Includes real-world case studies, recommendations for efficient plant layout and material handling as well as hundreds of illustrations and references

Explains the principles and methods of manual and computer-aided roll design and tool setup

Supplies equations to calculate number of passes, shaft diameters, and bending factors, published here for the first time

Presents guidelines for training personnel as well as for performing troubleshooting and maintenance

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.

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