COLD ROLL FORMING Process
For 100+ years, cold roll forming process has provided strong parts — quickly and cost-effectively — for numerous industries.
What is Cold Roll Forming?
Cold roll forming is a kind of cold bending processing, it is an efficient, effective shaping that delivers tight tolerances on complex profiles. It is the process of gradually bending a flat strip or coil of metal into a longitudinal, uniform profile. To get the desired shape, the operator passes the workpieces through a series of mated tool dies. Cold roll forming is a cold forming process that doesn’t require heating up the metal. High-temperature, specialized equipment isn’t necessary to produce cold rolled shapes.
Cold roll forming is a reliable, proven approach to metal shaping that is ideal for modern applications. This process uses a continuous bending operation where long metal strips, typically coiled steel, are passed through consecutive sets of rolls at room temperature. Each set of rolls performs incremental parts of the bend to produce the desired cross-section profile. Unlike other metal shaping methods, the cold roll forming process is inherently flexible. Secondary processes can also be integrated into a single production line. Cold roll forming increases efficiency while reducing operational and capital costs by eliminating unnecessary handling and equipment.
What are the raw materials for cold roll forming?
Raw material can be either flat or coiled sheets. It’s possible to use hot rolled steel in sheet form as the raw material in cold roll forming.
What is cold roll forming capability?
Typical cold roll forming mills can accommodate material gauges ranging from .010″ up to 0. 250″ thick. The bend radius is largely determined by the ductility of the metal. However, 180-degree bends are commonly achieved with the right material. Roll forming easily accommodates the integration of secondary operations such as welding, punching and precision laser cutting to optimize production efficiency.
What are the advantages and benefits of cold roll forming compared to other metal forming processes?
- Development, diversity and complexity of forms that meet all the needs of users.
- Curvature radius corresponding to the thickness of the metal strip.
- Lightening the weight of structures by roll forming steels with high elastic limits.
- Ease of implementation in assemblies with welding, riveting, bolting, gluing.
- Variety of possible delivery lengths of steel profiles, up to 30 meters.
- Diversity of surface conditions such as hot roll, pickled, cold rolled, prepainted, and galvanized.
Available roll forming materials
Cold roll forming can form a wide variety of metals, including:
- Cold rolled steel
- Hot rolled, pickled and oiled steel
- High-strength, low-alloy steel
- Galvanized / galvannealed steel
- Stainless steel
7 cold roll forming applications in disguise
Cold roll formed shapes are particularly useful due to their ability to be produced at a rapid pace while maintaining design accuracy. Yet it’s also ideal for parts with multi-bend profiles, or those that require high-end finishes.
Hole punching, bending, and cutting to-length are all easy to fit into one continuous process, rather than separate steps. In all of these cases, it’s simply more cost-effective and productive to use this tried-and-true method of metal forming.
- Power distribution components
- Warehouse & data storage
- Commercial food storage
- Trailers & trucks
- Guard rails & sign posts