Roll Forming Handbook / Edited by George T. Halmos
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hems, 5 -93
herring bone effect, 10-36, 44–5, 11-15
see also corner buckling
hidden bend lines, 4 -34–5
high-strength low alloy(HSLA) steel, 6 -13–14
hinged split spacers, 5 -50
historyofusing metals, 1 -1–2
hold-to-run control device, 13-11
hole-to-bend-line distance, 9 -15
hole-to-cut-edge distance, 9 -14–15
hole-to-hole distance, 9 -12–14
holes
buckling, 4 -41
deformation, 10-38, 51
elongation, 10-37
flanging, 4 -20
gaps between, 10-37
location, 5 -9–10, 10-48–9
number of passes, 5 -65–6,68
piercing, 4 -19
punching, 9 -14, 10-48–9
roll design, 5 -9–10, 65–6,68
tolerances, 5 -9–10, 9 -27–9
horizontal coil accumulator, 8 -17, 18
horizontal coil storage, 8 -3–5
horizontal distance, mill types, 5 -33–4
horizontal traps, 5 -79
horseshoe spacers, 5 -50
hot curving, 15-13
hot roll forming
equipment, 15-14–16
futuretechnologies, 15-11–13
tooling, 15-14–16
“U” channels, 15-7
variable cross-sections, 15-11–12
welding sections, 15-12–15
hot rolled, pickled and oiled (HRPO) steel, 6 -12
hot rolled steel (HRS) 6 -12, 23–4
hot rolling, 6 -10–12, 20–1
HRPO steel see hot rolled,pickled and oiled steel
HRS see hot rolledsteel
HSLA steel see high-strength low alloysteel
hydraulic cylinders, 2 -20
hydraulic lifters, 8 -14
hydraulic lubrication systems, 7 -16
hydraulic presses, 3 -12–14, 10-24
hydrodynamic lubrication, 7 -3
I
identification system, rolls, 5 -107–8
impeding device,safety, 13-11
improvements, productivity, 14-3
in-line bundle storage, 8 -7
in-line coil handling, 8 -9–14
in-line operations
futuretechnologies, 15-13–14
product design, 9 -10
sheet handling, 8 -22–3
“U” channel punching, 9 -13
in-plant loading, 8 -34
in-plant storage, 8 -31
indentations, panels, 4 -40
individual motor drivenshafts, 2 -27
inductivemethod, risk analysis, 13-4–5
influencing factors
number of passes, 5 -64–7
roll diameters, 5 -45
information, press installation/purchasing, 3 -15
insertion
metal strips, 4 -58, 59
plastic rolls, 4 -58, 60
inside curving roll diameters, 4 -33
installation
equipment, 10-1–13
lines, 10-1–8
mills, 10-3, 5
rolls, 10-8–14
stands, 10-22, 25
uncoilers, 10-5–6
instructions, lubrication, 10-15, 17
interchangeable rolls, 5 -42–4
interlocking devices, 5 -88–90, 13-10, 11
interrupted rib forming, 15-8
J
“jerking”,strips, 10-6, 7
jib cranes, 8 -37
joining
coil ends, 8 -15–16
different strip materials, 4 -58, 59
lock seams, 4 -56–7
materials, 6 -18, 9 -17
mechanical, 5 -16–17
parts/strips, 4 -56–60
pinching, 4 -57
snap-in joining, 4 -58
stapling, 4 -58
“jumps”,shafts, 10-22, 23
K
key heights, roll diameters, 5 -47
key sizes, mills, 5 -37
keyways, 5 -37, 49
“kick-out”product handling, 8 -26–7
know-how,personnel, 10-34
knurling, 4 -55–6
L
labels, safety, 13-14
laminates, nonmetallic, 6 -17–18
lances, troubleshooting, 10-49–50
lancing, 4 -20, 58
operations in line, 5 -16
product design, 9 -16
rotary dies, 4 -54–5
large-radius products, 5 -13, 9 -5
laser cutting methods, 3 -20
IndexI -8
last pass forming flower diagrams, 5 -78
last roll pass, 10-8
lead-in flanges, 5 -80–4,98–9
leading edges, 2 -29, 30
left-hand threaded nuts, 10-22, 25
legs, 4 -37, 40
flat elements, 9 -7–8
length adjustment, 2 -8
punching, 9 -15–16
“U” channels, 9 -21
length
conversion tables, A -2 –3
cross-section tolerances, 5 -10–11
hot strip thickness reduction, 15-12, 13
measurement, 12-6
rolls and spacers setup charts, 5 -108–9
spacers, 5 -49, 108–9
splitting rolls limitation, 5 -41
tolerance, 9 -25, 10-39–40
levelers, coils, 8 -21
levelling foundations, 10-4
Libertymutual risk evaluation, 13-6–8
