
  • Lightening the weight of structures by roll forming steels with high elastic limits.
  • Ease of implementation in assemblies with welding, riveting, bolting, and gluing.
  • Variety of possible delivery lengths of steel profiles, up to 30 meters.
  • Diversity of surface conditions such as hot roll, pickled, cold rolled, prepainted, and galvanized.

Available roll forming materials

Cold roll forming can form a wide variety of metals, including:

  • Cold rolled steel
  • Hot rolled, pickled and oiled steel
  • High-strength, low-alloy steel
  • Galvanized / galvannealed steel
  • Stainless steel
  • Aluminum
  • Copper
  • Brass
  • Bronze

7 cold roll forming applications in disguise

Cold roll formed shapes are particularly useful due to their ability to be produced at a rapid pace while maintaining design accuracy. Yet it’s also ideal for parts with multi-bend profiles, or those that require high-end finishes.

Hole punching, bending, and cutting to-length are all easy to fit into one continuous process, rather than separate steps. In all of these cases, it’s simply more cost-effective and productive to use this tried-and-true method of metal forming.

  • Power distribution components
  • Warehouse & data storage
  • Commercial food storage
  • Solar
  • Trains
  • Trailers & trucks
  • Guard rails & signposts

What is a cold roll forming machine?

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.

The cold roll forming machines have more group forming rollers to control the localized processing of the material to prevent folding and wrinkling during the process, it is designed to meet the needs of metal bending. As the workpiece passes along the line, each roller further reduces its thickness by a specified percentage until the piece reaches the desired thickness.

The cross-sectional profile is usually tailored to the specific needs of the customer.

6 components of cold roll forming machine

Infeed Section

The Infeed 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

The Roll Forming 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 realized, 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 model and to realize processing accuracy and cutting precision.

Additional Kit

When carrying out production, there may be many additional needs, such as printing logos, straightening, embossing, etc.