Roll Forming Handbook presents the first comprehensive, dedicated treatment to all facets of roll forming, supplying references to more in-depth information to fill in the gaps.

Features:

• Includes real-world case studies, recommendations for efficient plant layout and material handling as well as hundreds of illustrations and references
• Explains the principles and methods of manual and computer-aided roll design and tool setup
• Supplies equations to calculate number of passes, shaft diameters, and bending factors, published here for the first time
• Presents guidelines for training personnel as well as for performing troubleshooting and maintenance

Contents

Roll Forming Mill

• Mill Types
• Mill Components

Presses and Die Accelerators

• Mechanical Presses
• Pneumatic Presses
• Hydraulic Presses
• Information and Dimensions for Press/Die Purchasing and Installation
• Rotary and Other Cutting, Punching Equipment
• Flying Die Accelerators

Secondary Operations in the Roll Forming Line

• Secondary Operations
• Straightening
• Tight or Loose Line: Cutting Before, In-Between, or After Roll Forming
• Location of the Secondary Operations
• Stationary and Flying Dies
• Punching, Perforating, Notching, and Mitering
• Piercing and Partial Punching
• Flanging, Louvering, and Lancing
• Embossing and Drawing
• Bending
• Curving (Sweeping)
• Marking
• Swedging (Off Setting)
• Rotary Dies
• Mechanical Joining of Different Strips or Parts
• Adhesive Bonding
• Soldering and Brazing
• Resistance Welding
• Painting
• Foaming
• Packaging

Roll Design

• Roll Design Process
• Cross-Section
• Product Orientation and Other Operations in the Line
• Materials
• Roll Forming Mill
• Other Tool Design Considerations
• Spacers and Shims
• Calculating Strip Width
• Bend Lines
• Number of Passes
• Flower Diagram
• Roll Design
• Calculating Roll Dimensions Manually
• Computer-Aided Roll Design
• Roll Marking System
• Roll Orientation
• Setup Charts

Materials

• Design Considerations
• Mechanical Properties
• Crystalline Structure of Metals
• Forming Metals
• Increasing the Strength of Metals by Cold Working
• Hot Rolling
• H.R. and H.R.P.O. Steels
• Cold Rolled Steel
• Carbon Steel
• Alloyed Steel
• Stainless Steel
• Metallic Coatings
• Nonmetallic Coating and Laminating
• Joining Different Materials in the Roll Forming Process
• Aluminum
• Other Metals and Materials
• Influence of Primary Metal Processes on Roll Forming
• Guideline to Steel Prices

Lubrication

• Tribology of Lubrication
• Selection of Lubricants
• Surface Properties of Formed Material
• Lubricants for the Secondary Operations
• Application Techniques
• Preparation and Maintenance of Lubricants
• Operating Problems during Production

Coil Processing, Material Handling, and Plant Layout

• Flow of Material
• Coil Handling and Storage
• Sheet Handling and Storage
• In-Line Coil Handling
• Coil End Welding
• Strip (Coil) Accumulators
• Flattening and Leveling
• In-Line Sheet Handling
• Finished Product Handling
• Finished Product Storage
• Material Handling Equipment
• Material Handling Accessories
• Crane Controls
• Plant Layout

Designing Products for Roll Forming

• Developing Light Gage Products
• Design Considerations
• Secondary Operations
• Profiles Manufactured in Different Sizes
• Design of Specific Products
• Dimensioning and Tolerancing

Equipment Installation, Roll Setup, Maintenance, and Troubleshooting

• Installation of Roll Forming Lines
• Roll Installation and Setup
• Maintenance and Spare Parts
• Troubleshooting and Trouble Prevention

Behavior of Metal Strip During Roll Forming

• Various Types of Deformations
• Causes of Redundant Deformations
• Effects of Redundant Deformations on Product Defects
• Mathematical Simulation of the Deformation of a Metal Strip
• Computerized Design System for Roll Profiles
• CAE for Roll Forming

Acquiring Roll Forming Lines, Education, and Training

• Why Roll Form Products?
• Different Paths to Start Roll Forming
• Evaluating the Product
• Selecting Line Components
• Procuring Roll Forming Tooling
• Equipment and Tool Specifications
• Acceptance Test
• Education and Training
• Motivation

Safety

• Safety
• Common Safety-Related Definitions
• Safety Design Procedure
• Determining Limits of the Machinery or System
• Determining Hazards/Risk Estimation
• Risk Reduction by Design
• Safeguarding
• Selection of Guards and Protective Devices
• Required Characteristics of Guards and Protection Devices
• Signals and Warning Devices
• Personal Protective Equipment
• Training

Increasing Efficiency of Roll Forming Lines and Case Studies

• Output, Productivity, and Efficiency
• Line Utilization
• Improving Productivity
• Case Studies
• Preliminary Tool and Equipment Cost Analysis
• Preliminary Cost Analysis

Unusual, New, and Future Roll Forming Technologies

• The Last 100 Years
• The Future of Roll Forming
• Pull-Through Mills: Nondriven Rolls
• Tension Roll Forming
• Combining Roll Forming and Cold Drawing
• Developing New Roll Forming Methods
• Roll Forming Tools
• Reducing the Thickness of the Starting Material
• Forming at Elevated Temperature
• Hot Roll Forming Variable Cross-Sections
• Hot Thickness Reduction along the Length of the Strip
• Welding Hot Roll Formed Sections
• Other "Hot" Processes
• In-Line Soldering, Brazing, and Heat Treating
• Equipment and Tooling Requirements for Hot Roll Forming
• Press Tooling for Conventional Roll Forming Lines
• Computer-Controlled Roll Forming Lines

Index

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