Roll Forming Handbook / Edited by George T. Halmos
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stretched grooves, 5 -7–9
“stretched-in”ribs, 9 -9
strip accumulators, 8 -16–19
strip edge-to-hole distance, 9 -10–12
strips
behaviour during forming, 11-1–34
carbon steel, 6 -23
deformations
geometry, 11-21–4
redundant, 11-2–13
sheet, 11-24, 25
simulation, 11-19–29
steady-state incremental treatment, 11-21–2
thickness/power relationships, 11-26, 27
die accelerator effects, 3 -23–5
heat exchangers, 4 -55
hot thickness reduction, 15-12, 13
insertion effect, 4 -58, 59
“jerking” 10-6, 7
joining, 4 -56–60
leading edge direction, 2 -29
length, 15-12, 13
redundant deformations, 11-2–13
sheet deformations, 11-24, 25
thickness/deformation power relationships,
11-26, 27
threading, 4 -51
3-D curvedsurfaces, 11-26, 27
width, roll design, 5 -52–5,78
stroke definition, 3 -2
studs case study, 14-7–8
success key, 12-7–8
supervisors, 12-9
support, shafts, 2 -10
supported bottom, side-rolls, 5 -61
supports, duplex mills, 5 -28, 31
surface
appearancetolerance, 5 -10
bottom roll calculation, 5 -95–7
cross-section tolerances, 5 -10
deficiency, 10-37
geometry, 5 -95–7
marks, 10-37, 47–8
material tolerances, 5 -27–8
tolerances, 5 -10, 27–8
surfaceproperties, formed materials, 7 -8–9
surfacespeed differential, 5 -88
surfacetension role, 7 -5
swedging, 4 -46
sweeping
operations in line, 5 -18
product design, 9 -18
see also curving; hot curving
synthetic lubricants, 7 -6–7
T
“T”hanger bars, 5 -102, 104
tangent point dimensions, 9 -23
tapers, 5 -90
taping coil ends, 8 -16
temper designations, aluminum, 6 -19
temperatureconversion table, A -10–11
tensile strength, 6 -3
tension leveledmetal, 6 -22
tension roll forming, 15-6 –7
terminology,presses, 3 -2–4
testing materials, 6 -2–6
thick-film lubrication, 7 -3
thickness
conversion, A -4–7
conversion table, A -4 –7
curving, 4 -31
deformation power relationships, 11-26, 27
material tolerances, 5 -21–3
reduction
along strip length, 15-12, 13
starting material, 15-10–11
strips, 11-26, 27
threading strips, 4 -51
threads
direction, 2 -24
shaft direction, 2 -24
shafts, 2 -24
three dimensional view,cross-section, 5 -75–6
three-roll curving units, 4 -30
3-D curvedstrip surfaces, 11-26, 27
through-shaft duplex mills, 2 -8–9
throwdefinition, 3 -2
tight lines, 4 -9–13
definition, 4 -10
flying prepunching operations, 4 -11
tight width tolerance, flat elements, 9 -8
tilt tables, 8 -24–5
titanium, 1 -4, 6 -20, 7 -4, 15-11
tolerances
cross-section, 5 -9–11
flat elements, 9 -8
holes, 5 -9–10
length troubleshooting, 10-38–9
materials, 5 -21–8
notch location, 5 -9–10
number of passes, 5 -68
product design, 9 -24–9
“U” channel legs, 9 -21
tooling
conventional roll forming lines, 15-16
future technologies, 15-3, 9–10
hot roll forming, 15-14–16
preliminarycost analysis, 14-10–12
problem creation, 10-34
trouble prevention, 10-35–52
troubleshooting, 10-39–51
see also individual tools
tools
accelerated wear, 7 -18–19
adjustment/alignment, 4 -41
curving, 4 -32, 33, 41
design considerations, 5 -40–8
designers, 12-10–11
handling, 10-27 –30
lubrication, 4 -44–5
IndexI -18
matching profile, 4 -32, 33
materials, 4 -44–5
procurement, 12-7
specification, 12-7
storage, 10-27–30
top shaft drives, 5 -37–8
torque, presses, 3 -9–10
total productive maintenance, 7 -13–18
traditional lines study, 14-7
traditional orientation, 5 -27
trailer-mounted mills see truck-mounted mills
trailers, loading, 8 -33–4
training, 10-7 –8, 12-1, 7–11, 13-14–15
