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Understanding bending, moving material in roll forming-7

In manufacturing a wide product, moving unformed edges laterally is a serious design issue (see Figure 5).

Figure 5
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Forming wide sections is often a bigger challenge than forming narrow sections.

Figure 5A: The horizontal sections move horizontally. This section has a high moving resistance, which may cause edge waves. Another problem is that the unformed edges are very wide, and the edges will bounce up and down between forming stations. The bouncing motion may elongate the edges, causing edge waves.

Figure 5B: The horizontal sections slope downward to reduce moving resistance (in other words, this strategy does not move the horizontal sections horizontally). The bouncing is still a problem in this design.

Figure 5C: This approach begins to form the outside hats first. It does not have the long, unformed flanges of 5A and 5B; in its intermediate steps, 5C has formed sections (which are stronger than unformed sections) and unformed sections that are narrower than those in 5A and 5B. The unformed areas will move smoothly between forming stations. The formed edges are sloped down to make lateral movement easier.

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Understanding bending, moving material in roll forming-7

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