Roll Forming Handbook

Introduction to Roll Forming 1(1) George T. Halmos Introduction to Roll Forming 1(1) Roll Forming Mill 1(1) George T. Halmos General 1(1) Mill Types 1(17) Mill Components 18 References 32 Presses and Die Accelerators 1(1) George T. Halmos General 1(5) Mechanical Presses 6(4) Pneumatic Presses 10(2) Hydraulic Presses 12(3) Information and Dimensions for Press/Die Purchasing and Installation 15(1) Rotary and Other Cutting, Punching Equipment 15(5) Flying Die Accelerators 20 Secondary Operations in the Roll Forming Line 1(1) George T. Halmos Secondary Operations 2(1) Straightening 3(6) Tight or Loose Line: Cutting Before, In-Between, or After Roll Forming 9(5) Location of the Secondary Operations 14(1) Stationary and Flying Dies 14(2) Punching, Perforating, Notching, and Mitering 16(3) Piercing and Partial Punching 19(1) Flanging, Louvering, and Lancing 20(1) Embossing and Drawing 20(2) Bending 22(2) Curving (Sweeping) 24(22) Marking 46(1) Swedging (Off Setting) 46(1) Rotary Dies 46(10) Mechanical Joining of Different Strips or Parts 56(4) Adhesive Bonding 60(1) Soldering and Brazing 60(1) Resistance Welding 60(2) Painting 62(1) Foaming 62(1) Packaging 62 References 62 Roll Design 1(1) George T. Halmos Roll Design Process 2(2) Cross-Section 4(9) Product Orientation and Other Operations in the Line 13(6) Materials 19(9) Roll Forming Mill 28(12) Other Tool Design Considerations 40(8) Spacers and Shims 48(4) Calculating Strip Width 52(3) Bend Lines 55(9) Number of Passes 64(9) Flower Diagram 73(5) Roll Design 78(16) Calculating Roll Dimensions Manually 94(1) Computer-Aided Roll Design 95(5) Examples 100(3) Roll Marking System 103(4) Roll Orientation 107(1) Setup Charts 107 References 111 Materials 1(1) George T. Halmos Design Considerations 1(1) Mechanical Properties 2(5) Crystalline Structure of Metals 7(1) Forming Metals 7(3) Increasing the Strength of Metals by Cold Working 10(1) Hot Rolling 10(2) H.R. and H.R.P.O. Steels 12(1) Cold Rolled Steel 12(1) Carbon Steel 12(1) Alloyed Steel 13(2) Stainless Steel 15(1) Metallic Coatings 16(1) Nonmetallic Coating and Laminating 17(1) Joining Different Materials in the Roll Forming Process 18(1) Aluminum 18(2) Other Metals and Materials 20(1) Influence of Primary Metal Processes on Roll Forming 20(4) Guideline to Steel Prices 24 References 24 Lubrication 1(1) Joseph Ivaska Tribology of Lubrication 1(4) Selection of Lubricants 5(3) Surface Properties of Formed Material 8(2) Lubricants for the Secondary Operations 10(1) Application Techniques 11(1) Preparation and Maintenance of Lubricants 12(6) Operating Problems during Production 18 Coil Processing, Material Handling, and Plant Layout 1(1) George T. Halmos Joseph Horvath Flow of Material 2(1) Coil Handling and Storage 3(3) Sheet Handling and Storage 6(3) In-Line Coil Handling 9(5) Coil End Welding 14(2) Strip (Coil) Accumulators 16(3) Flattening and Leveling 19(3) In-Line Sheet Handling 22(1) Finished Product Handling 23(8) Finished Product Storage 31(3) Material Handling Equipment 34(4) Material Handling Accessories 38(2) Crane Controls 40(1) Plant Layout 41 References 43 Designing Products for Roll Forming 1(1) George T. Halmos Developing Light Gage Products 1(1) Design Considerations 2(8) Secondary Operations 10(10) Profiles Manufactured in Different Sizes 20(2) Design of Specific Products 22(1) Dimensioning and Tolerancing 22 References 29 Equipment Installation, Roll Setup, Maintenance, and Troubleshooting 1(1) George T. Halmos Installation of Roll Forming Lines 1(7) Roll Installation and Setup 8(6) Maintenance and Spare Parts 14(18) Troubleshooting and Trouble Prevention 32 Behavior of Metal Strip during Roll Forming 1(1) Manabu Kiuchi Various Types of Deformations 1(2) Causes of Redundant Deformations 3(3) Effects of Redundant Deformations on Product Defects 6(13) Mathematical Simulation of the Deformation of a Metal Strip 19(10) Computerized Design System for Roll Profiles 29(5) CAE for Roll Forming 34 Acquiring Roll Forming Lines, Education, and Training 1(1) George T. Halmos Why Roll Form Products? 1(1) Different Paths to Start Roll Forming 2(1) Evaluating the Product 3(1) Selecting Line Components 4(3) Procuring Roll Forming Tooling 7(1) Equipment and Tool Specifications 7(1) Acceptance Test 7(1) Education and Training 7(4) Motivation 11 References 11 Safety 1(1) Ashok Shah Safety 1(1) Common Safety-Related Definitions 2(1) Safety Design Procedure 2(1) Determining Limits of the Machinery or System 3(1) Determining Hazards/Risk Estimation 3(5) Risk Reduction by Design 8(1) Safeguarding 9(4) Selection of Guards and Protective Devices 13(1) Required Characteristics of Guards and Protection Devices 13(1) Signals and Warning Devices 14(1) Personal Protective Equipment 14(1) Training 14(1) Summary 15 References 16 Increasing Efficiency of Roll Forming Lines and Case Studies 1(1) George T. Halmos Output, Productivity, and Efficiency 1(1) Line Utilization 2(1) Improving Productivity 3(1) Case Studies 4(6) Preliminary Tool and Equipment Cost Analysis 10(1) Preliminary Cost Analysis 10 Unusual, New, and Future Roll Forming Technologies 1(1) George T. Halmos The Last 100 Years 2(1) The Future of Roll Forming 2(3) Pull-Through Mills: Nondriven Rolls 5(1) Tension Roll Forming 6(1) Combining Roll Forming and Cold Drawing 7(1) Developing New Roll Forming Methods 7(2) Roll Forming Tools 9(1) Reducing the Thickness of the Starting Material 10(1) Forming at Elevated Temperature 11(1) Hot Roll Forming Variable Cross-Sections 11(1) Hot Thickness Reduction along the Length of the Strip 12(1) Welding Hot Roll Formed Sections 12(1) Other ``Hot'' Processes 13(1) In-Line Soldering, Brazing, and Heat Treating 13(1) Equipment and Tooling Requirements for Hot Roll Forming 14(2) Press Tooling for Conventional Roll Forming Lines 16(1) Computer-Controlled Roll Forming Lines 16 References 17 Appendices 1(1) References 1(1) Index 1