Industrial Machinery News

Archive for the ‘Roll Forming News’ Category

The most commonly used lubricant to aid the roll-forming of building panels is vanishing oil. This product provides the necessary lubrication for the forming process and also has the advantage of evaporating over time to permit ease of handling and installation at the construction site. However, the vanishing oil or other lubricant should contain at least 95% solvents or be a water-based lubricant that leaves minimal residue. Care should be taken to allow the roll formed panels to be completely dried prior to shipment. No lubricants should be used on either acrylic coated GALVALUME or Galvanized steel that U. S. Steel identifies as ACRYLUME2 or ACRYZINC3, respectively.

Inadequate lubrication can cause problems with the roll former operation and/or in the finished panel. A common problem within the roll former is the bonding (welding or fusion) of coil coated products to the roll tooling. This is time consuming to remove. Some companies have had some success by mounting SCOTCH-BRIGHTTM rolls4 on the tooling to continuously remove coating build-up or by polishing the rolls while in operation. Problems can also extend to the finished panel. Part configuration, forming issues, oil canning, twist, bow, and improper finished dimensions can all result from inadequate lubrication.

 Aço terças são uma excelente opção para estruturas de piso, crista grandes vigas e paredes altas. Feita a partir de galvanização de aço galvanizado e fabricados por prensagem utilizando máquinas. Terças são de molde resistente, à prova de umidade, de energia eficiente e são recicláveis. Eles prevêem a carga elevada capacidade de carga são fáceis de montar, leve e mantenha fiel ao que forma. Máquinas de rolo formando como o PurlinMaster Samco fornecer uma gama de opções quando fabricação desses itens de construção comum. Estruturais e de edifícios projetados utilizar terças de aço horizontal e verticalmente. Cee e terças Zee prender as cargas para a plataforma do telhado, forro, e são apoiados por vigas e paredes do edifício. 

Na construção de metal para a construção de sistemas purlins telhado são usadas com freqüência e são fabricados pela formação (ou flexão) frio de aço galvanizado para Cee e Zee (ou Zed) seções. Outro nome usado para Cee e Zed (ou Zee) seções em uma construção da parede é ‘girts’. 

Montagem opções para o comum e não tão comum purlin 

Since the discovery of steel modern man has had the ability to create with unlimited potential.  The creation of modern machinery to manufacture and produce a wide range of metal formed products such as guardrails and highway beams, steel stud and zee purlins have enabled companies to manufacture high quality products. 

Many of today’s roads or driveways intersect a highway near to the end of a bridge or other immovable, restrictive features of the highway.  To protect and shield both the end of the bridge and the embankment, a strong post W-beam guardrail curved around the corner is used.  The manufacturing of these interstate or highway guardrails is typically done best with a roll former.  Roll forming equipment is used to bend and ‘form’ the various grooves and profiles in to a flat metal roll.  Compared to other forms of metal bending such as brake pressing or stamping roll forming is much more cost effective and produces a higher quality product.  It should be noted that the terms ‘roll forming’, ‘rollformer’, ‘cold roll forming’ and ‘metal roll forming’ are all interchangeable.  When selecting a roll forming company as with any other capital equipment purchase pricing is typically a less important part of the equation.

As with many other large capital pieces of equipment roll forming machines can be manufactured from very cheap to very expensive.  So how do you know which is the right guardrail roll forming machine for you?  Well, keep in mid several key factors.

1)      How long has the roll forming company been in business?

2)      Is the roll forming machine built for long term reliability?

3)      Are the roll forming stands built to handle repeated bending of metal?

4)      Will the profiles been the same day after day year after year?

5)      Does the roll forming company use FEA (finite element analysis) when designing roll tooling?

6)      Is the roll forming company ISO certified?

These are some important questions to ask yourself before you choose a roll forming manufacturer.  Another area that is very important is how much money will you spend on re-work scrapped or return product?  Often with cheap inexpensive roll forming machines from China you will have to factor in the cost of poor quality parts.  This cost can amount to a lot of money over a short period of time.  It is usually better to start with a quality roll forming machine such as the Samco Machinery roll former.  With in a short period of time you will see how cost is no longer the only factor to use when purchasing a roll former.  Quality, durability and long term re-work costs are some of the key issues to consider. 

