For over 85 years, Roller Die + Forming has been providing custom roll formed, stamped, powder coated and assembled metal parts, using lean manufacturing processes.
1. 4630 CR 209 S.
Green Cove Springs, FL 32043
904-284-5611
www.rollerdie.com
Roll Forming – Stamping – Press Brake – Powder Coating – Polishing – Welding - Assembly
2. Roller Die - Company Profile
Key Statistics
Revenue: $59 million (FYE 9-30-13)
Employees: 300
Corporate Headquarters: Louisville, KY
Plants: Louisville & Frankfort, KY
Green Cove Springs
(Jacksonville), FL
Rossville, Ga. (Chattanooga, TN)
Queretaro, MX
Stockton, CA
Founded in 1928
ISO 9001:2000 Certified
Privately Held
Lean (TPS) Culture
Press Brake
Light Gauge
Stamping
Assembly,
Finishing
Roll Forming
4. What is ROLL FORMING?
Roll forming is a
continuous forming
process taking sheet
or coil stock and
bending or forming it
to a desired cross
section.
The process is
performed between
successive pairs of
rolls that
increasingly shape
the metal until the
desired cross
section is achieved.
7. Materials
Almost any material that can tolerate
bending to a desired radius can be roll
formed.
The more ductile a material is, the
better it will roll form.
The roll forming process can handle
ferrous, nonferrous, hot rolled, cold
rolled, polished, plated, or pre-painted
metals producing excellent results.
8. Materials
Materials as thin as 0.005" and as
thick as 0.750" can be roll formed,
depending upon the size of the roll
form machine spindles.
Material pieces as narrow as 1/8" and
as wide as 72", or more, can be roll
formed, depending on machine size.
9. Design Considerations
Bend Radii:
Best practice is a one-metal-
thickness inside radius.
May need slightly larger in high-
strength steels
Sharper corners CAN be obtained at
the expense of tool life
Scoring the inside of the strip can
help make sharper corners in some
cases.
10. Design Considerations
Deep sections:
Require more passes, larger
machines, larger rolls and dies
Risk overstressing the edges of the
material
Typical machines – 100 mm max.
height of part
Short Legs:
Three times metal thickness is a
good minimum leg length
11. Design Considerations
Wide sections
Apply ribs or offsets to wide panels
Helps prevent wrinkles, “oil-
canning”
Often wide material has appearance
issues
12. Design Considerations
Cross Section Tolerances
Typically +/- .25 mm to +/- .75 mm
Tighter tolerances are achievable:
Different approach to tooling
Special quality materials
Angular Tolerances
Typically +/- 1º
13. Design Considerations
Length Tolerance
Influenced by many factors:
Length of part
Speed of rollformer
Measuring system
Cutoff system
Material properties
Commonly available: +/- 0.8 mm
Special equipment and tooling: +/-
0.25 mm
Long parts (3 M or more): +/- 3.0 mm
and up
14. Design Considerations
Straightness:
Bow (up or down) or Curve (side to side) –
1.0 mm per Meter
Twist - 1 degree per Meter
Flare:
Typically avoid measuring the cross
section within 50 mm of ends.
Flare can be controlled with special
attention
17. Roll Forming vs. Other Processes
Volume is key versus tooling costs
Typically see 25,000 LF of part to justify cost
of custom shape; BUT, if can use standard
shape, much less
Extrusions – aluminum – 3 x galvanized cost;
inexpensive tools, expensive part
Press brake – good for low volume;
inexpensive tools, expensive part (labor), limit
to length of part by brake bed
Stamping – good for single part; if multiple
lengths in family, tooling very expensive; if
done in multiple steps, expensive (labor)
Roll form lines allow piercing, features to be
done in-line, no secondary operation.
18. Roller Die
Why we should be Your Roll Form Source:
Long-time experience
Both Decorative and Structural Parts
Technical Expertise
Available to Assist in Design
Multiple Facilities, including Mexico
Lean Manufacturing Systems
Fully integrated engineering department
overseeing our custom tool & die shop on
site
Large library of standard shapes/stock
tools