![]() Incorporate fixtures, guides, side rolls, and straightening devices where applicable.Īfter the cross-section has been finalized, and before the rolls can be designed, the proper number of passes and rolling mill must be determined.Layout and design the Roll Forming Tooling around the flower. ![]() Produce a Bend Progression or “Flower.”.Develop a cross-sectional drawing (with part, material, and mill specifications/tolerances).The basics are essential for the beginning designer.įor each new tooling requirement, the designer should use the following steps: With this in mind, we will only scratch the surface in this “basic” design guide. More commonly formed, or basic, shapes tend to have fewer variables and limitations, which in turn have higher levels of results that are both theoretical and repeatable. Past experiences, correctly applied, are still the key ingredients to the design and development of these applications. Because the roll forming process has a seemingly limitless capacity to produce complex profiles with just as many variables, a high percentage of designs are one-of-a-kind. For a Roll Forming Tooling design, considering all the variables and applying “theory” whenever possible is vital in producing a good running product, with minimal start-up problems. In other words, a mixture of science and art is still very prevalent today in this industry. However, there are common design practices that must be understood and applied to the design process, coupled with a certain degree of “magic” (gained through previous experiences). ![]() Many roll designers have different approaches to both design and development (testing of tooling), and amazingly enough, there is more than one way to successfully form a profile. In my experience, the ideas expressed in this report can be applied to many situations, but I will stop short of claiming that these are the only solutions. This paper is intended to provide “basic” Roll Forming Tooling design instruction and tips for the beginning or novice designer. ![]() Calculate Square & Rectangle Tube & Pipe.Tube and Pipe and Roll Forming Mill Evaluation ![]()
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