Roll Forming Handbook / Edited by George T. Halmos
Подождите немного. Документ загружается.
Contributors
vii
GeorgeT.Halmos
Delta EngineeringInc.
Ontario,Canada
Joseph Horvath
Retired
Joseph Ivaska
Tower Oil &Technology Co.
205 W. Randolph St.
Chicago,IL60606
Manabu Kiuchi
Faculty of Informatics
Institute of Industrial Sciences
TeikyoHeisei University
Tokyo, Japan
Ashok Shah
The LockformerCompany
GerardInternationalCorporation
Naperville, IL
Contents
1 Introduction to Roll Forming George T. Halmos ........................................................................1-1
1.1 Introduction to Roll Forming .....................................................................................................1-1
2 Roll Forming Mill George T. Halmos ...............................................................................................2-1
2.1 General ..........................................................................................................................................2-1
2.2 Mill Types ......................................................................................................................................2-1
2.3 Mill Components .......................................................................................................................2-18
References .................................................................................................................................................2-32
3 Presses and Die Accelerators George T. Halmos ...........................................................................3-1
3.1 General ..........................................................................................................................................3-1
3.2 Mechanical Presses .......................................................................................................................3-6
3.3 Pneumatic Presses ......................................................................................................................3-10
3.4 Hydraulic Presses ........................................................................................................................3-12
3.5 Information and Dimensions for Press/Die Purchasing and Installation .............................3-15
3.6 Rotaryand Other Cutting,Punching Equipment ...................................................................3-15
3.7 Flying Die Accelerators ..............................................................................................................3-20
4 SecondaryOperations in the Roll Forming Line George T. Halmos ....................................4-1
4.1 SecondaryOperations ..................................................................................................................4-2
4.2 Straightening .................................................................................................................................4-3
4.3 Tight or Loose Line: Cutting Before, In-Between, or After Roll Forming ..............................4-9
4.4 Location of the SecondaryOperations .....................................................................................4-14
4.5 Stationaryand Flying Dies ........................................................................................................4-14
4.6 Punching, Perforating,Notching,and Mitering .....................................................................4-16
4.7 Piercing and Partial Punching ..................................................................................................4-19
4.8 Flanging,Louvering, and Lancing ............................................................................................4-20
4.9 Embossing and Drawing ............................................................................................................4-20
4.10 Bending .......................................................................................................................................4-22
4.11 Curving (Sweeping) ...................................................................................................................4-24
4.12 Marking .......................................................................................................................................4-46
4.13 Swedging (OffSetting) ...............................................................................................................4-46
4.14 RotaryDies .................................................................................................................................4-46
ix
4.15 Mechanical Joining of DifferentStrips or Parts......................................................................4-56
4.16 Adhesive Bonding .......................................................................................................................4-60
4.17 Soldering and Brazing ................................................................................................................4-60
4.18 Resistance Welding .....................................................................................................................4-60
4.19 Painting .......................................................................................................................................4-62
4.20 Foaming ......................................................................................................................................4-62
4.21 Packaging ....................................................................................................................................4-62
References .................................................................................................................................................4-62
5 Roll Design George T. Halmos ............................................................................................................5-1
5.1 Roll Design Process ......................................................................................................................5-2
5.2 Cross-Section ................................................................................................................................5-4
5.3 Product Orientation and Other Operations in the Line ........................................................5-13
5.4 Materials ......................................................................................................................................5-19
5.5 Roll Forming Mill ......................................................................................................................5-28
5.6 Other Tool Design Considerations ...........................................................................................5-40
5.7 Spacersand Shims ......................................................................................................................5-48
5.8 Calculating Strip Width .............................................................................................................5-52
5.9 Bend Lines ...................................................................................................................................5-55
5.10 Number of Passes .......................................................................................................................5-64
5.11 Flower Diagram ..........................................................................................................................5-73
5.12 Roll Design ..................................................................................................................................5-78
5.13 Calculating Roll Dimensions Manually ....................................................................................5-94
5.14 Computer-Aided Roll Design ....................................................................................................5-95
5.15 Examples ...................................................................................................................................5-100
5.16 Roll MarkingSystem ................................................................................................................5-103
5.17 Roll Orientation .......................................................................................................................5-107
5.18 Setup Charts .............................................................................................................................5-107
References ...............................................................................................................................................5-111
6 Materials George T. Halmos ................................................................................................................6-1
6.1 Design Considerations .................................................................................................................6-1
6.2 Mechanical Properties ..................................................................................................................6-2
6.3 Crystalline StructureofMetals ...................................................................................................6-7
