Roll forming
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Roll forming is a continuous bending operation in which a long strip of metal 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.
A variety of cross-section profiles can be produced, but each profile requires a carefully crafted set of roll tools. Design of the rolls starts with a flower pattern, which is the sequence of profile cross-sections, one for each stand of rolls. The roll contours are then derived from the profile contours. Because of the high cost of the roll sets, simulation is often used to validate the designed rolls and optimize the forming process to minimize the number of stands and material stresses in the final product.
