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Roll forming and Flat rolling

Roll forming and Flat rolling

Roll forming, roll bending or plate rolling is a continuous bending operation in which a long strip of metal (typically coiled steel) is passed through consecutive sets of rolls, or stands, each performing only an incremental part of the bend, until the desired cross-section profile is obtained. Roll forming is ideal for producing parts with long lengths or in large quantities. There are 3 main processes: 4 rollers, 3 rollers and 2 rollers, each of which has as different advantages according to the desired specifications of the output plate.

Flat rolling is the most basic form of rolling with the starting and ending material having a rectangular cross-section. The material is fed in between two rollers, called working rolls, that rotate in opposite directions. The gap between the two rolls is less than the thickness of the starting material, which causes it to deform. The decrease in material thickness causes the material to elongate. The friction at the interface between the material and the rolls causes the material to be pushed through. The amount of deformation possible in a single pass is limited by the friction between the rolls; if the change in thickness is too great the rolls just slip over the material and do not draw it in.[1] The final product is either sheet or plate, with the former being less than 6 mm (0.24 in) thick and the latter greater than; however, heavy plates tend to be formed using a press, which is termed forming, rather than rolling.[citation needed]

Often the rolls are heated to assist in the workability of the metal. Lubrication is often used to keep the workpiece from sticking to the rolls.[citation needed] To fine tune the process the speed of the rolls and the temperature of the rollers are adjusted.[16]