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[...]... (in.) 12 36 36 48 48 50 50 50 50 100 0.036 0.036 0. 020 0. 020 0. 020 N/A N/A N/A N/A ¼ 0. 022 in 1.5 2. 75 2. 5 3.0 3.0 48 12 48 50 50 50 0. 020 0.375 0. 020 1 1 1 ffi 1 rffiffiffiffiffi 6 100 ð100 ksi yieldÞ £ 50 £ 2 (stretched groove) 1 (check bearing) £ 0.6 (edge forming) ¼ 0.040 in N/A ¼ 0.0 12 in 3.5 4 .25 2. 75 FIGURE 2. 2 Cantilever mill (Courtesy of Metform International Ltd.) Roll Forming Mill 2- 3 FIGURE 2. 3 Cantilever... .11 -29 CAE for Roll Forming 11-34 12 Acquiring Roll Forming Lines, Education, and Training George T Halmos 12- 1 12. 1 Why Roll Form Products? 12- 1 12. 2 Different Paths to Start Roll Forming 12- 2 12. 3 Evaluating the Product 12- 3 12. 4 Selecting Line Components . 12- 4 12. 5 Procuring Roll Forming Tooling . 12- 7 12. 6 Equipment... 4 George T Halmos .2- 1 2. 1 General 2- 1 2. 2 Mill Types 2- 1 2. 3 Mill Components .2- 18 References 2- 32 3.1 3 .2 3.3 3.4 3.5 3.6 3.7 George T Halmos 3-1 General 3-1 Mechanical Presses .3-6 Pneumatic Presses 3-10 Hydraulic Presses 3- 12 Information and Dimensions... Tool Specifications 12- 7 12. 7 Acceptance Test 12- 7 12. 8 Education and Training . 12- 7 12. 9 Motivation 12- 11 References . 12- 11 13 Safety Ashok Shah .13-1 13.1 Safety 13-1 13 .2 Common Safety-Related Definitions 13 -2 13.3 Safety Design Procedure 13 -2 13.4 Determining Limits of the... profit 2 Roll Forming Mill 2. 1 2. 2 2. 3 George T Halmos Delta Engineering Inc 2. 1 General Mill Types Cantilevered Mills † Duplex Mills † Through-Shaft Duplex Mills † Standard (Conventional) Mills † Double-High Mills † Rafted (Plated, Cassetted) Mills † Side-by-Side Mills † Pull-Through Mills † Spiral-Tube Mills † Truck-Mounted Mills † Special Mills 2- 1 2- 1 Mill Components 2- 18... to form many simple, narrow sections (Figure 2. 2) To utilize the mill for two sections, the opposite side of the “cantilevered” shaft ends can be tooled to form another section (Figure 2. 3) The advantages of the cantilevered mills are: * * Relatively low cost Capability to form the edge of sheets of any width 2- 1 2- 2 Roll Forming Handbook FIGURE 2. 1 TABLE 2. 1 Cross-section of cantilever mill Shaft Diameter... .4- 62 4 .20 Foaming 4- 62 4 .21 Packaging 4- 62 References 4- 62 5 6 Roll Design George T Halmos 5-1 5.1 Roll Design Process 5 -2 5 .2 Cross-Section 5-4 5.3 Product Orientation and Other Operations in the Line 5-13 5.4 Materials 5-19 5.5 Roll Forming Mill 5 -28 5.6 Other... reduced by F 2 F 2 defla 1 1 2 2 (a) supported at one ends F deflb 1 (b) supported at both ends defla = 4 deflb FIGURE 2. 4 Cantilevered shaft deflects four times more than a shaft supported at both ends 2- 4 Roll Forming Handbook FIGURE 2. 5 Connecting the operator side of the cantilevered shafts reduces deflection FIGURE 2. 6 Rafted cantilever mill stand (Courtesy of CompuRoll Inc.) Roll Forming Mill 2- 5 using... (by checking the gap between the tooling) C C L2 L 4 Both the single cantilevered and duplex mills C C C CC C L1 L 3 L1 L2L 3 L4 must have long entry and reasonably long exit guides (Figure 2. 9) The uneven roll pressure, 12 34 4 321 uneven or asymmetric forming, and bent shafts 1 2 3 4 1 ,2, 3 can generate uneven driving forces, resulting in a skewed entry or exit of the product (Figure 2. 10) (a) one side... Secondary Operations 9-10 9.4 Profiles Manufactured in Different Sizes 9 -20 9.5 Design of Specific Products .9 -22 9.6 Dimensioning and Tolerancing 9 -22 References 9 -29 10 Equipment Installation, Roll Setup, Maintenance, and Troubleshooting 7.1 7 .2 7.3 7.4 7.5 7.6 7.7 Joseph Ivaska 7-1 Tribology of Lubrication 7-1 . 12- 2 12. 3 Evaluating the Product 12- 3 12. 4 Selecting Line Components 12- 4 12. 5 Procuring Roll Forming Tooling 12- 7 12. 6 Equipment and Tool Specifications 12- 7 12. 7 AcceptanceTest 12- 7 12. 8 Education. 11 -29 11.6 CAE for Roll Forming 11-34 12 Acquiring Roll Forming Lines, Education, and Training George T. Halmos 12- 1 12. 1 WhyRoll Form Products? 12- 1 12. 2 DifferentPaths to StartRollForming 12- 2 12. 3. LockformerCompany GerardInternationalCorporation Naperville, IL Contents 1 Introduction to Roll Forming George T. Halmos 1-1 1.1 Introduction to Roll Forming 1-1 2 Roll Forming Mill George T. Halmos 2- 1 2. 1 General 2- 1 2. 2 Mill Types 2- 1 2. 3