lifting devices, 8 -8, 14
light dutyconveyers, 8 -23
light gage product development, 9 -1–2
limit determination, machinery/system, 13-3
limited movement control device, 13-11
limiting edge stress, 5 -69
lines
acquisition, 12-1–3
case studies, 14-4–10
component selection, 12-4–7
direction, 5 -40
efficiency increasing, 14-1–12
installation, 10-1–8
lubrication instructions, 10-15, 17, 18
mill component selection, 12-4–6
operators, 12-8–9
plant layout, 10-1–2
press component selection, 12-6
press tooling, 15-16
secondaryoperations, 4 -1–63
studs case study, 14-7
utilization, 14-2–3
see also hot roll forming
linkage-type drive-side stands, 2 -22
lips, 9 -7–8
loading
product design/curving correlation, 4 -26–7
rolls, 6 -20–1
test materials, 6 -3–4
see also truck loading
“local heating method”, 11-11
location
cutouts, 10-48–9
locks, 2 -12
rolls and spacersetup charts, 5 -108–9
secondaryoperations, 4 -14
lock seams, 4 -56–7
longitudinal bending, 11-5–6
longitudinal bow, 5 -25–6, 9 -27, 11-6–9
longitudinal elongation, 11-3, 4
longitudinal membrane strain
ERWpipes, 11-28, 29
guide roll modification, 11-10
longitudinal warp relationship, 11-6, 8
roll profile/position, 11-7–9
stand number effect, 11-7, 9
transversal distribution, 11-7–9
longitudinal warp/ membrane strain relationship,
11-6, 8
loop beforeand after press, 4 -12–13
loose lines, 4 -9–13
definition, 4 -10
punching, 4 -10–12
stationaryprepunching operations, 4 -12
louvering, 4 -20
operations in line, 5 -16
product design, 9 -16
rotary dies, 4 -54–5
troubleshooting, 10-49–50
lubricants
additives, 7 -7–8
chemical solutions, 7 -6–7
comparisons, 7 -5, 6
evaporativecompounds, 7 -5–6
maintenance/preparation, 7 -12–18
petroleum-based, 7 -7
selection, 7 -5–8
semisynthetics, 7 -7
standard, 10-16
synthetic, 7 -6–7
lubrication, 7 -1–23
air compressors, 7 -16
air lines, 7 -15
airless sprayers, 7 -12
aluminium, 7 -9
application techniques, 7 -11–12
automatic lubricators, 7 -16, 17
cutoffdies, 7 -10
formed material properties, 7 -8–9
guide, 7 -8
hard-to-lubricate surfaces, 7 -20–1
hints, 7 -17, 18
hydraulic systems, 7 -16
instructions, 10-15, 17–20
mechanisms, 7 -3–5
mills, 2 -31, 5 -40
post forming operations, 7 -10
postnotching, 7 -10
prenotching, 7 -10
presses, 10-20
production operating problems, 7 -18–22
programs, 10-15
punching, 7 -10
recirculating systems, 7 -11–12
roll forming lines, 10-15, 17, 18
secondaryoperations, 7 -10
selecting lubricants, 7 -5–8
standardlubricants, 10-16
stands, 10-17
steel, 7 -8–9
Index I -9
surfaceproperties, 7 -8–9
surfacetension role, 7 -5
tools, 4 -44–5
total productive maintenance, 7 -13–18
tribology, 7 -1–5
variable speed drives, 10-19
wetting role, 7 -5
M
machinerylimits, 13-3
macroemulsions, 7 -7
magnetic rolls, 8 -26–7,29
magnets, sheet handling, 8 -7
maintenance, 10-1, 14 –31
bearings, 10-18–21
chains, 10-21
databases, 7 -17
drivebelts, 10-21
gears, 10-18
hydraulic presses, 10-24
lubricants, 7 -12–18
manuals, 10-14
mechanical presses, 10-23–4
mills, 10-15–23
personnel, 12-9
pneumatic presses, 10-24
preventative, 7 -13–17
shafts, 10-15–16
stands, 10-21–3
trouble prevention, 10-32–52
see also preventativemaintenance
male rolls, 5 -61, 82–3
managers, 12-10
see also personnel
mandrels, uncoilers, 10-6
manuals, maintenance, 10-14
manufacturingpaths, 12-2–3
manufacturingplant, 1 -4–5
marking, 4 -46
added/correctedpasses, 10-9
finished products, 8 -32
left-hand threaded nuts, 10-22, 25
operations in line, 5 -17
product design, 9 -18–19
roll setup charts, 5 -108–9
spacers, 5 -49, 108–9
marks on surfaces, 10-37, 47–8
martensitic stainless steels, 6 -15
mash seam welding, 8 -15
