ROLLER FORMER MACHINE

Product Description

A Roller Former Machine (also known as a Roll Forming Machine) is a piece of machinery used in the manufacturing process of shaping and forming metal into specific profiles or shapes through a series of rollers. This machine is primarily used for producing metal components with constant cross-sectional profiles that are typically used in industries such as construction, automotive, and appliance manufacturing.

How a Roller Former Machine Works:

1. Material Feeding:

   • The process begins with feeding a flat sheet or coil of metal (usually steel, aluminum, or other metals) into the roller former machine. The material is unwound from a coil, and its fed into the system at a precise speed.

2. Roller Stations:

   • The machine consists of multiple roller stations (or sets of rollers) arranged in a series. Each roller station gradually shapes the material by bending or curving it at a specific angle.
   • As the metal passes through the rollers, it is progressively formed into the desired shape, such as a channel, angle, or other cross-sectional profiles.

3. Forming Process:

   • The rollers progressively form the material without cutting it. This process helps produce continuous lengths of metal profiles with consistent dimensions.

4. Final Shaping:

   • The final rollers shape the metal to its final form, after which it exits the roller former as a fully formed piece, often cut to a specified length.

5. Cutting to Length:

   • After the material is formed, some roller former machines include a cutting station where the formed metal is cut to specific lengths, usually with a shearing blade or flying saw.

Features of a Roller Former Machine:

• Multiple Rollers: The rollers gradually shape the material by applying force at multiple stages, which ensures that the metal doesnt undergo too much stress or strain in one step.

• Adjustable Rollers: The rollers can be adjusted to create different profiles, widths, and shapes. This makes the machine flexible and versatile for various applications.

• High-Speed Production: Roller former machines operate at high speeds, allowing for mass production of long metal sections in continuous lengths.

• Automated Control Systems: Modern roller formers are equipped with sophisticated control systems for automatic speed adjustment, material feeding, and cutting to ensure precision.

Types of Profiles Produced by Roller Forming Machines:

Roller forming machines are used to produce a wide range of profiles, including:

1. C-Sections:

   • Often used in construction and roofing, C-sections are shaped like the letter "C" and are used in structural applications.

2. U-Sections:

   • These are U-shaped profiles commonly used in framing and construction.

3. Z-Sections:

   • Z-profiles are used for building structures, often as purlins in steel building frames.

4. I-Beams and Channels:

   • I-shaped beams and U-shaped channels are often produced for structural applications, where strength and durability are important.

5. Corrugated Sheets:

   • Corrugated profiles, typically used for roofing and cladding, can be produced through a roller former machine by passing metal sheets through specialized rollers that create wave-like patterns.

6. Ridge Caps:

   • Used in roofing, ridge caps are formed to fit along the peak of a roof.

7. Trim and Flashing Profiles:

   • Roller forming machines are also used to create trim and flashing used in construction, ensuring weather resistance and aesthetic appeal.

Applications of Roller Former Machines:

1. Construction Industry:

   • Used to manufacture roofing panels, wall panels, and structural components such as beams and purlins.
   • Common materials used include galvanized steel, aluminum, and stainless steel.

2. Automotive Industry:

   • Automotive parts such as door panels, roof rails, or reinforcements can be made using roller forming machines.

3. Appliance Manufacturing:

   • Appliance manufacturers use roller forming to create parts for products like refrigerators, washing machines, and ovens, which often require precise metal shaping.

4. Furniture Industry:

   • In the furniture sector, roller forming machines are used to create metal profiles for frames, legs, or other structural components.

5. Solar Panel Frames:

   • Solar panel manufacturers use roller forming to create frames that hold solar panels in place.

6. Agricultural Machinery:

   • Parts like chassis frames or metal covers for farming equipment are often produced through roller forming.

Advantages of Roller Forming Machines:

1. High-Speed Production:

   • Roller forming allows for continuous, high-speed production of long metal profiles, making it highly efficient for mass production.

2. Precision and Consistency:

   • The process produces very consistent and precise profiles, which is critical in industries where uniformity is essential.

3. Cost-Effective:

   • The continuous process reduces material waste and lowers production costs, especially for long runs.

4. Flexibility in Design:

   • The machine can produce a wide variety of shapes and sizes, making it versatile and adaptable to different needs.

5. No Need for Cutting or Welding:

   • Since the material is shaped rather than cut or welded, roller forming preserves the integrity of the material and reduces the risk of defects like cracks or deformations.

Maintenance and Considerations:

• Roller Adjustment: Regular maintenance and adjustment of rollers are necessary to maintain the quality of the profile being produced and to prevent wear.

• Lubrication: Proper lubrication is crucial to reduce friction between rollers and the material to prevent damage and ensure smooth operation.

• Tooling Changes: Depending on the profile to be produced, tooling (such as roller designs) may need to be changed. This requires expertise and knowledge of how to make the necessary adjustments.

• Material Compatibility: The machine is typically designed for specific materials (like steel or aluminum), so its important to choose the right type of material for the machines capabilities.

Common Roller Forming Machine Brands/Manufacturers:

1. Forming Machines from YX (China): Known for manufacturing a variety of roller forming machines used in the construction and automotive sectors.
2. NASCORP Roller Forming: A manufacturer based in the United States, specializing in equipment for custom metal forming.
3. Bielomatik: A German manufacturer known for advanced and automated roller forming machines.
4. Boschert: A company that offers both standard and custom roller forming systems.