transversal elongation, 11-1–2
generation mechanism, 11-4, 5
redundant deformationcauses, 11-3–4
transversal tensile force generation mechanism, 11-4, 5
traps, 5 -78, 98–9
trenches, 10-2–3
tribology of lubrication, 7 -1–5
friction, 7 -1–2
lubrication mechanisms, 7 -3–5
wear, 7 -2–3
trip devices, 13-11
triple duplex mills, 2 -8
troubleshooting, 10-1, 32–52
cross-section, 10-40–1
equipment, 10-39–51
flare, 10-41–2
guide, 10-36–51
length tolerance, 10-38–9
materials, 10-39–51
springback, 10-41
tooling, 10-39 –51
truck-mounted mills, 2 -17–18
trucks
loading finished products, 8 -32–4
routes, 8 -34
types, 8 -33–4
see also forklift trucks
tubular parts, 4 -29
Turks-head straighteners, 4 -5
turning, roll edge radii, 5 -84
turnstiles, 8 -10–12
twist, 4 -3, 10-36
asymmetry, 4 -28
material tolerances, 5 -26
redundant deformationeffects, 11-6–9
straighteners, 2 -31
troubleshooting, 10-42–3
two-hand control device, 13-11
types of mills, 2 -1–18
U
“U” channels
custom-tailored, 15-13
cutting, 9 -13
dimensioning, 9 -27–8
flow of material, 15-3
forming, 5 -100–2
overbending, 5 -59, 61
punching, 9 -11–13
sections, 2 -8
six hole manufacture, 4 -14
sizes, 9 -20–1
starting material, 15-7
UHSS see ultra high-strength steels
ultimate strength of materials, 6 -2–6
ultra high-strength steels (UHSS) 6 -13–14
uncoilers
alignment, 10-5–6
backplates, 10-5–6
dislocation, 10-6, 7
installation, 10-5–6
mandrels, 10-6
problem creation, 10-34
undriven (live) roller conveyers, 8 -23
“unedited” rolls, 5 -97–8
unilateral tolerance, 9 -24
units, conversion, A -1–11
universal joint driven shafts, 2 -23
unloading test materials, 6 -3
unsupported bottom, side-rolls, 5 -61
unsupported products, bending forces, 2 -6
updating, setup chart, 5 -111
upending coils, 8 -6, 39
urethane, blocks, 10-22, 23
used line purchase, 12-3
V
vacuum cups, 8 -8, 28, 29
van loading, 8 -33
variable speed drivelubrication, 10-19
vertical alignment, roll length, 5 -91
vertical axis storage, coils, 8 -5–6
vertical coil accumulator, 8 -17–18
vertical distance, rolls, 5 -34, 36
vertical guide plane, 5 -74
vertical height, rolls, 5 -36–7
vertical movement only straighteners, 4 -7
vertical rotaryaccumulators, 8 -17
vertical traps, 5 -79
vibration, presses, 3 -4–5
visual observation, 5 -18
visual signals, safety, 13-14
W
wall thickness, spacers, 5 -48
warning devices, 13-14
warping see bow
water see service lines
waviness, 10-36
center,hot and cold rolling, 6 -21–2
cross-section, 5 -6–7
material tolerances, 5 -26–7
troubleshooting, 10-43–4
see also center waviness; edge waviness
weak curving rolls, 4 -35
Index I -19
wear, 7 -2–3
rolls, 5 -44
tools, 7 -18–19
web buckling, 4 -28–9
web width adjustment, 2 -8
weighing finished products, 8 -32
welding
coil ends, 8 -14–16, 20
edge waviness, 9 -18–19
hot roll formed sections, 15-12–15
operations in line, 5 -18
product design, 9 -18–20
resistancewelding, 4 -60–1
specialist types, 4 -61
wetting role, lubrication, 7 -5
“what if ”method, risk analysis, 13-5
white rust, 7 -21–2
whyroll form products? 12-1–2
wide panels, 5 -34, 14-11
wide sections, 5 -30, 91–2
width
changing, 5 -43
flat elements, 9 -6–8
interchangeable rolls, 5 -43
material tolerances, 5 -23–4
wing bending, 4 -23–6, 5 -16
wood protectors, 8 -30
work hardening rates, 6 -11
workforce see personnel
wroughtaluminum, 6 -18
Y
yard cranes, 8 -37 –8
yield strength, materials, 6 -2–6
Z
“Z” sections, 2 -8–9
sizes, 9 -21
twist, 5 -26–7
zinc flaking, 6 -17
zinc pickup see metal pickup
zirconium, 5 -19, 6 -10, 20, 15-13
IndexI -20