Roll Forming

ROLL FORMING: Major Advantages

Roll forming is superior to other metal forming processes and has advantages over aluminum extrusions, for many reasons.

Roll forming also makes it easier to produce longer lengths than are typically available on a stamping press. We can put holes in the part in-line, and we can provide you with the end cut you desire. The limiting factor on the length of a roll formed part is transportation, not the roll forming machine. We regularly roll parts that are 40-feet long.

Our engineers happily cater to all client needs, handling any job size with ease.

Custom Roll Forming Processes, Techniques, and Services

With roll forming services from Roller Die, your company can take advantage of an economical and efficient way of getting the metal components it needs. Our roll forming process features a team with decades of experience in the custom metal components business, allowing us to quickly produce strong metal components that are made to your exact specifications. We are also focused on technology and innovation and regularly invest in new equipment, software, and training to stay on top of changes in the industry.

The roll forming process works by passing sheet metal through a series of rollers, with each of these rollers adding shape to the metal. The rolls work together to form the desired cross-section. Since the process is consistent and easy to repeat, roll forming provides a great way to precisely produce very high volumes of metal components.

Our roll forming services, which include aluminum roll forming, can be used to create components for a wide variety of industries. In addition, we operate over 90 roll machines, with spindle sizes ranging from one inch to three inches. This means that we are able to quickly handle all your roll forming needs, whatever those needs might be. We can create both standard shapes and custom jobs, both of which are produced at the highest quality levels possible.

To get started with your custom roll forming project, contact us today for a free quote.

What is Roll Forming?

The desired cross section is gradually formed as it passes through the rollers. The material starts as a flat coil or blank and each pair of rolls adds to the shape.

Roll forming is a continuous metal forming process taking sheet, strip, or coil stock and bending or forming it to a continuous cross section. The process is performed between successive pairs of rolls that change the shape until the desired section is completed.

The roll forming process can be used to form a wide variety of cross-section profiles. An open profile is most common, but a closed tube-like shape can be created as well. Because the final form is achieved through a series of bends, the part does not require a symmetric cross-section.

123456789

Advantages of Roll Forming A Metal Part

There are several advantages of using roll forming for your projects:

Roll Forming Metal Frames
  • The roll forming process allows operations such as punching, notching, and welding to be performed in-line. Labor cost and time for secondary operations are reduced or eliminated, reducing part costs.
  • Roll form tooling allows for a high degree of flexibility. A single set of roll form tools will make almost any length of the same cross-section. Multiple sets of tools for varying length parts are not required.
  • It can provide better dimensional control than other competing metal forming processes.
  • Repeatability is inherent in the process, allowing easier assembly of roll formed parts into your finished product, and minimizing problems due to “standard” tolerance build up.
  • Roll forming is typically a higher speed process.
  • Roll forming offers customers a superior surface finish. This makes roll forming an excellent option for decorative stainless steel parts or for parts requiring a finish such as anodizing or powder coating. Also, texture or pattern can be rolled into the surface during forming.
  • Roll forming utilizes material more efficiently than other competing processes.
  • Roll formed shapes can be developed with thinner walls than competing processes.
Roll Forming Techniques

There are two common roll forming techniques with variations:

1) Pre-cut or cut-to-length roll forming

  • Strips are pre-cut and processed, then fed into the roll former as individual strips. These strips may be cut from a coil or sheet.
  • Processing may include piercing, notching, embossing.
  • Typically used for low-production parts or parts with certain types of notches.

2) Post-cut roll forming

  • Pieces of the cross section are cut to length after forming. This process involves working from a coil of material.
  • A strip can be pierced, notched, or further processed before the cutoff operation.
  • The cut-off system moves with the strip and can add other features.

Roll Forming Materials

Almost any material that can tolerate bending to a desired radius can be roll formed. The more ductile the material is, the better it will roll form. The roll forming process can handle ferrous, nonferrous, hot rolled, cold rolled, polished, plated, or pre-painted metals producing excellent results.

Almost any material that can tolerate bending to a desired radius can be roll formed. The more ductile the material is, the better it will roll form. The roll forming process can handle ferrous, nonferrous, hot rolled, cold rolled, polished, plated, or pre-painted metals producing excellent results.

Material Spec Qualification:

  • Materials as thin as 0.005″ can be roll formed.
  • Material pieces as narrow as 1/8 “ and as wide as 72″ or more can be roll formed, depending on machine size.
  • Roller Die’s range of materials is:
    • .005″ to .187″ thick
    • .500″ to 20.00″ wide
Custom Roll Formed Shapes

Unable to find an exact match in our metal roll forming standard tooling library?

