TPT May 2011

rollforming Using spring loaded top rolls

Rollforming using spring loaded top rolls is a viable, practical and economical option for many applications. Since the rolls are not held perfectly rigid as other types, their design offers advantages depending on their use. It will be very forgiving to minor changes in material thickness and have less potential for damage if accidentally misfed. Using this type of arrangement the machine can compensate for varying material thicknesses without manual adjustment. Roll grip is set for minimum material thickness and the springs allow the rolls to lift for heavier gages to enter and maintain drive on the material. Since they can be adjusted to have a very light grip, they are well suited to forming very cosmetic materials such as prepainted, embossed or polished. Spring loaded rollformers are proven in a wide range of custom applications frommirror frames to garage doors. They are common in the shelving and storage industries, appliance, wall and roof panels. A dedicated machine, making a family of products for an OEM in the sheet metal industry is where this machine is a top performer. Many times there will be up to four rollsets mounted on one rollformer and the operator will simply feed material into the correct rollset to make the part required. If this type is installed in an automatic line, it will have provision to traverse perpendicular to line, direction to line up rollsets with other line equipment, ie uncoiler, and cut-off.

Best applications will meet most of the following criteria: 1) Rollsets are rarely or never changed on the machine. 2) Material thickness changes are frequent and common 3) Operator have little knowledge of machine adjustments. 4) Product to be formed is 2” tall or less 5) Expected production cannot justify cost of rigid, micrometer adjust roll mill.

Initial investment can be a significant cost saving over more traditional rollformers, usually about 40% , so payback time can be significantly reduced. A well maintained machine will run in production for 15 to 20 years . Many have been in service for 30 or more . Those who look beyond the initial perception will see a time proven design, as dependable as it is economical. Partnering for Innovation Comet Roll Engineers partner with our customers to identify process improvements to help drive down finished part costs, improve quality and reduce turnaround. “Making it work – whatever the material” Comet has designed roll form tooling for even the most demanding materials including: - All types of Aluminum

- Martensitic Steels - Hot-dip galvanized - Pre-coated and painted metals - HR pickled-and-oiled - Stainless - HSLA

Another variation is the panel or duplex rollformer. This machine will have two rollformers mounted parallel to each other on one base to form two opposing edges of a wide sheet simultaneously. One or both sides are made moveable to adjust for the desired width range of the product.

CONTACT

Phone: (630) 268-1407 Fax: (630) 268-1425 Email: sales@cometroll.com Web: www.cometroll.com

Comet Roll & Machine Co. 405 Stone Drive St. Charles, IL 60174 USA