matching tools to profile, 4 -32
material handling, 8 -1–43
accessories, 8 -38–40
equipment, 8 -34–8
finished products, 8 -23–31
sheets, 8 -6–9,22–3
materials, 6 -1–25
alloyed steel, 6 -13–15
aluminum, 6 -18–20
cold working, 6 -10
crystalline structure, 6 -7
design considerations, 6 -1–2
flow of material, 8 -2–3, 8 -41–2, 15-3–5
formed surfaceproperties, 7 -8–9
forming metals, 6 -7–10
future trends, 15-2, 3–4
hot rolling, 6 -10–12
joining, 6 -18, 9 -17
joining different types, 4 -58, 59
laminates, 6 -17–18
mechanical properties, 6 -2–6,9,13–14
metallic coatings, 6 -16–17
nonmetallic coating, 6 -17–18
number of passes, 5 -64–5
other metals and materials, 6 -20
primarymetal processes, 6 -20–3
problem creation, 10-33, 51–2
roll design, 5 -19–28
roll diameters, 5 -47
stainless steel, 6 -15–16
steels, 6 -12–16, 23–4
testing, 6 -2–6
thickness, 5 -47, 64–5
tools, 4 -44–5
trouble prevention, 10-51–2
troubleshooting, 10-39–51
mathematical simulation see simulation
mats, safety, 13-11
maximum roll diameter, 5 -47–8
measurement
length, 12-6
straightness, 4 -9
mechanical hazards, 13-3 –4
mechanical installation/removal, 5 -41
mechanical joining see joining parts/strips
mechanical presses, 3 -6–10
capacity, 3 -6–9
four-post undercrank, 3 -6, 7
lubrication instructions, 10-20
maintenance, 10-23–4
mechanical properties, materials, 5 -19, 6 -2–6,9,13–14
mechanical restraining device, 13-11
metal inert gas (MIG) welding, 8 -15
“metal pickup”, rolls, 6 -17, 7 -19–20
metal strips see strips
metal use history, 1 -1–2
metallic coatings, 6 -16–17
metallurgical processes, 6 -20
metals, historical use, 1 -1–2
method organized for asystematic analysis of risks
(MOSAR), 13-5
microemulsions, 7 -7
MIG welding see metal inert gas welding
mills, 2 -1–33
additional operations, 2 -32
base to bottom shaft distance, 5 -36
beds, 2 -18–19
bottom shaft drives, 5 -38–9
cantilevered, 2 -1–5
components, 2 -18–32
double-high, 2 -10–11
duplex mills, 2 -5–8
IndexI -10
flow of material, 15-3–4
futuretechnologies, 15-3–5
guides, 2 -29–30
hot roll forming, 15-15
installation, 10-3, 5
in last 100 years, 15-2
line component selection, 12-4–6
lubrication systems, 2 -31
maintenance, 10-15–23
motor speeds, 5 -40
power trains, 2 -26–7
profile sizes, 9 -22
pull-through, 2 -15–16
rafted, 2 -11–13
roll design, 5 -28–40
dimensions, 5 -34
with rolls, curving, 4 -30–1
shafts, 2 -21–6
side-by-side type, 2 -13–15
special, 2 -18
spiral-tube type, 2 -16–17
standard, 2 -9–10, 5 -32, 33, 40–1
stands, 2 -19–21
straighteners, 2 -30–1, 5 -40
truck-mounted, 2 -17–18
types, 2 -1–18, 5 -28–32
minimizingedge stretch, 11-30–1
minimum bending radii, 9 -4–6
minimum curving radius, 4 -28–30
mirrors, checking gaps, 10-14
mitering, 4 -16–19, 9 -17
mixed drivepower trains, 2 -27
mixed lubrication, 7 -4
monorails, 8 -37
MOSAR see method organized for asystematic
analysis of risks
motivation, 12-11
motor speeds, 5 -40
motorized straighteners, 4 -8
motors, 3 -9–10
movable guards, 13-10
moving finished products, 8 -25–9
multiple height storage, 8 -31
multipurpose rolls, 10-10, 11
N
narrow sections
base prices, 14-11
cantilever mills, 5 -30
roll lengths, 5 -90–1
“natural flow”technologies, 15-3–5
new product introduction, 12-2
new technologies, 15-1–17
see also futuretechnologies
nickel alloys, 6 -20, 15-13
nip point, risk evaluation, 13-5–7
no traps, 5 -80
non-uniform spring back deformation, 11-7, 15 –17
see also flare
noncontinuous bend lines, 15-8
nondriven
pull-through mills, 2 -16, 15-5
rolls, 15-5
top shafts, 2 -27
nonflat starting material, 15-7–8
nonmetallic coating and laminating, 6 -17–18, 7 -9
nonparallel/nonstraight bend lines, 9 -18, 15-8–9
