How to adjust roll forming machine

How to adjust roll forming machine

1. Twist 

twist in the roll-formed part is like a corkscrew effect and often caused by excessive forming pressure and asymmetrical profiles.  generally, twists can be held to less than 5 degrees in 10 feet or 3 meters.

the twist problems are usually attributable to setup mistakes.  The twist is the rotation of two sides of the profile directions.  there is so important notice" Twist in a formed part is generally the result of excessive forming pressures along the longitudinal radii" .

there is a list of some of the problems about a twist in roll forming machine and some remedies for the roll form operators:

Troubleshooting Roll Forming Checklist table for twist problem:

1. 1-Roller Set-Up

• 1-Balance rollers gaps

• 2- Increase the roll gap in an area where twisting occurs.

• 3- Reduce the degree of forming in several stands,

• 4- allowing a smoother strain distribution

1. 2-Profile drawing

• 1-Normally Symmetrical panels run without twist issues

• 2-Nonsymmetrical panelsare most susceptible to twist.

  3-Material

• Changes in thickness across the width of material can causetwist, especially if the edges are thicker than the center.The edges will deformation more than the center and twisting can result.

1. 4-Heat

• 1- check the roll gaps for heat expansion(increase Heat of rollers from the forming process can reduce the roll gaps than originally set, resulting in a twist. If the panel runs okay at startup and subsequently twist appears)

• 2- use lubricants can reduce temperature increase during forming.

• 3- maintain the sharpest corners cool as possible(Sharp corners are a source of localized heat expansion, which can beminimized by lubrication)

  5-Cut off

• make sure the cutting blade is in the right position and won' t make any distortion or reflection on the profile during passing the profile through the blade.

1. 6-Clean rollers

2. 1-Clean the rollers periodically to remove any pick up from them, Galvanized or coating pickup on the rollers can reduce the roller gap than first adjusted.

3. 2-The use of a lubricant can reduce or eliminate roll pickup.

 2.Bow 

The vertical plane deviation from a straight line can be a cross or longitudinal bow, it is caused by uneven vertical gaps on symmetrical cross-sections and uneven forming areas on asymmetrical sections in the general bow can be held to plus or minus 1/8 inch in 10 feet or 3mm in 3 meters.

The bow is the variation from a straight line in the vertical plane. It can be either crossbow or longitudinal bow. The bow is often caused by the existence of irregular vertical spaces on symmetrical sections and from uneven forming areas on unsymmetrical sections.

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