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Roll Formers

A reliable source for Roll Formers information and leading Roll Formers Companies & Suppliers.

Roll formers are machines that perform roll forming procedures of metals. Roll formers can also be defined as the companies that perform roll forming procedures. A long strip of metal, typically in a coil shape, is the first step in this distinctive metal-forming procedure. Read More…

Roll Formers Roll formers are industrial process machinery composed of multiple sets of rollers that bend and form sheets, strips or rods of metal to produce shaped metal products.
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Leading Manufacturers

Skokie, IL  |  847-965-6700

Our roll forming is among the best in the world. Located in Chicago, Illinois we are able to provide products to the world. We have technicians that are able to work with you in order to come up with the product that you have been searching for.

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Samson Roll Formed Products Company $$$

Berkeley, IL  |  708-449-7050

Johnson Bros. is a leading manufacturer when it comes to roll forming metals, pre-finished and plain. Such as profiles, U-Channels, C-Channels, J-Channels, Hat Channels, Box Channels, Zee Channels, Strut Channels, moldings, and more.

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Johnson Bros. Roll Forming Co. $$$

Elkhart, IN  |  800-998-5940

With over 50 years of experience, United Roll Forming specializes in roll forming for a variety of industries. Our products are the result of state-of-the-art machines that provide both quality and efficiency.

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United Roll Forming, Inc. $$$

Louisville, KY  |  502-969-1327

Producing five different standard products, as well as complicated roll forming sections and secondary operations such as notching, punching and fabricating, is Roller Die & Forming Company, Inc.

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Roller Die & Forming Company, Inc. $$$

Ixonia, WI  |  920-261-9650

ISO 9001:2008 certified manufacturer specializing in custom roll forming. Unique profiles are run in gauges from 0.005" to 0.165" and widths up to 48" on 35 lines. Adding in-line operations may enhance your product.

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M.P. Metal Products, Inc. $$$

Racine, WI  |  262-633-2200

Premier Products of Racine is a full-service company established in 1999 that provides custom roll formed products for applications such as outdoor appliances, tanker trucks, and office furniture.

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Premier Products of Racine, Inc. $$$
placeholder image Samson Roll Formed Products Company Johnson Bros. Roll Forming Co. United Roll Forming, Inc. Roller Die & Forming Company, Inc. M.P. Metal Products, Inc. Premier Products of Racine, Inc.

What are Roll Formers?

Roll formers are machines that perform roll forming procedures of metals. Roll formers can also be defined as the companies that perform roll forming procedures. A long strip of metal, typically in a coil shape, is the first step in this distinctive metal-forming procedure.

To produce a homogeneous shape, a roll forming machine pushes material through a number of mated tool dies. The workpiece is gradually bent throughout each phase of the process until it takes on the desired shape. The metal is turned, pulled, and pushed with each pass. The product is chopped to length by a machine; then, the roll forming manufacturer labels and packages it on a runoff table.

Rollers are expertly created with a flower pattern that shows the metal strip's successive modifications. Each roller's shape comprises the flower pattern's portions. Roll forming is simulated using CAD or CAM renderings so that any mistakes or faults can be fixed before manufacturing. Engineers can choose calibrations and profiles for folding or bending angles using software tools to generate new geometries by clicking their mouse.

Roll Forming Process

In traditional stamping, the complete portion is created at once. When the forces from forming surpass what the metal can withstand before splitting, the component shape is limited, especially how complicated it can be. Only a little area of a roll-formed part is ever bent since, even here, only a small amount of forming strain is applied to the part during each station. As a result, properly designed roll forming processes can produce more complicated shapes.

A coil or several lengthy strips are passed through a roll forming line during the forming process, transforming the flat sheet into a contoured cross-sectional profile. The distinctive feature of this method is the employment of succeeding forming stations, each of which moves the metal in the direction of the desired shape.

A computer designs the track and determines the best location and form for the rollers based on the desired profile. More rollers are used as the desired form becomes more sophisticated. The roll forming line can bend metal, form it into tubes, build metal structures that resemble mazes, and punch holes in the metal.

Precision-contoured metal rollers shape the incoming sheet metal. They frequently double as rollers with motorized drives that draw the strip through the roll forming machine. The geometries of these rollers can be as straightforward as the cylindrical rollers used to push bags through airport scanners, or they can be much more complex. After the last station of forming, the strip is sheared to the desired length for the finished product.

Roll Forming Process

Types of Roll Formers

The different types of roll formers include:

Wrap Roll Forming

In wrap roll forming, roll forming machines create rated L-shaped edges or flanges on sheets of metal. Wrappers resemble large dining tables with a set of rollers running the table's length. They can produce both basic and complex flanges at speeds of fifty feet (15 m) per minute.

Beam Roll Forming

Box beams for construction are made using beam roll forming. The plans result in beam profiles with flutes for floor framing and decking. High tensile strength steel is used to make beams, including single thickness webbing and double thickness flanges for added strength.

Box Beam

Stud and Track Roll Forming

Stud and track machines make assembly frames for sturdy, lightweight partitions that can be up to 32 feet (9.75 m) long with a variety of thicknesses.

Angle Roll Forming

The most fundamental of the roll formed profiles, equilateral or uneven perpendicular angles, are manufactured by angle roll forming machines using high tensile strength steel. Roll formed angles are mostly used for framing, although they can also be used for rails, posts, supports, and brackets.

Seamless Roll Forming

The production of rectangular, square, oblong, and circular tubing is the main application for seamless roll forming. A rolled tube is joined together using the TIG process at the conclusion of the roll forming procedure, as shown in the diagram. Tubing is manufactured from various ferrous and non-ferrous metals, just like many roll-formed items.

Seamless Roll Forming

Roll Former Informational Video

 

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