Roll Forming Troubleshooting

Roll Forming Troubleshooting

It is often difficult to pinpoint the exact cause of product quality problems because of the many potential contributing sources.  When a new set of rolls is installed, it almost always requires some minor modification to correct the usually unforeseen problems caused by the roll design. Common problems in the roll forming machine, The setup of the roll form tooling.  here we will show the reader some Common Roll Forming Problems.

Summary Most of the factors that Couse problems in roll forming machine:

1-Entry Guide Stand:

Sometimes entry guide stands, in the Beginning, which can cause the twist or camber problem. When you are trying to adjust the straightener, but twisting it back and then trying to eliminate twist but nothing happens? in this case, firstly Check the entry table and make sure the material be perpendicular to the rolls.

Make sure the stand is in good working order (twist can be induced if the stand is allowed to move off one side to the other). If the sides are not aligned properly, use a 24" scale and place half of it on the front or flat face of the first pass. Align the guide parallel to the scale and tighten the stand. This is a quick and easy way to potentially minimize twists.

Roll Forming Guide

2- Excessive Pressure

Excessive Pressure there are on the Inboard or Outboard Side of the Tooling is a common mistake that operators make when they are adjusting the rolls. operators adjust the rollers without material in the machine at first which can lead to twisting, down bow, up the bow, etc.

In order to solve this, gauge the roll form tooling without the material and check the rolls using a mirror to view between each pass, and check rolls are matched properly. Then start the material through the first pass and re-gage the rolls. Set the roll gaps based on the actual material thickness you are running. Then forward the machine about one inch and check the gap, you may need to do this a few times to get the proper gap. Continue this process for the remaining passes.

3-unsuitable Roll Match

Matching the roll form rollers should be a procedure during setup. After you have the rolling set up and adjusted to the material thickness, you should make a habit of checking the match between top and bottom rolls. Take a mirror and a sheet of white paper and hold the paper at a slight angle between the rolls On the other side of the roll, look in the mirror and check the outline of the rolls where the material will be formed. You should have an equal gap around the form and just a small amount (0.005-0.010" ) more between the top and bottom rolls.

Set up for roll forming success

4- Lack of Lubrication

maybe you don' t believe that the roll forming effect is dependent on lack of lubrication. These days, we are designing and manufacturing roll forming machines for very difficult profiles. These profiles can involve multiple material thicknesses and types. At the same time, we are asked to do all of this with one set of rollers. Depending on the rollers' design, there may be issues with the material fighting drag with all compression and stretching as it is being formed. Sometimes just a little bit of lubricant works wonders. If the product cannot have lubricant on it, there are many types of vanishing oil that dissipate after the product has been formed.

some of the parameters that determine straightness include:

• Twist

• Bow/cross blow

• camber/Sweep/curve.

• Edge wave

• Flare

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