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Roll forming Technology History Introduction

Roll forming began in Europe approximately in the 1960s. Due to the advantages of high production efficiency, material saving, and increased product strength, the roll forming I-shape is not only used in the threaded fastener industry, but also in the automotive, bicycle and other industrial sectors to process complex-shaped parts. With the advancement of technology and the development of production, the roll forming process has attracted more and more attention.

Compared with the cutting and grinding processes, the roll forming process not only has high production efficiency, saves materials, but also has high product strength and stable quality. This process is particularly suitable for processing special long and short workpieces that are difficult to cut, especially for annual production. For millions of high-volume products, the roll forming process is the most advantageous and the economic benefits are the most impressive.

The rolling process is a cold forging process, and there are many materials that can be rolled. Among them, low-carbon steel is a commonly used material for roll forming, and non-ferrous metals are more suitable for roll forming.
Roll-formed parts are generally upset by a cold heading machine to forge blank parts, and then rolled by a thread rolling machine. The equipment that can carry out thread rolling and rolling forming includes: various reciprocating flat thread rolling machines, planetary thread rolling machines, two cylindrical thread rolling machines and three cylindrical thread rolling machines. The most common roll forming machine is the reciprocating flat thread rolling machine. Therefore, for manufacturers who have cold heading machines and thread rolling machines, it is only a matter of designing roll forming molds.

A movable wire plate and a fixed wire plate of roll forming are relatively reciprocated. Roll forming is to roll different structural designs of the wire plate onto the workpiece. According to needs, various threads, convex rings, knurling, end chamfers, grooves of different depths and widths and other shapes can be rolled out.

Roll forming is more complicated and more demanding than rolling threads. The mold design is based on the different shapes of the workpieces, the thread rolling board is designed into one section or several sections, which can be synchronized or graded. When the diameter of the blank along the axis is the same or substantially the same, synchronous rolling can be used; when the diameter of the blank along the axis is not the same, and when several diameters of different structures are required to be rolled, the graded rolling is used forming. Generally, it can be roll-formed once, and roll-formed twice for complicated shapes

Roll forming is an advanced processing technology, and its remarkable process characteristics are valued by the automobile industry at home and abroad. The United States, Japan, Britain, Germany, France, Russia and other countries have all vigorously developed this technology. The United States uses roll forming technology to process automobile shafts at 200 pieces per minute, which is more than 40 times higher than the original cutting process. The British and Japanese automobile industries also use the rolling process to produce automobile connecting rod parts

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