Many quality companies use the Samco Machinery (http://www.samco-machinery.com) roll formers when they produce steel formed products.  The output is always of a higher quality and the cost per unit production is lower then less costly poor output machines.

Roll Forming Machines in India manufacture for the local market producing quality profiles

There are many roll forming machine manufactures around the world.  The question as to what company is the right one to produce roll formed profiles can be tough to answer.   So where do you start?  Looking at a roll forming machine for building corrugated roofing sheets must take in to consideration several key factors.  The machine durability is one of the most over looked elements in the decision making process.  Too often companies choose largely based on price rather then quality.  This often leads to roof panels that are manufactured poorly and require re-work or scrapping.  This will lead to a higher cost per panel when roll formed with a low cost machine.  The roll forming process is very precise even for the most common roll formed profiles and shapes.  The use of sheet metal to make roofing panels has long been the material of choice.  The sheet metal forming process to produce the corrugated profiles utilizes many machines in order to manufacture quality panels.  The tools and dies on these machines are an important part of the overall quality.  Also the strength of each roll tool stand is equally important in producing quality profiles over and over.  Can you imagine using small lightweight roll tooling or stands to bend sheet metal reliably?  It is obvious that you must use a strong machine built by a reputable company who has years of experience.  One such company Samco Machinery, is well known around the world for producing quality machinery for the roofing panel industry.  They also have a roll forming machine division in India to produce local equipment.  If you’re looking for a roll forming line to manufacture corrugated roofing or wall panels I would start with a leader in the market.  Companies like Samco (http://www.samco-machinery.com) manufacture custom machinery that are highly cost effective.  

Many processes utilize roll forming machinery as a simple effective way to produce metal formed products.  Repeatable profiles and low cost per unit are some of the main advantages to rollforming.  When manufacturing highway guardrails, 2-space w beam guardrails or beams for highways using a quality roll former is important in producing quality parts.  Steel highway sign posts can also be made using a roll forming machine.  Many manufacturers of highway guardrails enjoy the cost benefits of manufacturing with a roll former versus a stamping or press machine.  Roll formers reduce the labor costs while increasing the overall part quality and operation throughput.

How can you tell what roll former is a quality one?

This is often a difficult question to answer.  Many companies claim to have quality roll formers at reduced prices.  As the old saying goes ‘you get what you pay for”.  An area that is often missed when evaluating the cost of a roll former is the cost of re-work, poor quality parts and unhappy customers.  These real costs must be added in to the overall calculation used when purchasing a roll forming system.  Companies like Samco Machinery have reputations as leaders in the industry.  They are equipment to handle any application regardless of how complex or standard it is.  Years of experience and a wide range of knowledge make them a valuable source in the industry.

So when buying a guardrail roll former I would start with the experts in the field.  Look for companies like Samco Machinery for solid understanding on how to do the job at a low cost with a high quality product.
 

Sheet metal workers in manufacturing plants make sheet metal parts for products such as stud and track framing, purlin, corrugated roofing and siding, and air-conditioning duct systems, trapezoidal roofs, automotive parts; and many other steel products. The work can be highly repetitive and labor intense. Sheet metal workers stand for long periods, lift heavy materials and finished products. The last thing they need is a manually operated press brake, requiring repetitive exertion with every bending operation.

How to manufacture better? Using a fully automated roll forming machine will increase quality, through-put and profit. They are more flexible, have a higher capacity, and are faster than other techniques for metal forming. They also reduce the overall number of operators and labors. Labor costs are cut dramatically and worker through-put. A roll forming machine reduces labor costs while increasing productivity. The use of rafted tools also allows for faster change over’s, as found on the Samco Machinery mills, and higher quality. This allows your business to manufacture more products in less time.

So, what do I need to look for in my next roll former machine?

• High quality product output.
• Rugged construction for long, trouble-free operation in heavy duty service.
• The ability to form continuous or pre-cut lengths repeatability without compromise in full-length or continuous feed operations accurately and economically.
• Hydraulic controls that index quickly and accurately.
• Dies that are quick and easy to change.
• The ability to perform a variety operations.
• A proven service record with years of experience.
• Replacement parts and optional components that are readily available.