No problem.

With nearly 200 years of cumulative metal roll forming and shop experience, our engineers and in-house tool room can still meet your needs. Fill out our request for quote form to send specifications for your upcoming metal roll forming project and/or upload your CAD designs.

Custom Roll Formed Parts

Roll Forming Examples From Roller Die’s

supportrail1

#1 Fairing Support Rail – 7835

  • .071″ G90 HDG
  • 20 roll passes on 2″ mill
  • All holes pre-notched, repeating pattern with multiple lengths
  • Parts powder coated black
  • Multiple angles in a relatively heavy gauge
  • Straightness, twist, bow, flatness of this section is very critical – total indicator reading for flatness
camery-shade

#2 Rear Window Shade Toyota Camry – 7824

  • CRS 0.029″ thick
  • 24 passes
  • Pre-notch, part complete off roll machine
  • Very difficult section
  • Very close tolerances on slots and holes
partition

#3 Main Frame For Office Partition – 7864

  • 0.056″ thick CRS
  • Uses 26 pass roll line
  • Uses striped pre-painted steel
  • Location of striping critical due to welding process
  • Difficult roll section due to shape and need to keep section uniform
  • Twist, bow, and straightness critical
  • Tolerances and shape of section critical to customer assembly

Design Considerations

Bend Radii:

  • Best practice is a one metal thickness inside radius
  • May need to be slightly larger in high strength steels
  • Sharper corners can be obtained at the expense of tool life
  • Scoring the inside of the strip can help make sharper corners in some cases

Deep Sections:

  • Require more passes, larger machines, and larger rolls and dies
  • Risk overstressing the edges of the material
  • Typical machines – 100 mm max

Short Legs:

Three times metal thickness is a good minimum leg length

Wide Sections:

  • Apply ribs to offsets on wide panels
  • Helps prevent wrinkles and “oil-canning”
  • Often wide material has appearance issues

Cross Section Tolerances:

  • Typically +/- .25 mm to +/- .75 mm
  • Tighter tolerances are achievable: a) different approach to tooling and b) special quality materials
  • Angular tolerances; typically +/- 1 degree

Length Tolerances:

  • Influenced by factors, including length of part, speed of rollformer, measuring system, cutoff system, and material properties
  • Commonly available: +/- 0.8 mm
  • Special equipment and tooling: +/- 0.25 mm
  • Long parts (3M or more): +/- 3.0 mm and up

Straightness:

  • Bow (up or down)
  • Curve (side to side) – 1.0 mm per meter
  • Twist – 1 degree per meter

Flare:

  • Typically avoid measuring the cross section within 50 mm or ends
  • Flare can be controlled with special attention

Our Roll Forming Capabilities

At Roller Die + Forming, we offer sheet metal fabrication and assembly services. Our team of experts can handle virtually all types of metal assembly to your unique requirements. We use the best tools and processes to achieve accurate and highly durable parts, with no room for inconsistencies. From prototype to production, Roller Die + Forming remains your reliable partner for your various metal assembly needs.

Our Roll Forming Capabilities

At Roller Die + Forming, we offer sheet metal fabrication and assembly services. Our team of experts can handle virtually all types of metal assembly to your unique requirements. We use the best tools and processes to achieve accurate and highly durable parts, with no room for inconsistencies. From prototype to production, Roller Die + Forming remains your reliable partner for your various metal assembly needs.

Roller Die + Forming News & Articles

roll form parts for your project

The Importance of Quality

When you’re considering roll form parts for your project, you’re initially attracted to the cheap cost per piece and the low material waste. However, if the quality isn’t present in the parts, then those advantages can quickly disappear. At Roller Die, we strive to meet and exceed our customer’s quality expectations. Our customers need to […]

Booming Solar Industry Drives Demand for Racking

Booming Solar Industry Drives Demand for Racking

The solar industry is booming. You’ve probably seen the large utility-scale solar fields spread across valleys and hillsides. Or you’ve had the option to add renewable energy to your electricity bill. Maybe you’ve invested in solar panels for your roof and cut your electric bill down. Any of these, and more, are indications that over […]

Roll Forming for Greenhouses

Roll Forming for Greenhouses

Using roll form parts to create a greenhouse is a great combination of two green and scalable technologies. Whether your greenhouse product is large or small, roll forming can provide the custom metal structure you need to create a strong, light, and functional product. Roller Die + Forming makes roll form parts from aluminum and […]