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4630 CR 209 S. Green Cove Springs, FL 32043 904-284-5611 www.rollerdie.com Roll Forming – Stamping – Press Brake – Powder Coating – Polishing – Welding - Assembly

Roll Forming Presentation

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4630 CR 209 S.Green Cove Springs, FL 32043

904-284-5611www.rollerdie.com

Roll Forming – Stamping – Press Brake – Powder Coating – Polishing – Welding - Assembly

Roller Die - Company Profile

Key Statistics

Revenue: $59 million (FYE 9-30-13)

Employees: 300

Corporate Headquarters: Louisville, KY

Plants: Louisville & Frankfort, KY

Green Cove Springs (Jacksonville), FL

Rossville, Ga. (Chattanooga, TN)

Queretaro, MX

Stockton, CA

Founded in 1928

ISO 9001:2000 Certified

Privately Held

Lean (TPS) Culture

Press Brake

Light Gauge Stamping

Assembly,Finishing

Roll Forming

Industries We Serve

3

What is ROLL FORMING? Roll forming is a

continuous forming process taking sheet or coil stock and bending or forming it to a desired cross section.

The process is performed between successive pairs of rolls that increasingly shape the metal until the desired cross section is achieved.

Pictorial View of Roll Form Process

Roll Forming Lines

Materials

Almost any material that can tolerate bending to a desired radius can be roll formed.

The more ductile a material is, the better it will roll form.

The roll forming process can handle ferrous, nonferrous, hot rolled, cold rolled, polished, plated, or pre-painted metals producing excellent results.

Materials

Materials as thin as 0.005" and as thick as 0.750" can be roll formed, depending upon the size of the roll form machine spindles.

Material pieces as narrow as 1/8" and as wide as 72", or more, can be roll formed, depending on machine size.

Design Considerations Bend Radii:

Best practice is a one-metal-thickness inside radius.

May need slightly larger in high-strength steels

Sharper corners CAN be obtained at the expense of tool life

Scoring the inside of the strip can help make sharper corners in some cases.

Design Considerations Deep sections:

Require more passes, larger machines, larger rolls and dies

Risk overstressing the edges of the material

Typical machines – 100 mm max. height of part

Short Legs: Three times metal thickness is a good

minimum leg length

Design Considerations

Wide sections Apply ribs or offsets to wide panels Helps prevent wrinkles, “oil-canning” Often wide material has appearance

issues

Design Considerations

Cross Section Tolerances Typically +/- .25 mm to +/- .75 mm Tighter tolerances are achievable:

Different approach to tooling Special quality materials

Angular Tolerances Typically +/- 1º

Design Considerations Length Tolerance

Influenced by many factors: Length of part Speed of rollformer Measuring system Cutoff system Material properties

Commonly available: +/- 0.8 mm Special equipment and tooling: +/- 0.25

mm Long parts (3 M or more): +/- 3.0 mm

and up

Design Considerations Straightness:

Bow (up or down) or Curve (side to side) – 1.0 mm per Meter

Twist - 1 degree per Meter Flare:

Typically avoid measuring the cross section within 50 mm of ends.

Flare can be controlled with special attention

Roll Form Product Samples

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Heavy Gauge Steel 5mm thick

Roll Forming vs. Other Processes Volume is key versus tooling costs Typically see 25,000 LF of part to justify cost of custom

shape; BUT, if can use standard shape, much less Extrusions – aluminum – 3 x galvanized cost;

inexpensive tools, expensive part Press brake – good for low volume; inexpensive tools,

expensive part (labor), limit to length of part by brake bed

Stamping – good for single part; if multiple lengths in family, tooling very expensive; if done in multiple steps, expensive (labor)

Roll form lines allow piercing, features to be done in-line, no secondary operation.

Roller Die

Why we should be Your Roll Form Source: Long-time experience

Both Decorative and Structural Parts Technical Expertise

Available to Assist in Design Multiple Facilities, including Mexico Lean Manufacturing Systems Fully integrated engineering department

overseeing our custom tool & die shop on site Large library of standard shapes/stock tools