nonsplit rolls, 5 -82–3
nonwelded closed sections, 4 -38
notching, 4 -16, 17, 19, 41, 10-38
location tolerances, 5 -9–10
number of passes, 5 -65–6,68
operations in line, 5 -14–15
product design, 9 -16
tolerances, 5 -9–10, 9 -27–9
number of passes
available number, 5 -40
roll design, 5 -2–4,64–73
sections, 5 -70–2
O
Occupational Safety and Health Administration
(OSHA), 13-1, 6–7
occurrence mechanism
center waves, 11-13–14
flare, 11-18
herring bone effect, 11-15
longitudinal bending, 11-6
longitudinal elongation, 11-3, 4
shrinkage, 11-3, 4
offsetting see swedging
oil canning (“oil canny”) see center waviness
one-pieceshims, 5 -52
open bed truck loading, 8 -33–4
open section, cross-section, 5 -5
operations in line, roll design, 5 -13–18
operators
angle adjustment, 5 -78
convenient horizontaldistance, 5 -35
definition, 13-2
lines, 12-8–9
optimization procedure, 11-24
orientation, products, 5 -27
OSHA see Occupational Safety and Health
Administration
outdoor storage, 8 -31
output, 14-1–2
outside corners forming, 5 -102, 105
overall width definition, 3 -2
“overbending and bending back method”, 11-18
overbending rolls
bending radii, 5 -85–6
constant radius forming, 5 -59
design concepts, 5 -93–4
overhead cranes, 8 -36–7
overhead loop coil accumulator, 8 -17
own product holding tools, 4 -7
oxyacetylene welding, 8 -14–15
Index I -11
P
packaging, 4 -62
painting, 4 -62
pallet decoilers, 8 -17–19
panels
base prices, 14-11
cross-section, 5 -5
curving, 4 -39
forming ribs, 5 -101–3
grooving rolls, 2 -7
indentations, 4 -40
interlocking, 5 -89
mills, 5 -91–2
nonparallel/nonstraight bend lines, 15-9
nonuniform spring back deformation, 11-15–17
pressbrakes, 4 -39
rolls, 5 -89
sizes, 9 -20–1
straightening, 4 -9
parallel linkages, 3 -19–20
partial punching, 4 -19, 20, 9 -16
parts joining, 4 -56–60
pass line height, 5 -39–40, 46
passes see number of passes
paths to manufacture, 12-2–3
peeled coating, 10-37
pendulum control, cranes, 8 -40
perforating, 4 -16–18
personal protective equipment, 13-14
personnel
know-how, 10-34
maintenance/setting up, 12-9
operators, 12-8–9
trouble prevention, 10-52
petroleum-based lubricants, 7 -7
PHA see preliminaryhazardanalysis
PHD see plastohydrodynamic lubrication
“pick-and-place”unit, 8 -28, 29
pick-up die accelerators, 3 -25
piercing, 4 -19
pinch point definition, 13-2
pinch rolls, coil flattening, 8 -20
pinching, 4 -57
pipes
flying saws, 4 -44, 45
helical wound, 4 -43–4
spiral pipes, 4 -37, 39–40
pits, presses, 3 -5
plant layout, 8 -41–2, 10-1–2
plant managers, 12-9
plasma jet cutting methods, 3 -20
plastic deformation, 6 -2
plastic rolls insertion, 4 -58, 60
plastohydrodynamic (PHD) lubrication, 7 -4–5
plate storage, 2 -13
plated mills see rafted mills
plugs, curving, 4 -37–8
pneumatic cylinders, shaft bending, 2 -20
pneumatic die accelerators, 3 -20–2
pneumatic presses, 3 -10–12
cutting curvedproducts, 3 -10
large, 3 -12
maintenance, 10-24
typical, 3 -11
pocket wave see center waviness
point of operation definition, 13-2
positioning shafts, 15-4–5
positivestop die accelerators, 3 -25
post forming lubrication, 7 -10
postcutting, 4 -10
postnotching lubrication, 7 -10
postpunching, 9 -15
power
chain drives, 2 -26
conduits, 10-2
deformations, 11-26, 27, 28
gear drives, 2 -26–7
mixed drives, 2 -27
trains, 2 -26–7
prebuckling, 4 -36, 38
precutting
curving, 4 -9–10, 30
piece distances, 5 -35, 36
predictivemaintenance, 7 -18, 10-14–15
preforming, 11-11–12, 15-10
preliminarycost analysis, 14-10–12
preliminaryhazardanalysis (PHA) 13-5
prenotching, 7 -10
preparation
lubricants, 7 -12–13
setup chart, 5 -110–11
prepunching, 9 -14, 20
presence sensing device, 13-2, 12
