ROLL FORMING

Presented by ;

Benget, S, Sinaga
(101 06 11 001)

M. Harsono
(101 06 11 017)
 ROLL FORMING
Definition
• Is the process of reducing the thickness or changing the
cross section of a long work-piece by compressive forces
applied through a set of opposed rotating rolls.

Roll forming, is a continuous bending operation in which a

long strip of metal (typically coiled steel) is passed through
consecutive sets of rolls, or stands, each performing only
an incremental part of the bend, until the desired cross-
section profile is obtained. Roll forming is ideal for
producing parts with long lengths or in large quantities.
 HISTORY
• In 1779 a rolling was created in
Fontley, Hampshire where Henry Cort
developed ideas for rolling
processes.
• In 1783 Cort received a patent for his
groove rolling process.
 PROCESS
• The process of roll forming is one of
the simpler manufacturing
processes.
• It begins with a large spool of metal
strips, usually between 1 in. and
20in. in width, and 0.004 in. and
0.125 in. thick.
 Clasification of Rolling
Process
• Rolling produces many products;
including flat sheet, I – beams, round
bars, and tubular products. Steel &
Aluminum are the most commonly
rolled materials.
• Classification based on Temperature:
Hot rolling & cold rolling.
• Classification based on Shape: Flat
rolling & Shape rolling.
 HOT ROLLING
• Rolling is first carried out at elevated
temperatures (hot rolling), where the
coarse-grained, brittle, and porous
structure of the ingot or continuously
cast metal is broken down into a
wrought structure, with finer grain
size.
 COLD ROLLING
• Cold rolling is the process of rolling
at low temperatures. It is usual
applied as finishing process after hot
rolling to enhance strength and
hardness, and ensure high surface
quality. During cold rolling, annealing
may take place to facilitate further
cold rolling.
 FLAT ROLLING
The most basic operation in rolling is flat
rolling, that produces flat plates and
sheets, which are used in applications
such as ship hulls, and nuclear vessels, as
well as food containers and Aluminum foil.
In flat rolling the final shape of the
product is either classed as sheet
(typically thickness less than 3 mm, also
called "strip") or plate (typically thickness
more than 3 mm).
 SHAPE ROLLING
Shape rolling is one of the most complex deformation
processes in comparison with that of the plates, the
sheets, and the bars because the workpiece is non-
uniformly reduced by grooved rolls. In the case of a
product that has an irregular cross-section, the rolled
product is severely bent because of the non-uniform
deformation of the material in the cross-section.
Various shapes can be produced by shape rolling
– Bars
– Channels
– I-beams
– Railroad rails
• In general, it requires shaped rolls and expensive
equipment, low to moderate labor cost and moderate
operator skill.
 RING ROLLING
A thick ring is expanded into a large diameter ring
– The ring is placed between the two rolls
– One of which is driven
– The thickness is reduced by bringing the rolls together
• The ring shaped blank my be produced by:
– Cutting from plate
– Piercing
– Cutting from a thick walled pipe
Various shapes can be produced by shaped rolls
• Typical applications of ring rolling:
– Large rings for rockets
– Gearwheel rims
– Ball-bearing and roller-bearing races
• Can be carried out at room temperature
• Has short production time
• Close dimensional tolerances
RING ROLLING
(a) Schematic illustration
of
Ring-rolling operation.
Thickness reduction
results
in an increase in the part
diameter.
(b) Examples of cross-
sections
that can be formed by
 Defects in Rolled Plates & Sheets
•Undesirable
– Degrade surface appearance
– Adversely affect the strength
• Sheet metal defects include:
– Scale, Rust, Scratches, Gouges, Pits, & Cracks
– May be caused by impurities and inclusions
• Wavy edges
– result of roll bending
• Alligatoring
– complex phenomenon
 REFERENCES
• http://en.wikipedia.org/wiki/Rolling_(meta
• http://en.wikipedia.org/wiki/Roll_form
ing
• http://steel.keytometals.com/Articles/Art
THE END

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