Roll Forming Handbook: 1st Edition (Hardback) book cover

Roll Forming Handbook

1st Edition

Edited by George T. Halmos

CRC Press

584 pages | 723 B/W Illus.

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pub: 2005-11-29
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Description

Roll forming is one of the most widely used processes in the world for forming metals. Most of the existing knowledge resides in various journal articles or in the minds of those who have learned from experience. Providing a vehicle to systematically collect and share this important knowledge, the Roll Forming Handbook presents the first comprehensive, dedicated treatment to all facets of roll forming, supplying references to more in-depth information to fill in the gaps.

This book spans from conception of the roll forming operation, purchasing and specifying equipment, and roll design to maintenance, troubleshooting, safety, and operator training. Detailed discussions reveal how material, equipment, tooling, and operator factors affect overall efficiency and product quality. Expert contributors share insights based on many years of hard-won experience, including effects of secondary operations such as punching, embossing, curving and cutting in the line; designing products for efficient roll forming; mechanical properties of metals, lubrication and the influence of coatings on roll design and forming; and mathematical simulations of various deformations that occur during processing to determine their causes and find a solution.

Outlining a practical approach to select, set up, and operate roll forming lines, the Roll Forming Handbook combines scientific background and practical know-how that enables you to set up cost-effective and high-quality roll forming lines with confidence.

Table of Contents

INTRODUCTION TO ROLL FORMING; George T. Halmos

Introduction to Roll Forming

ROLL FORMING MILL; George T. Halmos

General

Mill Types

Mill Components

References

PRESSES AND DIE ACCELERATORS; George T. Halmos

General

Mechanical Presses

Pneumatic Presses

Hydraulic Presses

Information and Dimensions for Press/Die Purchasing and Installation

Rotary and Other Cutting, Punching Equipment

Flying Die Accelerators

SECONDARY OPERATIONS IN THE ROLL FORMING LINE; George T. Halmos

Secondary Operations

Straightening

Tight or Loose Line: Cutting Before, In-Between, or After Roll Forming

Location of the Secondary Operations

Stationary and Flying Dies

Punching, Perforating, Notching, and Mitering

Piercing and Partial Punching

Flanging, Louvering, and Lancing

Embossing and Drawing

Bending

Curving (Sweeping)

Marking

Swedging (Off Setting)

Rotary Dies

Mechanical Joining of Different Strips or Parts

Adhesive Bonding

Soldering and Brazing

Resistance Welding

Painting

Foaming

Packaging

References

ROLL DESIGN; George T. Halmos

Roll Design Process

Cross-Section

Product Orientation and Other Operations in the Line

Materials

Roll Forming Mill

Other Tool Design Considerations

Spacers and Shims

Calculating Strip Width

Bend Lines

Number of Passes

Flower Diagram

Roll Design

Calculating Roll Dimensions Manually

Computer-Aided Roll Design

Examples

Roll Marking System

Roll Orientation

Setup Charts

References

MATERIALS; George T. Halmos

Design Considerations

Mechanical Properties

Crystalline Structure of Metals

Forming Metals

Increasing the Strength of Metals by Cold Working

Hot Rolling

H.R. and H.R.P.O. Steels

Cold Rolled Steel

Carbon Steel

Alloyed Steel

Stainless Steel

Metallic Coatings

Nonmetallic Coating and Laminating

Joining Different Materials in the Roll Forming Process

Aluminum

Other Metals and Materials

Influence of Primary Metal Processes on Roll Forming

Guideline to Steel Prices

References

LUBRICATION; Joseph Ivaska

Tribology of Lubrication

Selection of Lubricants

Surface Properties of Formed Material

Lubricants for the Secondary Operations

Application Techniques

Preparation and Maintenance of Lubricants

Operating Problems during Production

COIL PROCESSING, MATERIAL HANDLING, AND PLANT LAYOUT; George T. Halmos and Joseph Horvath

Flow of Material

Coil Handling and Storage

Sheet Handling and Storage

In-Line Coil Handling

Coil End Welding

Strip (Coil) Accumulators

Flattening and Leveling

In-Line Sheet Handling

Finished Product Handling

Finished Product Storage

Material Handling Equipment

Material Handling Accessories

Crane Controls

Plant Layout

References

DESIGNING PRODUCTS FOR ROLL FORMING; George T. Halmos

Developing Light Gage Products

Design Considerations

Secondary Operations

Profiles Manufactured in Different Sizes

Design of Specific Products

Dimensioning and Tolerancing

References

EQUIPMENT INSTALLATION, ROLL SETUP, MAINTENANCE, AND TROUBLESHOOTING; George T. Halmos

Installation of Roll Forming Lines

Roll Installation and Setup

Maintenance and Spare Parts

Troubleshooting and Trouble Prevention

BEHAVIOR OF METAL STRIP DURING ROLL FORMING; Manabu Kiuchi

Various Types of Deformations

Causes of Redundant Deformations

Effects of Redundant Deformations on Product Defects

Mathematical Simulation of the Deformation of a Metal Strip

Computerized Design System for Roll Profiles

CAE for Roll Forming

ACQUIRING ROLL FORMING LINES, EDUCATION, AND TRAINING; George T. Halmos

Why Roll Form Products?

Different Paths to Start Roll Forming

Evaluating the Product

Selecting Line Components

Procuring Roll Forming Tooling

Equipment and Tool Specifications

Acceptance Test

Education and Training

Motivation

References

SAFETY; Ashok Shah

Safety

Common Safety-Related Definitions

Safety Design Procedure

Determining Limits of the Machinery or System

Determining Hazards/Risk Estimation

Risk Reduction by Design

Safeguarding

Selection of Guards and Protective Devices

Required Characteristics of Guards and Protection Devices

Signals and Warning Devices

Personal Protective Equipment

Training

Summary

References

INCREASING EFFICIENCY OF ROLL FORMING LINES AND CASE STUDIES; George T. Halmos

Output, Productivity, and Efficiency

Line Utilization

Improving Productivity

Case Studies

Preliminary Tool and Equipment Cost Analysis

Preliminary Cost Analysis

UNUSUAL, NEW, AND FUTURE ROLL FORMING TECHNOLOGIES; George T. Halmos

The Last 100 Years

The Future of Roll Forming

Pull-Through Mills: Nondriven Rolls

Tension Roll Forming

Combining Roll Forming and Cold Drawing

Developing New Roll Forming Methods

Roll Forming Tools

Reducing the Thickness of the Starting Material

Forming at Elevated Temperature

Hot Roll Forming Variable Cross-Sections

Hot Thickness Reduction along the Length of the Strip

Welding Hot Roll Formed Sections

Other "Hot" Processes

In-Line Soldering, Brazing, and Heat Treating

Equipment and Tooling Requirements for Hot Roll Forming

Press Tooling for Conventional Roll Forming Lines

Computer-Controlled Roll Forming Lines

References

APPENDICES

REFERENCES

INDEX

About the Series

Manufacturing Engineering and Materials Processing

Learn more…

Subject Categories

BISAC Subject Codes/Headings:
TEC009070
TECHNOLOGY & ENGINEERING / Mechanical
TEC020000
TECHNOLOGY & ENGINEERING / Manufacturing
TEC021000
TECHNOLOGY & ENGINEERING / Material Science