For certain sheet metal applications, roll forming with spring-loaded top rolls is a practical production method. This article explains the process, describes various machine configurations, and outlines the criteria for suitable applications. It also discusses product requirements that are incompatible with this process.
Best Applications:
The best applications for spring-loaded roll formers will meet most of the following criteria.
1. Roll sets are rarely or never changed on the machine.
2. Material thickness changes are frequent and common.
3. Operators have little knowledge of machine adjustments.
4. Product to be formed is 2 in. tall or less.
5. Expected production cannot justify the cost of a rigid, micrometer-adjusted roll mill.
Nonsuitable Applications
Applications not well-suited to spring-loaded roll formers include:
1. Products taller than 2 in.
2. Gauges heavier than 14 (depending on profile form).
3. Products requiring extreme dimensional accuracy.
4. Production speeds in excess of 250 FPM.
5. Large numbers of roll sets need to be mounted on the machine on a regular basis.
While these machines are lighter-duty versions of their rigid, micrometer-adjustable brothers, they perform very well in their intended environment. Those who look beyond the initial perception will see a time-proven, dependable, and economical design.
