QUEZON CITY POLYTECHNIC UNIVERSITY BATASAN CAMPUS IBP ROAD, BATASAN HILLS, QUEZON CITY DEPARTMENT OF INDUSTRIAL ENGINEERING Three-Roll FormingSubmitted By:Astorga, Romy A. Submitted to: Prof. De Jesus, Norberto
QUEZON CITY POLYTECHNIC UNIVERSITY BATASAN CAMPUS IBP ROAD, BATASAN HILLS, QUEZON CITY DEPARTMENT OF INDUSTRIAL ENGINEERINGRoll formingRoll forming is a continuous bending operation in which along strip of metal (typically coiled steel) is passedthrough consecutive sets of rolls, or stands, eachperforming only an incremental part of the bend, until thedesired cross-section profile is obtained. Roll forming isideal for producing parts with long lengths or in largequantities. There are mainly 3 main processes, 4 rollers,3 rollers and 2 rollers, and have different advantagesaccording to the specifications of the plate (thicknesslength and diameter) and the shapes.Three-Roll FormingTHREE-ROLL FORMING is a process for forming plate, sheet, bars, beams, angles, orpipe into various shapes by passing the work metal between three properly spacedrolls.Three-roll forming machines, can also pre-bend both ends of a plate with a singleinsertion into the machine, for reduction in material- handling time and cost. Thesemachines can act as single-pinch machines or as pyramid machines, allowing thefabricator to select the best procedure for a particular job. The wide opening betweenthe rolls allows short, heavy plate to be rolled and, with accessory tooling, rolling ofstructural sections and bar stock on edge. Pinch- pyramid machines drive all 2 rolls-the
QUEZON CITY POLYTECHNIC UNIVERSITY BATASAN CAMPUS IBP ROAD, BATASAN HILLS, QUEZON CITY DEPARTMENT OF INDUSTRIAL ENGINEERINGtop roll is fixed and one lower roll moves in a straight path or an arc toward the top roll.Cone rolling is done by tilting the lower rollsBASIC SHAPES:All forms, regardless of complexity, have, as their basis, one or a combination of basicshapes. Although an object may not perfectly duplicate a basic shape, the shapes arepresent. Objects are three dimensional in structure. The three dimensions are height,width, and depth. The four basic shapes are the cube, the sphere, the cylinder, and thecone. Describing objects by using basic forms simplifies the process of drawing andlaying out forms on a page. Draw basic shapes as if they were made of glass to seeboth the inside and outside of the objects. This technique is called drawing through anobject and enables you to give objects depth as well as height and width.
QUEZON CITY POLYTECHNIC UNIVERSITY BATASAN CAMPUS IBP ROAD, BATASAN HILLS, QUEZON CITY DEPARTMENT OF INDUSTRIAL ENGINEERINGAdvantagesIncreased production and less downtimeEnd flare, twist, camber and bow defects are easier to controlPart lengths are not limited by mill specs (i.e. horizontal centers); if floor space is anissue, the parts can be run directly to the outside of the buildingCombination roll tooling that forms multiple strip widths does not require shear diechangeoverParts with severe notches or complex cross-sections may not cut well after roll formingDisadvantagesStrips must self-thread without damage to the lead edges, normally requiring additionalforming stationsMaterial can jam or double up in production and cause damage to the roll former andtoolingIf floor space is a concern, longer parts require a material conveyor between the pre-notch press and the roll former, equal to or greater than the longest partConclusionFrom the research that have been done, it can be concluded that the rollforming method is better than the conventional Cast-In-Situ method in termsof the labor productivity. It can be seen in the number of work hours toinstall structural components by using roll forming is less compared to theCast-In-Situ method.Typical applications