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Types of Roll Forming Processes

2021-06-04

Type of Roll Forming Processes

Every roll forming manufacturer uses a unique set of rolling processes to create their products. Some specialize in tubing, while others produce roofing and siding. The most common types of rolling are:

Shape Rolling
Ring Rolling
Roll Bending
Flat Rolling
Plate Rolling

Below is a discussion of these methods:

Roll Forming Methods

A) Roll Bending

Roll bending can be used for thick large metal plates. Three rollers bend the plate to produce the desired curve. The placement of the rollers determines the exact bend and angle, which is controlled by the distance between the rollers.

B) Flat Rolling

The basic form of roll forming is when the end material has a rectangular cross-section. In flat rolling, two working rollers rotate in opposite directions. The gap between the two rollers is slightly less than the thickness of the material, which is pushed through by the friction between the material and the rollers, which elongates the material due to the decrease in material thickness. The friction limits the amount of deformation in a single pass making several passes necessary.

C) Shape Rolling/Structural Shape Rolling/Profile Rolling

Shape rolling cuts different shapes in the workpiece and does not involve any change in the thickness of the metal. It produces molded sections such as irregular shaped channels and trim. Shapes formed include I-beams, L-beams, U channels, and rails for railroad tracks.

D) Ring Rolling

In ring rolling, a ring of small diameter workpiece is rolled between two rollers to form a ring of larger diameter. One roller is the drive roller, while the other roller is idle. An edging roller ensures that the metal will have a constant width. The reduction in width of the ring is compensated for by the diameter of the ring. The process is used to create seamless large rings.

E) Plate Rolling

Plate rolling machines roll sheets of metal into tightly shaped cylinders. The two different varieties of this type of equipment are four roller and three roller. With the four roller version, there is a top roller, pinch roller, and side rollers. The three roller version has all three rollers producing pressure with two on the top and one on the bottom. The diagram below is a four roller systems forming a cylinder.

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