presheared/prenotched metals, 9 -6
presses, 3 -1–26
alignment, 10-7, 8
beds, 3 -2
capacity, 3 -1–2
curvedproducts, 4 -43, 44
definitions, 3 -2–4
die rails, 3 -3, 4
die slides, 3 -3
energy, 3 -9–10
flywheels, 3 -9–10
forces, 3 -9–10
foundations, 3 -4–5
hydraulic, 3 -12–14
impact, 3 -4–5
installation information, 3 -15
line component selection, 12-6
lubrication instructions, 10-20
mechanical, 3 -6–10
motors, 3 -9–10
parts, 3 -2–4
pits, 3 -5
pneumatic, 3 -10–12
problem creation, 10-34
purchasing information, 3 -15
ram deflection, 3 -2
IndexI -12
roll forming lines, 15-16
shut height, 3 -3
tooling, 15-16
torque, 3 -9–10
typical data, 3 -16
vibration, 3 -4–5
see also hydraulic presses; mechanicalpresses;
rotarydevices
pressure conversion tables, A -8–9
pressure rolls, 4 -33–4
pressure sensitivedevices, 13-11–12
preventative maintenance, 7 -13–17
chains/gears/sprockets, 7 -15
dirtycoolant tanks, 7 -14
gear housings, 7 -14–15
lubrication hints, 7 -17
rolls, 7 -14
shafts, 7 -14
preventive maintenance, programs, 10-14–15
prices, steel, 6 -23–4
primarymetal processes, 6 -20–3
problem creation
design, 10-32–3
drawings, 10-32–3
equipment, 10-33–52
materials, 10-33, 51–2
problems, flare, 5 -20
procurement, tools, 12-7
product design, 9 -1–30
bending radius, 9 -3–6
design considerations, 9 -2–10
dimensioning, 9 -22–9
light gage products, 9 -1–2
profile sizes, 9 -20–2
secondaryoperations, 9 -10–20
specific products, 9 -22
tolerancing, 9 -24–9
production lubrication problems, 7 -18–22
accelerated tool wear, 7 -18–19
hard-to-lubricate surfaces, 7 -20–1
“metal pickup”onrolls, 7 -19–20
white rust, 7 -21–2
production rate costanalysis, 14-10
productivity, 14-1–4
products
curved, 3 -10
curving effects, 4 -31, 32, 33
deformationdefects, 11-6–19
designers, 12-3–4,10
evaluation, 12-3–4
flattening, 3 -18
futuredesign, 15-2
futurestandards, 15-2
handling finished products, 12-6–7
introducing new, 12-2
marking, 8 -32
orientation, 5 -13 –18
pneumatic press cutting, 3 -10
roll design, 5 -13–18, 42
scoring, 3 -18
shape, 4 -31
storage, 7 -21–2
wedged in mill, 4 -25
whyroll form? 12-1–2
width, 5 -42
width effects, 4 -32, 33
profile sizes, 9 -20–2
propeller typecutting equipment, 3 -19
protecting finished products, 8 -29–31
protective devices, 13-11–14
protective equipment, personal, 13-14
pull-through mills, 2 -15–16
futuretrends, 15-5
pulling belts, tension roll forming, 15-6–7
punches
rake, 3 -5, 8
staggered, 3 -5, 8
stuck in dies, 10-38
punching
definition, 4 -16, 18
equipment, 3 -15–20
holes, 10-48–9
loose lines, 4 -10–12
lubrication, 7 -10
operations in line, 5 -14–15
partial, 4 -19
product design, 9 -10–15
rotary, 4 -47, 48, 49 –53, 9 -14, 16
welding considerations, 9 -20
purchase
agents, 12-10
used lines, 12-3
purchasing information, presses, 3 -15
Q
questionnaire, “standard mills” 5 -29–30
quick exchange roll sets, 2 -7
quick removalDelta spacers, 5 -51
quick-change dies, 4 -18
R
rack and pinion die accelerators, 3 -22–3
racks for storage, 8 -3, 4, 10–11, 31
radii
bending, 5 -11–13, 83–6
computer-aided design, 5 -98–9
roll design, 5 -11–13, 83–7,98–9
roll edges, 5 -83–6
stabilizing rolls, 4 -36
radio control, cranes, 8 -40
rafted cantilevered mills, 2 -4
rafted mills, 2 -11–13
cantilevered, 2 -4
locating locks, 2 -12
mechanisms, 2 -12
roll change requirements, 5 -41
rails, coil cars, 8 -13
Index I -13
railway car loading, 8 -34
rake
angles, 3 -8
punches, 3 -5, 8
ram deflection definition, 3 -2
ram stroke definition, 3 -2
rawrolls see “unedited” rolls
receiving coils, 8 -3
recirculating lubrication systems, 7 -11–12
rectangular bar curving, 4 -29
reductions see thickness reduction
