Modelling & Simulation of Roll Forming Process

  • One of the first decisions to make when a new roll forming line is designed is the number of forming steps needed to produce a profile. This is dependent on the material properties, the cross-section geometry and the tolerance requirement.
  • During the roll forming process, a long strip of sheet metal is continuously bent into the desired cross-section. The strip passes through a number of sets of rollers, where each set performs a part of the total desired bend, until the final profile is obtained.
  • FE-analysis has been used to validate the design that the CAE system proposes.

  • Greater production efficiency: As the material used in roll forming operation is in coil form, the process proceeds at much higher speeds and requires lower manual involvement. These capabilities allow for faster production of larger volumes

  • Lower production costs: Other cost savings come from the process’s greater material utilization (reducing material waste and overall cost), incredible energy efficiency in the forming process superior surface finishes (eliminating the need for further machining or finishing), produce complex parts and shapes at speeds of 30-100 feet per minute and lower tool wear (decreasing the cost of tooling replacement over time).

  • Better part design flexibility: The roll forming process easily produces complex profiles that are difficult to achieve through alternative manufacturing methods (e.g., stamping, bending), such as round, closed, and C-shape forms. Additionally, while other processes (such as extrusion) are limited to aluminum or brass, roll forming is suitable for virtually any metal, ferrous or nonferrous.

  • Superior precision, quality, and consistency: Compared to press braking, roll forming can meet tighter tolerances while creating parts and products that are more consistent and uniform across multiple runs. Compared to extrusion, the process produces higher quality products.

Driving Innovation Through Accurate Analysis

Thanks to our Design & Analysis Engineers,We are able to provide High Grade equipments with accurate outputs.