Roll forming line is a complete production line for manufacture of desired metal section profiles. A roll former or roll forming machine is a simplest roll forming line, a roll forming line is  composed of roll forming machine and many value-added equipments to achieve different metal forming operations such like notching, slotting,perforating,welding and other secondary operation. The basic roll forming line is divided into four sections.: entry section, forming section, cutting section, finish section.

Entry section: The entry section is for the material loading and feeding, usually the material is continuous feeding in coils.This section is combined of uncoiler, guiding and leveling device

Uncoiler is optional with manual passive type,hydraulic uncoiler, the loading car is optional for loading the coils. The feeding device can be integrated as passive type or automatic servo feeding with motor.

Forming section: The forming section is combined by machine base,roll tooling stands, roll form toolings, main drive and rafted cassette system.

Machine base is welded by high strength heavy gauge carbon steels, the whole structure is designed for heavy duty load-bearing. There are two different structure ,integrated type and split type.

Roll tooling stands is fixed on the machine base to fasten and support roll form toolings. There are three basic types of roll tooling stands : integrated type ,s series and M series. Integrated type is a whole steel plate welded on the machine base, it is a whole structure can’t be break down. S series is one kind of split type roll tooling stand, all the parts on the stands can be break down into parts. The M series is for the heavy duty roll forming, the stands are originally a cast steel design , the cap and shaft ,bearings are mounted and can be break down easily.

Roll form tooling are combined by rollers and shafts. The material of the rollers are selected depends on the product material , CNC machining , heat treatment and chromed. The rollers are durable and accurate , ensure the tolerance and quality . The shafts are CNC machined from high strength steel.

Main drive system are combined by main motor ,reducer and transmission system. Main motor and reducer can be designed concealed or visible, the power is upon the roll forming product.There are two basic transmission way , by chain or by individual gearbox

The cutting device is divided into stationary cut and flying cut .There are two different power for cutting , hydraulic cutting or saw cutting.It can be designed post-cutting or pre-cutting.  It all depends on the roll formed product.

In-line punching is one value added operation, it can be designed as Post-punching or pre-punching. It all depends on the roll formed product.

The collecting section is what we call run out table , it can be designed as passive type and automatic stacker,all depends on the requirement from client.

Roll forming advance

Nowadays the cost on labor is become a challenge for a company, so it is required that a machine can be automatic control without hands. The CAD/CAM must be come into play. Roll forming also can be controlled by program automatically, by set and change data on the touch screen.

Control panel-touch screen

The basic for a roll forming process is starts from the product shapes, no matter you are starting your business on the roll formed profiles or you already experienced in the field, you can find something interesting in Bemco. Over 20 years experiences in the designing and manufacturing of roll forming machine , we are proud to offer roll forming machines for standard roll forming shapes and custom roll forming shapes.

Standard roll forming shapes:

Over the years roll forming experience of Bemco, we have created a extensive library of the standard roll forming shapes that are commonly used in many industry application. Such like : “C” Channels, “U” Channels, “Z” Sections, Sigma sections, Omega section,Box Channels, Hat Sections, and Angles.Flat panel with ribs ,without ribs,corrugated .Even sometimes closed section such like lock seamed tube,pipe and ring or other closed profiles with welded sections.We are very experienced at the roll forming machine for the standard roll forming shapes.

Custom roll forming shapes:

For over 15 years we have been an industry leader in the design and production of custom roll forming machines.Our designer is skilled and experienced,many of the complex roll forming shapes can be roll formed by Bemco . The complex roll formed profile sometime involving other technology such as punching,hemming, ribbing ,pinching,notching, and welding to achieve asymmetrical,seam locked ,welded, multiple bends and other challenging complex profile.To roll forming of complex profiles ,sometimes we will need to incorporate in-line punching, side rollers, or value-added in-line operations.

The picture below shows some samples of complex roll formed profiles that we have provided for our customers. If you would like us to help you on developing your custom profiles, send us your profile drawing , we will evaluate the Possibility of roll forming and quota based on an action plan.

Technically specking almost all the metal material can be used in roll forming.The more ductile the material is , the better it will foll form.The material is divided into type, thickness,strength and surface treatment.

Material type: Ferrous metals and non-ferrous metals, such like , steel, aluminum ,copper, they are the common used for roll forming, specially the steel roll forming,the roll formed steel parts is almost in every industry.

Material strength : the yield strength is the hardness of the material, the more harder the difficult for roll forming, because the roll forming speed and roll form tooling material will be different .The common yield strength can be from 250mpa-550mpa.

Material thickness: the thickness of the material, the more thick ,the harder for roll forming , because the roll forming speed and roll form tooling material will be different .The common thickness for roll forming will be 0.3mm-8mm.

Surface treatment: the roll forming is only the shape change of the metal, it will remain the surface treatment of the material. The common surface treatment of the material is plated, pre-painted,polished.

Material size: the roll forming process is not for infinite width and length of material, because it is hard for a super sized roll forming. The common width of the material is from 20mm to 1550mm，The length of the finished roll formed part is only restricted by the length that can be functionally handled after the finished part exits the roll forming machine.

Sometimes,a single strip can roll formed to several sections or several strips can be roll formed in one combined section. There is only one absolute material requirement for composite forming. The material must be capable of being formed at room temperature to the desired radius.

These are the basic material for roll forming, special material and requirement on the roll forming ,please contact us for more information.