redundant deformations, 11-2–13
bending back, 11-5–6
bulging, 11-5
causes, 11-3–6
edge wave, 11-10–13
effects, 11-6–19
longitudinal bending, 11-5–6
longitudinal bow, 11-6–9
longitudinal elongation, 11-3
shear, 11-3–4
shrinkage, 11-3
strips, 11-2–13
transversal elongation, 11-3–4
twist, 11-6–9
relief, roll design, 5 -87–9
resistancewelding, 4 -60–1, 8 -16
seams, 4 -61
spot welding, 4 -61
restraint devices, 13-11
revsper minute (rpm) ratio, 5 -39
ribs
forming, 15-8
panel forming, 5 -101–3
see also stiffener ribs
ring embossment, 4 -21
ripple effect, 10-44–5
risk
analysis methods, 13-4–5
definition, 13-2
estimation, 13-3–8
evaluation, 13-5–8
reduction by design, 13-8–9
riveting, 4 -59 –60
roll design, 5 -1–113
bend lines, 5 -55–64
computer aided, 5 -95–100
concepts, 5 -78–94
cross section, 5 -4–13
dimensions,manual calculation, 5 -94–5
examples, 5 -100–7
flower diagram, 5 -73–8
hot roll forming, 15-15
materials, 5 -19–28
mill, 5 -28–40
number of passes, 5 -64–73
operations in line, 5 -13–18
process, 5 -2–4
product orientation, 5 -13–18
roll marking system, 5 -103–7
roll orientation, 5 -107
setup charts, 5 -107–11
shims, 5 -52
spacers, 5 -48–52
strip width calculation, 5 -52–5
tool design considerations, 5 -40–8
roll edge radii, 5 -83–6
roll flowers, 11-31–3
see also roll profiles
roll forming definition, 1 -3–4
roll forming lines see lines
roller coater lubrication method, 7 -11
roller conveyers, 8 -22–3,26–7
roller shaft bearings, 7 -14
rolls
asymmetric arrangements, 4 -35
at both ends, cantileveredmills, 2 -3
cambering, 6 -22
cantilevered mills, 2 -21
change requirements, tool design, 5 -40–1
checking gaps, 10-12–14
coil flattening, 8 -20
computer-aided roll design, 5 -97–8
convex, radii, 5 -83–5
deflection, 6 -20–1
diameters, 5 -45–8, 10-10, 12
dimensions, 5 -94–5
distancebetween, curving, 4 -35
edge chipping, 5 -43
elastic outside pressurerolls, 4 -33–4
ending with flat surface, radii, 5 -85–6
forming speed, 5 -40
fully dimensioned, 5 -97–8
gap adjustment, 5 -23–4
gap checking, 10-12–14
gap control systems, 11-17
guide modification, 11-10
handling/storage, 10-27–30, 31
identification system, 5 -107–9
installation, 5 -45, 10-8–14
interchangeable rolls, 5 -43
length design, 5 -90–2
loading, 6 -20–1
longitudinal membrane strain, 11-7–8,9
marking systems, 5 -103–7
“metal pickup” 7 -19–20
multipurpose, 10-10, 11
nondriven, 15-5
optimized profiles, 11-30, 32, 33
orientation design, 5 -107
preventativemaintenance, 7 -14
product width, 5 -42
profile design systems, 11-29–33
quick exchange sets, 2 -7
radius stabilizing, 4 -36
roll diameters, 5 -45
security, 2 -21
setup, 5 -107–9, 10-1, 8–14
shafts, 10-10–12
splitting roll weight, 5 -41
IndexI -14
stiffener ribs, 9 -9
for straightening, 4 -4–5
surfacespeed, 5 -45
thin, 10-12
tool design, 5 -40–1,45–8
wall thickness, 5 -47
weight, 5 -41
width tolerance, 5 -23–4
roofing, 9 -10, 14-9
rotarydevices, 3 -15–20
cutting equipment, 3 -18–20
motion risk estimation, 13-3
rotarydies, 4 -46–56
coining, 4 -55–6
concepts, 4 -46–8
embossing, 4 -53–4
expanding, 4 -56
grooving, 4 -55–6
knurling, 4 -55–6
lancing, 4 -54–5
louvering, 4 -54–5
slitting, 4 -56
stands, 4 -46–8
rotarypunching, 4 -47–53, 9 -14, 16
alignment, 4 -52
burrs, 4 -51, 53
dies, 4 -51, 52
dimpling, 4 -53
driving diameters, 4 -50
hand cranking, 4 -49
operations in line, 5 -16
punch angle entry, 4 -50
roll strengths, 4 -51
slippage, 4 -51
staggering, 4 -52–3
rotating crane hook, 8 -40
rotation methods, straighteners, 4 -6
rpm (revs per minute) ratio, 5 -39
“runout” 5 -24
S
SAE see Society of AutomotiveEngineers
safeguarding, 13-2, 9–12
safety, 13-1–17
