Roll Forming Process
As one of the simpler processes in the world of manufacturing, roll forming is an ideal method for producing parts that are long in length or that will be made in large quantities. Roll forming lines begin with metal strips housed on a large spool. These strips generally measure between 1" and 20" in width and 0.0004 and 0.125" in thickness. This strip is unrolled from the spool (which is held on a dispenser) and fed into the special metal fabrication machinery that has been designed specifically for this process. The metal strip, after passing through the cutoff attachment, is sent through the forming rolls, from which the process gains its name. Generally, shaped rolls have been arranged in a sequence in order to create the intended shape over a series of stages. Some common roll layouts include overhung spindle rolls, flower-shaped, side rolls, and progressive upper/lower rolls. The arrangement depends on the desired final shape.