Roll forming

Abstract

Roll forming is cost-effective compared to other sheet metal forming processes for uniform profiles. The process has during the last 10 years developed into forming of profiles with varying cross sections and is thereby becoming more flexible. The motion of the rolls can now be controlled with respect to many axes enabling a large variation in the profiles along the formed sheet, the so-called 3D roll forming or flexible roll forming technology. The roll forming process has also advantages compared to conventional forming for high-strength materials. Furthermore, computer tools supporting the design of the process have also been developed during the last 10 years. This is quite important when designing the forming of complex profiles. The chapter describes the roll forming process, particularly from the designer’s perspective. It gives the basic understanding of the process and how it is designed. Furthermore, modern computer design and simulation tools are discussed.