6.4 Forming Metals ............................................................................................................................6-7
6.5 Increasing the Strength of Metals by Cold Working ...............................................................6-10
6.6 HotRolling .................................................................................................................................6-10
6.7 H.R. and H.R.P.O.Steels ...........................................................................................................6-12
6.8 Cold Rolled Steel ........................................................................................................................6-12
6.9 Carbon Steel ................................................................................................................................6-12
6.10 Alloyed Steel ................................................................................................................................6-13
6.11 Stainless Steel ..............................................................................................................................6-15
6.12 Metallic Coatings ........................................................................................................................6-16
6.13 Nonmetallic Coating and Laminating ......................................................................................6-17
6.14 Joining Different Materials in the Roll Forming Process .......................................................6-18
6.15 Aluminum ...................................................................................................................................6-18
6.16 Other Metals and Materials .......................................................................................................6-20
Contentsx
6.17 Influence of PrimaryMetal Processes on Roll Forming .........................................................6-20
6.18 Guideline to Steel Prices ............................................................................................................6-24
References .................................................................................................................................................6-24
7 Lubrication Joseph Ivaska ...................................................................................................................7-1
7.1 TribologyofLubrication ..............................................................................................................7-1
7.2 Selection of Lubricants ................................................................................................................7-5
7.3 SurfaceProperties of Formed Material ......................................................................................7-8
7.4 Lubricants for the SecondaryOperations ................................................................................7-10
7.5 Application Te chniques ..............................................................................................................7-11
7.6 Preparation and Maintenance of Lubricants ...........................................................................7-12
7.7 Operating Problems during Production ..................................................................................7-18
8 Coil Processing,Material Handling, and Plant Layout
George T. Halmos and Joseph Horvath .....................................................................................................8-1
8.1 Flow of Material ...........................................................................................................................8-2
8.2 Coil Handling and Storage ..........................................................................................................8-3
8.3 Sheet Handling and Storage ........................................................................................................8-6
8.4 In-Line Coil Handling .................................................................................................................8-9
8.5 Coil End Welding .......................................................................................................................8-14
8.6 Strip (Coil) Accumulators .........................................................................................................8-16
8.7 Flattening and Leveling ..............................................................................................................8-19
8.8 In-Line Sheet Handling .............................................................................................................8-22
8.9 Finished Product Handling .......................................................................................................8-23
8.10 Finished Product Storage ...........................................................................................................8-31
8.11 Material Handling Equipment ..................................................................................................8-34
8.12 Material Handling Accessories ..................................................................................................8-38
8.13 Crane Controls ...........................................................................................................................8-40
8.14 Plant Layout ................................................................................................................................8-41
References .................................................................................................................................................8-43
9 Designing Products for Roll Forming George T. Halmos .........................................................9-1
9.1 Developing Light Gage Products ................................................................................................9-1
9.2 Design Considerations .................................................................................................................9-2
9.3 SecondaryOperations ................................................................................................................9-10
9.4 Profiles Manufactured in Different Sizes ..................................................................................9-20
9.5 Design of Specific Products .......................................................................................................9-22
9.6 Dimensioning and To lerancing .................................................................................................9-22
References .................................................................................................................................................9-29
10 Equipment Installation, Roll Setup,Maintenance, and Troubleshooting
George T. Halmos .....................................................................................................................................10-1
10.1 Installation of Roll Forming Lines ............................................................................................10-1
10.2 Roll Installation and Setup ........................................................................................................10-8
10.3 Maintenanceand Spare Parts..................................................................................................10-14
10.4 Troubleshooting and Trouble Prevention ..............................................................................10-32
Contents xi
11 Behavior of Metal Strip during Roll Forming Manabu Kiuchi ...........................................11-1
11.1 Various Types of Deformations .................................................................................................11-1
11.2 Causes of Redundant Deformations .........................................................................................11-3
11.3 Effects of Redundant Deformations on Product Defects ........................................................11-6
11.4 Mathematical Simulation of the Deformation of aMetal Strip ..........................................11-19
11.5 Computerized Design System for Roll Profiles .....................................................................11-29
11.6 CAE for Roll Forming ..............................................................................................................11-34
12 Acquiring Roll Forming Lines, Education, and Training George T. Halmos ...................12-1
12.1 WhyRoll Form Products? .........................................................................................................12-1
12.2 DifferentPaths to StartRollForming ......................................................................................12-2
12.3 Evaluating the Product ..............................................................................................................12-3
12.4 Selecting Line Components .......................................................................................................12-4
12.5 Procuring Roll Forming Tooling ...............................................................................................12-7
