What Is Sheet Roll Forming + Types, Applications, and Advantages
Steel sheets are important products in various industries, produced from steel billets. These sheets are widely used in the production of diverse products and in industrial and construction projects. In order to make steel sheets functional for industries, different processes are performed on them. Sheet roll forming is an important process used to shape various types of steel sheets and turn them into practical products.
Roll forming is one of the modern and optimized methods for reshaping sheets, replacing many old methods such as pressing. Compared to traditional methods, this technique has numerous advantages. If you want to fully understand the roll forming process and know what forming is, continue reading.
This article examines the following topics:
What Is Sheet Roll Forming?
If you are reading this article, you surely want to know: what is roll forming? Sheet roll forming is a process in which long strips of metal sheet are passed through a series of paired rollers arranged sequentially, transforming the sheet into an engineered shape. Each roller creates gradual, successive bends and changes in the sheet. The accumulation of these continuous deformations eventually produces a complex profile.
This process is used not only for shaping metal sheets such as steel, aluminum, brass, and copper, but also for certain non-metallic materials like plastic. Roll forming is a cold bending process and is applied to mass-produce uniform metal parts. Another question you may have is: what is the difference between “sheet forming” and “sheet roll forming”? Sheet forming generally means shaping metals, while roll forming is a specific method that falls under forming.
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How Is the Sheet Roll Forming Process Performed?
Now let’s address how the sheet roll forming process works. First, the coil is loaded onto the decoiler, which is the starting point. The coil rotates so that the strip unwinds and is fed into the straightener for leveling. The straightener eliminates pre-existing defects before further steps.
If a pre-punching stage is required, the strip is guided into this unit. Then the sheet strip enters the roll forming machine, which contains a series of rollers, and gradual forming begins. If performed by the cold method, roll forming takes place at room temperature; if done by the hot method, it requires heat under controlled conditions. Temperature control prevents damage and cracking of the sheet.
In the roll forming machine, a set of rollers gradually bends and reshapes the sheet as it passes through. At bending points, thickness usually decreases. After complete deformation, the final product passes through a profile straightener to remove warping caused during the process. In the last stage, the product is cut to the desired length by a cutting press. To improve efficiency, finishing operations such as punching, coating, etc. may also be applied.
Advantages of the Roll Forming Process
An important factor in any process is the advantages it provides. Roll forming is no exception. By using the sheet roll forming process, you gain many benefits. The table below summarizes these advantages of roll forming:
Advantage | Explanation |
High accuracy and quality | Due to precise tolerances and good surface quality |
Ability to produce in high volumes at lower cost | Thanks to high process speed, continuous and repetitive production, lower final cost |
No limitation in size | Because of using sheet coils and continuous passage through rollers |
Applicable to various sheets | Suitable for different sheet types such as black, coated, galvanized, steel, aluminum, copper, and some non-metallic sheets |
Reduced workforce needs | Because no direct operator is required |
Types of Forming
To use roll forming, we must know which type we need. Let’s examine the types of forming. Sheet roll forming is done in two methods: hot and cold. These methods have different characteristics and produce different final products.
Hot Forming
Hot sheet forming is suitable for thick steel sheets, where heat plays an important role. Heating reduces the pressure needed to shape thick sheets. In hot forming, precise and uniform temperature control is important to prevent sheet damage. Products of hot forming include I-beams, angles, and plates.
Cold Forming
But what is cold forming? This method is suitable for thin sheets less than 3 mm thick. Unlike hot forming, it does not use high heat, because the sheets are thin and do not need heat for shaping. Cold roll forming is fast and easy. Since thin sheets like galvanized, stainless steel, low-carbon steel, and aluminum are widely used in industries, cold forming is more popular. Cold forming products include pipes, profiles, corrugated sheets, etc.
How Does a Roll Forming Machine Work?
A sheet forming machine consists of the following components:
- Feeding system
- Guiding unit
- Forming stations
- Cutting unit
- Punching unit
- Control and automation unit
- Transfer system
- Cooling system
- Safety system
In the feeding system (decoiler), the sheet coil is unwound. Then the guiding unit directs the sheet into the correct path. In the forming station, which contains shafts, bearings, and rollers, the sheet is reshaped. Because of heat and friction, a cooling system is necessary. After shaping, the product is cut in the cutting unit. If required, punching is done in the punching unit.
The transfer system sends parts out of the machine. The control and automation unit coordinates machine activities, and safety systems minimize hazards. With this machine, various profiles, special and complex parts, and U-sections can be produced. Roll forming machines are categorized into light forming and heavy forming.
Industrial Applications of Roll Forming
Now it is time to see what industrial applications roll forming has. Sheet roll forming has wide applications in different industries, including:
- Construction industry: Roll forming products are widely used in construction, such as metal profiles (for beams, columns, doors and windows, studs), HVAC ducts and pipes, decorative components, walls, prefabricated units, and roofing.
- Automotive industry: In car manufacturing, roll forming is used to make interior parts and body components to increase safety and reduce vehicle weight.
- Home appliance industry: Roll forming is applied in producing parts of appliances like washing machines, refrigerators, stoves, etc., to increase durability and quality.
- Profile and pipe production: Roll forming is used to manufacture different types of pipes and profiles applied in industries such as oil, gas, petrochemicals, and water transmission lines.
Conclusion
For the final product of the roll forming process to be of excellent quality, the quality of the roll forming machine itself must be ensured. Therefore, it is essential to purchase sheet forming machines from a reliable company. Mazs Group is one of the reputable suppliers of roll forming machines.
By ordering from Mazs, you will receive not only high-quality machines at a reasonable price but also excellent after-sales services. These include installation and commissioning by experienced engineers, maintenance, and supply of spare parts. For purchasing consultation and ordering roll forming machines, contact our experts now. You can also request catalogs and order roll forming molds from Mazs Group.
FAQ
Sheet roll forming is a continuous metal forming process in which a long strip of metal passes through multiple rollers that gradually bend and shape it into a desired profile.
Roll forming can be applied to steel, galvanized steel, stainless steel, aluminum, copper, brass, and even some non-metallic materials such as plastics.
A roll forming machine typically includes a feeding system, guiding unit, forming stations, cutting unit, punching unit, transfer system, cooling system, automation and control unit, and safety system.
