Advanced Roll Forming - Part II: Reduce Cost & Simplify Operations - by Paul Williams

As a follow up to our recent blog examining the potential pitfalls to the roll-forming process, this discussion will focus on how advanced technology has virtually eliminated these costly and aggravating hindrances with recent innovations.

Product Changeover

This is a significant challenge to productivity due to the many processes that take place – from complete removal of a tool set to an entire machine reset. Over the course of time, technological advancements have been made that virtually mitigate or minimize these burdens on time and efficiency.

• Duplex and telescoping shaft machines: this equipment provides movable banks of inboard and outboard housings to allow for quick changes in part width and eliminate the changing cross section of material thickness

• Rafted roll forming machines: this machine is typically used to change out an entire bank of roll tooling. The steel plate (known as the “raft”) along with the inboard and outboard housings and roll tooling for one job, is removed from the roll former base and replaced with another containing the tooling for the next job

• Roll formers featuring 2-side mounted roll tooling: this machine is powered by a single drive and allow product to be made on one set while the other set is changed out. In addition you can find roll formers that have a supplemental set of intermediate passes, which are significantly taller than the others to allow for an upper and lower roll tooling setup

Recent Innovations Yield Impressive Renovations

Manufacturers of roll forming devices have long observed the need to develop systems around specific types or “families” of products used in specific industries. The focal point should always be on the method that delivers the most significant cost savings and efficiencies. Select the process that produces stock in high volume based on the similarity of the product such as geometric characteristics (like items include steel framing, studs, track, joists and other structural building components).  These building items are usually “C” or “U” shaped with variation being.......read  the complete blog by visiting the B&K Metal Framing Blog

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