When investigating a new roll former machine, make sure that you match the equipment to your requirements and obtain the highest quality product with appropriate features. Looking at only the cost can sometimes be deceiving, as versatility, productivity, efficiency of labor, and life cycle costs all need to be accounted for.

For more than 30 years, Samco Machinery has been improving the productivity of the steel metal forming industry. Visit our Roll Forming Machine website for details on our complete line of forming machines.

Roll forming machines are used to bend flat metal into many unique shapes and profiles.  As the flat metal plate moves through the machine it is formed and bent along the way in to the final profile design.  I have always wondered how the engineering is done to decide how many stands are to be used.  The stands are the sections that hold the rolls that press and bend the metal in to its shape.  Each stand changes the profile design slightly until the final profile is made. 

So how do they decide the number of stands to use?

I have learned that many companies use trial and error.  Some use cost as the main reason.  Each stand adds additional cost to the overall cost of a roll former.  Other companies that provide high quality profiles use engineering software (FEA) to design the roll forming machines with the correct number of stands.  Having more stands does not really impact the true cost of a roll former machine.  Imagine that you produce a part with a low cost roll former machine that has fewer stands.  This machine will most likely produce products that are out of specification.  Typically low cost roll formers have a high re-work and poorer quality end product.  Imagine if you sent your product to your customer and they rejected that parts based on poor quality.  You would incur these costs as well as the scarp material, transportation costs.  Your overall rework and negative impact on your image would be far greater a cost impact to your business then adding the right number of roll stands to your roll forming equipment. 

When I look at quality roll forming machines I often come across Samco Machinery.  They are a company that uses special FEA software to assist in the design of their roll forming equipment. 

So in the end I would be very careful when selecting a roll former machine solely based on cost.  You must consider overall quality and life repeatability when making this decision.
 

Metal production experts use a variety of different techniques to produce customized parts, fittings, and other industrial and commercial solutions. Each technique produces a completely different product with different characteristics. Whether it is sheet metal fabrication, bar milling, or roll forming, each has its own purpose and set of benefits.

Roll Forming

Using an automated roll forming machine, which runs with high accuracy, this machine literally bends and forms metal into precise shapes. Many machines can work with a range of material thicknesses and often utilize automated systems to gauge material thickness. The roll former can be feed with either pre-cut material or a continuous roll of steel. When required holes can be pre-pinched in to the material or post punched depending on the specific needs of the part manufactured. Deciding when to punch holes is critical to the accuracy of the final part. Roll forming companies such as Samco Machinery (http://www.samco-machinery.com) have the experience and engineering staff needed to make that decision with you. So what is it used for? If you need to manufacture a large volume of parts, steel stud for construction, purlin for roofing, corrugated roof panels, automotive chassis or even shelving and racking, this method will likely be the one used. This is an ideal solution for anyone needing to manufacture repeatable high quality parts with minimal labor costs.

Punch Anywhere

Punch Anywhere is a system that allows for dynamic punching of steel plate in metal roll forming systems. This advanced method for punching holes and notches allows manufactures of steel products the flexibility to change patterns quickly and easily. Older systems typically incorporate stationary dedicated punch presses that require die changes to modify the pattern. With the Punch Anywhere system you can now change your process to match your changing market.

Sheet Metal Fabrication

Sheet metal fabrication is ideal for custom forming and repeatable profiling. With this method, specialists can use roll forming machines and shears to create virtually anything from this super-thin and flexible metal product.  It is used for everything from corrugated siding, trapezoidal roofing, shelving and racking to insolated roofing and wall panels. Sheet metal fabrication works to build all sorts of products for the building and construction industry and is found around the globe in places like Mexico, South Africa, Middle East, U.S.A and other countries. Whether it is sheet metal fabrication, roll forming, or some other technique, there is a process and the corresponding technology to produce the exact item you need.
 

I was watching Business News Network (BNN) and saw an interview on Squeeze Play that caught my interest. In the interview president and COO, of Samco Machinery Bob Repovs’ talked about his company. He discussed how business can learn to thrive during a down economy. Specifically, how they helped Tata nano build cars in India. Theirroll forming machine is used to help build parts for the automaker.