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End distortion on roll formed parts-7

Side rolls are necessary for forming a prenotched product. They should be set up to form more than 50 percent of the forming angle for the following forming pass. For very thin and very soft metal, the side rolls may form 80 percent or even 100 percent of the forming angle for the following forming pass. This eliminates the toeing in of the back edge of the notch caused from the impact force (Figure 3).

Consider additional forming passes, especially for prenotched products.

Figure 6 illustrates three post-treatments. The C method in Figure 6 is a counterforming method in which all residual moments and stresses are balanced.

The S method in Figure 6 is a straightening method in which the alternating bending flattens out the ends and eliminates distortion.

The CS method in Figure 6 is a combination of the counterforming method and the straightening method. It balances the residual moment and the surface stresses and flattens out the ends and eliminates distortion.

Distortion caused by a pushing-out-style slug cutoff die with a vertical cutting motion (see Figure 4) is reduced or eliminated by changing to a slugless cutoff die with a 45-degree cutting direction.

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End distortion on roll formed parts-7

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