12.6 Equipment and To ol Specifications ..........................................................................................12-7
12.7 AcceptanceTest ...........................................................................................................................12-7
12.8 Education and Training .............................................................................................................12-7
12.9 Motivation ................................................................................................................................12-11
References ...............................................................................................................................................12-11
13 Safety Ashok Shah ...............................................................................................................................13-1
13.1 Safety...........................................................................................................................................13-1
13.2 Common Safety-Related Definitions ........................................................................................13-2
13.3 SafetyDesign Procedure ............................................................................................................13-2
13.4 Determining Limits of the MachineryorSystem ...................................................................13-3
13.5 Determining Hazards/Risk Estimation .....................................................................................13-3
13.6 Risk Reduction by Design .........................................................................................................13-8
13.7 Safeguarding ................................................................................................................................13-9
13.8 Selection of Guards and ProtectiveDevices ...........................................................................13-13
13.9 Required Characteristics of Guards and Protection Devices ................................................13-13
13.10 Signals and Warning Devices ..................................................................................................13-14
13.11 Personal ProtectiveEquipment ...............................................................................................13-14
13.12 Training .....................................................................................................................................13-14
13.13 Summary...................................................................................................................................13-15
References ...............................................................................................................................................13-16
14 Increasing Efficiency of Roll Forming Lines and Case Studies George T. Halmos ........14-1
14.1 Output, Productivity, and Efficiency ........................................................................................14-1
14.2 Line Utilization ...........................................................................................................................14-2
14.3 Improving Productivity.............................................................................................................14-3
14.4 Case Studies ................................................................................................................................14-4
14.5 PreliminaryTool and Equipment Cost Analysis ...................................................................14-10
14.6 PreliminaryCost Analysis .......................................................................................................14-10
15 Unusual, New, and Future Roll Forming Technologies George T. Halmos ......................15-1
15.1 The Last 100 Years ......................................................................................................................15-2
15.2 The Future of Roll Forming ......................................................................................................15-2
Contentsxii
15.3 Pull-ThroughMills: Nondriven Rolls .......................................................................................15-5
15.4 Tension Roll Forming ................................................................................................................15-6
15.5 Combining Roll Forming and Cold Drawing ..........................................................................15-7
15.6 Developing NewRollForming Methods .................................................................................15-7
15.7 Roll Forming Tools .....................................................................................................................15-9
15.8 Reducing the Thickness of the Starting Material ..................................................................15-10
15.9 Forming at Elevated Te mperature..........................................................................................15-11
15.10 Hot Roll Forming Variable Cross-Sections ............................................................................15-11
15.11 Hot Thickness Reduction along the Length of the Strip ......................................................15-12
15.12 Welding Hot Roll Formed Sections ........................................................................................15-12
15.13 Other “Hot”Processes .............................................................................................................15-13
15.14 In-Line Soldering,Brazing,and HeatTreating ......................................................................15-13
15.15 Equipment and Tooling Requirements for Hot Roll Forming .............................................15-14
15.16 Press Tooling for Conventional Roll Forming Lines .............................................................15-16
15.17 Computer-Controlled Roll Forming Lines ............................................................................15-16
References ...............................................................................................................................................15-17
Appendices ............................................................................................................................................. A-1
References ............................................................................................................................................... R-1
Index ......................................................................................................................................................... I-1
Contents xiii
1
Introduction to Roll
Forming
GeorgeT.Halmos
Delta Engineering Inc.
1.1 Introduction to Roll Forming .......................................... 1 -1
AShort History of Using Metals
†
Forming of Sheet
Metals
†
What is Roll Forming?
†
Basic Requirements
1.1 Introduction to Roll Forming
1.1.1 AShortHistoryofUsing Metals
Our ancestors used wood and stone tools for over 1.7 million years, give or take afew hundred thousand
years, beforemaking use of metals. It was only around 6000 B.C. when naturally available gold (and later
copper), meteorite iron, and afew other metals were shaped by hammering to makeornaments, tools,
and weapons. Afterwards, our forefathers discovered how to reduceores, melt and alloymetals, and
utilize them for moreelaborate products.
Gold was mainly used for jewelrybecause it is too soft for implements. Copper was only slightly
harder,but by adding arsenic and tin to copper,the early Bronze Age smiths could produce good-quality
axes and other ar ticles. Gradually,more and morebronze articles were used and the Bronze Age
superseded the Stone Age.
Gold, copper,tin, lead, silver,iron, and mercurywere the only seven known and used metals until the
thirteenth centuryand only five more metals werediscovered up until the seventeenth century. Today, we
knowthat about twothirds of all known elements are metals.
The first iron products dated back to 3000 to 4000 B.C., but they werescarceand expensive. The edges
of iron implements were too soft; therefore, iron articles weresuitable for ornaments but not for tool and
weapons. The discovery of carbonizing around 1200 to 1300 B.C. brought major change and heralded the
beginning of the Iron Age. Steel products became better for tools and weapons. Transition was slow,but
eventually cast and forged iron products replaced bronze in most areas. Furnaces became larger and steel
became better.The early smiths producedexcellent qualityaxes, chisels, hoes, swords, and other
implements. In 1350, the ironmakers of central Europe succeeded in melting and casting iron troughthe
use of primitiveblast furnaces [438].
Making complex items, such as body armor assembled fromhundreds of matching pieces of
hammeredplates and wires, required considerable skill and experience. The process was extremely
labor-intensive because of the long hours of hammering required. Actually,uptothe seventeenth
century, to the dawn of the Industrial Revolution, everynoncast item, from ornamental to utilitywas
made by hand, through labor-intensive forging.Not manypeople could afford to own metal products.
1 -1