definitions, 13-2
design procedure, 13-2, 8–9
determination, 13-3–8
guardrequirements, 13-13
hazards, 13-3–8
machinerylimits, 13-3
mats, 13-11
personal protectiveequipment, 13-14
pressure sensitivedevices, 13-11–12
principles, 13-9
protectivedevices, 13-13
requirements for devices, 13-13
risk estimation, 13-3–8
risk reduction by design, 13-8–9
safeguarding, 13-9–12
selecting guards/protectivedevices, 13-13
signals, 13-14
summary, 13-15
system limits, 13-3
training, 13-14–15
warning devices, 13-14
satisfying customers, 1 -4
“scallop pattern” 5 -25
schedulers, 12-10
“scored” bend lines, 9 -4
scoringshallowproducts, 3 -18
screws
calibrated, 2 -20
“stop”screws, 2 -28
seams, 4 -56–7,61
secondaryoperations
adhesivebonding, 4 -60
bending, 4 -22–4
brazing, 4 -60
curving, 4 -24–46
dimpling, 4 -20
flanging, 4 -20
flying dies, 4 -14–16
foaming, 4 -62
hole flanging, 4 -20
joining parts/strips, 4 -56–60
lancing, 4 -20
location, 4 -14
louvering, 4 -20
lubrication, 7 -10
marking, 4 -46
notching, 4 -17, 18
packaging, 4 -62
painting, 4 -62
parts joining, 4 -56–60
perforating, 4 -17
piercing, 4 -19
postcutting, 4 -10
product design, 9 -10–20
punching, 4 -16
resistancewelding, 4 -60–1
roll forming line, 4 -1–63
rotary dies, 4 -46–56
soldering, 4 -60
straightening, 4 -3–9
strip joining, 4 -56–60
swedging, 4 -46
typical, 4 -2–3
sections
base prices, 14-11
case studies, 14-5–6
closed non/welded, 4 -38
depth, 5 -4–6, 5 -45
dimension tolerances, 5 -23–4, 9 -25–7
fully closed, 4 -35–6
hidden bend lines, 4 -34–5
hot roll forming, 15-12–15
number of passes, 5 -70–2
reshape by cutoffdies, 10-38
Index I -15
stuck in cutoffdies, 10-50–1
vertical height distances, 5 -36
segmented side-rolls, 10-10, 11
self-adjusting guards, 13-10, 11
semisynthetic lubricants, 7 -7
sensor-controlled curving unit, 15-16
separating
finished products, 8 -29–31
sheets, 8 -7–8
service lines, 10-2–3
servo motors, 15-16–17
setting up
personnel, 12-9
rolls, 10-1, 8–14
straighteners, 10-14
setup charts, 5 -107–11
shafts
alignment spacers, 10-26, 28, 29
bearings, 10-18, 21
bending
calibrated screws, 2 -20
eliminating, 15-5
pneumatic/hydraulic cylinders, 2 -20
springs, 2 -20
calibrated screws, 2 -20
cantileveredmills, 2 -2
chain driven, 2 -23
diameters
cantileveredmills, 2 -2
mills, 2 -2, 5 -33
roll diameters, 5 -47
selection, 2 -25
forcing end effect, 10-18, 21
hydraulic cylinders, 2 -20
individual motor driven, 2 -27
“jumps” 10-22, 23
maintenance, 10-15–16
mills, 2 -21–6
nondriven, 2 -27
pneumatic cylinders, 2 -20
positioning, 15-4 –5
preventativemaintenance, 7 -14
rusted, 7 -14
shoulder alignment, 2 -32, 10-24–30
springs, 2 -20
straightness checking, 10-24, 26
support, 2 -10
thread direction, 2 -24
universal joint driven, 2 -23
shallowproduct scoring, 3 -18
shallowsections depth, 5 -5
shape
coil flattening, 8 -21
correctors, 8 -21
factor, 5 -68
functions, 11-20–1
side-rolls, 5 -62
sharp inside radii, 5 -12
shear deformationcauses, 11-3–4
sheets
conveyers, 8 -22
grabs, 8 -22
handling, 8 -6–9,22–3
in-line handling, 8 -22–3
separating and grabbing, 8 -7–8
storage, 8 -6–9
shelving, 4 -26, 5 -16, 17, 14-6–7
shims
definition, 5 -48
interchangeable rolls, 5 -44
roll design, 5 -52
setup charts, 5 -109
shinystreaks, 10-37
shoes, curving, 4 -37–8
shoulder alignment
shafts, 2 -32, 10-24–30
table, 10-28
shrinkage, 11-3, 4
shut height definition, 3 -3
side loaders, 8 -34–5
side-by-side mills, 2 -13–15
side-by-side panel mills, 2 -15
side-rolls
bend lines, 5 -60–3
diameters, 5 -62
horizontal distance, 5 -35
passes, 10-9
stands, 2 -27–8
sidings case study, 14-9
signals, safety, 13-14
signs, safety, 13-14
simplicity,product orientation, 5 -13 –14