Roll forming Tolerance

Tolerances are affected by material, line speed, tool quality, operator skill, measuring system and length. Typical ranges are:

Length and pre-punched features location:+/- 0.05mm to +/-1.5mm

Cross-sectional:+/- 0.05mm to +/-0.1mm

Angle : +/- 1 degree to 3 degree

Twist : Not exceed 1 degree per foot

Straightness : Not exceed 0.5mm per foot

Only the imagination limits the potential applications for roll formed shapes.Roll forming can produce almost any shapes with any raw material , even two or three different material or shapes can be jointed together.Every day there maybe a new shape requires the roll forming technology.

Bemco Machinery is capable of custom roll forming design . Our engineer is comprised of some of the most experienced and respected professionals in the roll forming industry. Their previous expertise of designing for many industries can help them work out the whole solutions for you in a very short time.

When designing a new roll forming line, you should know that all the details about the desired product .

There are a few crucial elements that an engineer should considered before designing :

Material: The material is the basic considered element for roll forming design , because different roll tooling solutions basic on different materials. Suck like the coil material , yield strength of coil,it’s from light gauge to heavy gauge, they will all impact the design of roll toolings. Check here to know about the material for roll forming.

Size:The other important factor of the considered element is the size of the product. As all known that roll forming machine is a continuous production line with high product volume, the line speed is not as fast as good,it’s all depends on the size of the product.All the component and in-line operation equipment will be designed upon the product size, such like the cutting method ,punching method, feeding method will be all different.

Shape:The most important element for roll forming design is the product shape, it is the first step that a manufacturer choosing the right equipment ,press braking or roll forming. Roll forming is special for the very complex product shape, it will decide how many the roll forming stations will be, the max production line speed will be, what value-added equipment will be integrated etc.

Roll forming line design process overview:

Design drawing

Each roll forming line is special designed upon desired product.The design process step by step as follow:

• Create a CAD drawing according to client’s design(material,grade ,size, shape)
• Figure out the feeding width of metal coil
• Produce the “flower”drawing of roll forming
• Layout and basic design of roll forming line according to “flower”drawing,for example the roll tooling stands, roll forming machine base type and material,roller’s material etc.
• Secondary design for secondary operation such like punching, welding ,notching etc.For example ,pre-punching or post-punching.
• Control system and electrical parts design according to product volume .
• Safety design for a safety operation and protection.
• Color design according to client’s design

Roll forming design flower drawing

 Design for Roll Forming lines

For more information about the design of a complete roll forming line, please contact as or give us a call. We look forward to sharing some of the advantages that roll forming can provide for you.

When choose a metal processing equipment ,it all depends on the product you need .

Below is some considered factors:

• Product volume
• Production line speed
• Material thickness,yield strength,surface treatment
• Desired product surface appearance
• Secondary operation
• Desired product length,width and height
• Shape complexity
• Desired tolerances

These factors is not for only one kind of metal forming process, sometimes it requires both of the metal forming ,for example : press braking and roll forming to make the metal shutter box.

 Roll forming is superior compare with others , the main benefits of roll forming as follows：

• Suitable for any project : roll forming allows various types of in-line fabrication to create any shapes , no matter how complex.It helps you on innovating new products with very complex shape ,hole configuration as well as accurate and uniform cross section. Technically speaking , any kind of product can be custom roll formed.
• Suitable for any size: roll forming has no limit on the product cutting length because it is continuous coiling feeding, various sizes can be roll formed with only one sets of roll tooling without changing any parts. Various shapes of processing products can be rapid changeover in only one roll forming line.
• Suitable for high product volume: roll forming is a continuous metal processing with almost any gauge of metal material , it is controlled by automatic program to save labor cost, adjustable production line speed can easily handle high product volume and low product volume .
• Tight tolerance :Due to the more gradual forming sequence, roll forming produces extremely tight tolerances as well as an attractive finish.No matter on hole punches or section size.

Who will use roll forming in their business?

In planning your business you must consider the options of buying material from a supplier or manufacture with appropriate equipment.  For example In the area of downspouts and elbows, you need to scope the volume of the business you are doing and evaluate the payback you might get from investing in buying an equipment rather than buying your parts from a supplier.  In particular, the investment required for an industrial-grade downspout machine is substantial and needs to be carefully evaluated.

The roll formed parts is almost in every industry such as the automobile industry, tools, and dyes industry, metal furniture industry, construction, railways and others. See more application of roll forming industry , pls click here.

Roll forming is a common and cost-effective metal profile manufacturing method , it is widely used technology almost every where into our life. Have a ever wondered how the slide track on your sliding door is manufactured ? Or which machine can make the shutter door lath ? Every buildings , vehicle, container , agriculture , industry, roll forming as a classic metal process way still plays a very important character even in the future.

How does roll forming machine work ?

The roll forming machine bends flat metal strip with numbers of roll forming stations ,each station have up and bottom rollers and sometimes side guide rollers. When passing through the stations, the metal sheet changing shapes a little more than previous station, till the flat sheet finished with the correct cross-section. It is a continuous processing of bending.

Cold roll forming is a continuous shape processing of metals.The purpose of the roll forming process is to make the desired section metal profile from flat metal strip.It is a continuous, efficiency, cost-effective metal bending operation .The shapes of the metal sheet changing when passing through a bunch of matching pairs of contoured rolls and finally get your desired shapes.The acting machine is called the roll forming machine, or roll former.

Below is the simple picture about roll forming process:

The roll former is the simplest roll forming line, which is integrated by different kinds of components.Below is a typical and simple example:

• Decoiler
• Main roll forming machine
• Shear device ( stationary or follow )
• Product run out table

A complete roll forming line can be integrated with many value-added equipment such like welder , press machine, and other secondary operation equipment, these equipment can be designed in-line process together with the whole production line or off-line , the roll forming line is a cost-effective and flexible metal processing solution.