simulation
analysis results, 11-26–9
deformations, 11-19–29
six hole manufacture, “U” channels, 4 -14
sizes, profiles, 9 -20–2
skewed roller conveyers, 8 -23
sleeves, bearing blocks, 2 -21
slides, bend lines, 5 -64
slings, 8 -39–40
slippage, rotarypunching, 4 -51
slitting
primarymetal processes, 6 -22
product design, 9 -17
rotary dies, 4 -56
small “C” notching hydraulic presses, 3 -14
small radius bending, 5 -11–13
“smoothing flow line method” 11-12–13
snap-in joining, 4 -58
SocietyofAutomotiveEngineers (SAE) 6 -13
soldering, 4 -60
future technologies, 15-13–14
product design, 9 -19–20
spacers
definition, 5 -48
identification system, 5 -108–9
product width, 5 -42
roll design, 5 -48–52
setup charts, 5 -107–9
shafts, 10-26
spare parts, 10-14, 30 –1
IndexI -16
special mills, 2 -18
special products case study, 14-9–10
special straighteners, 4 -7–9
specialized lines, 14-7–8
specifications
dies, 3 -17
equipment, 12-7
presses, 3 -16
tools, 12-7
speed, roll forming, 5 -40
spiral forming, 4 -27, 36 –7,39–40
spiral pipes, 4 -37, 39–40, 9 -20–1
spiral-tube mills, 2 -16–17
split flower diagram, 5 -4, 74
split lines, 5 -43
split rolls, 5 -82–3,85–6
split shims, 5 -52
split spacers, 5 -50–2
splitting, 11-15
splitting rolls, 5 -41–4
spot welding, 4 -61
springback, 10-36
bending radius, 9 -5
materials, 5 -19
overbending, 5 -93
troubleshooting, 10-41
springs, 2 -20, 6 -3
sprocket maintenance, 7 -15
stack feeder,coils, 8 -17–19
stacker cranes, 8 -4, 37
staggered punches, 3 -5, 8, 4 -52–3
stainless steel, 6 -15–16, 7 -9
stamping definition, 4 -18
standardcleaners/greases/lubricants, 10-16
standardmills, 2 -9–10, 5 -32–33, 40–1
standardspacers, 5 -49–50
standardtolerances, 9 -24–5
standards see product standards
stands
cantileveredmills, 2 -4
cluster-rolls, 2 -27–8
fastening methods, 2 -19
gear driven, 2 -22
linkage-type drive-side, 2 -22
longitudinal membrane strain, 11-7, 9
lubrication instructions, 10-17
maintenance, 10-21–3
mills, 2 -19–21
number effect, 11-7, 9
permanent number installation, 10-22, 25
rafted cantileveredmills, 2 -4
side-rolls, 2 -27–8
stapling, 4 -58
start-up, 10-7–8
starting material, 15-7–8,10–11
stationarydies, 4 -14–16
stationaryprepunching operations, 4 -12
steady-state incremental treatment, 11-21–2
steels
alloyed steel, 6 -13–15
carbon steel, 6 -12–13
cold rolled, 6 -12
galvanized, 7 -9
hot rolled, 6 -12
lubrication, 7 -8–9
prices, 6 -23–4
stainless steel, 6 -15–16, 7 -9
stiffener heads, 9 -2
stiffeners
buckling reduction, 4 -37
curving, 4 -32, 37
ribs, 9 -2, 9–10, 15-8
stitching coil ends, 8 -16
“stop”screws, 2 -28
stop-and-go lines, 4 -13
storage
coils, 8 -3–6,9–10
finished products, 8 -31–4
plates, 2 -13
products, 7 -21–2
rolls, 10-27–31
sheets, 8 -6–9
tools, 10-27–30
straight pass line, 5 -66
straighteners
automated, 4 -8
driven belts/rolls, 4 -8–9
flare, 4 -9
mills, 2 -30–1, 5 -40
motorized, 4 -8
own product holding tools, 4 -7
rotationmethods, 4 -6
setting up, 10-14
special, 4 -7–9
Turks-head, 4 -5
vertical movement only, 4 -7
straightening, 4 -3–9
basic rules, 4 -3–4
blocks, 4 -4–7
combinations, 4 -5
panels, 4 -9
rolls, 4 -4–5
units, 4 -6–7
straightness
checking shafts, 10-24, 26
cross-section tolerances, 5 -9
deviations, 4 -3
measurement, 4 -9
shaft checking, 10-24, 26
tolerancedeviations, 9 -27
strain increment definition, 11-22–4
strapping finished products, 8 -30
strength, materials, 6 -2–6,10–11
stress–strain diagrams
cold working, 6 -11
forming metals, 6 -7–8
test materials, 6 -4–6
stress–strain relationships, 11-24–6
stresses
computer-aided roll design, 5 -98, 101
conversion tables, A -8 –9
tubular parts, 4 -29
Index I -17