Beam Roll Forming Machine
A Beam Roll Forming Machine is a piece of equipment that bends metal strips into specific shapes and configurations. Unlike other metal fabrication methods, roll forming uses fixed rollers that bend the metal as it travels through the machine.
This process is highly energy efficient, as it doesn’t require heating the metal or using other types of energy to form a part. It also results in an extremely accurate, uniform product.
Types
A Beam Roll Forming Machine is a metal forming machine that fabricates specific configurations out of long strips of metal. It is used to manufacture a variety of products, including boxes, angles, and tubing.
Box beams are a common rolled formed profile and are usually made from high-tensile steel with double thickness flanges for additional strength. They are used for framing and floor decking.
Beams can also be produced in a range of sizes, allowing them to be a suitable addition to any construction project. These machines can be equipped with a programmable logic controller to ensure that the parts being shaped are accurate and within a certain tolerance.
Using a series of precisely placed rollers, a roll forming machine works to shape metal into specific patterns and shapes. The process involves a continuous stream of metal, which is fed into the machine.
The machine uses a set of rollers that are mounted on consecutive stands and each one completes a small step in the formation of the metal strip. Each stand moves crosswise and rotates through a numerical control, which identifies the sequential changes in the strip as it is being shaped.
These machines are usually gang driven, which allows them to produce complex designs and a wide range of materials. They also have a high production capacity, which helps to keep the cost per product down.
Another common rolled formed profile is a wrapped L-shaped edge or flange. Wrap machines can reach speeds of fifty feet per minute, allowing them to make a wide variety of flanges.
Some wrap forming machines can also be fitted with a TIG welding system to weld the finished products together. This can save on both production and energy costs, which is a significant benefit for many businesses.
A roll forming machine can be designed to withstand a variety of conditions and environments, making it an ideal choice for a wide range of applications. In particular, it can be used to form a wide range of curved surfaces, including car and truck body panels and other types of automotive body work.
Applications
A Beam Roll Forming Machine is an industrial machine that Beam Roll Forming Machine bends and forms metals using a series of rolled sheets or strips. The process can be used to produce a variety of shapes including rectangular, curved and circular ones.
Often, a Beam Roll Forming Machine is designed to create large-sized structures such as rails and bridges. It can also be used to create small-sized parts such as brackets and handles.
The type of metal that is used can be the determining factor in what type of shape a Beam Roll Forming Machine produces. This is because different metals have different yield points, ductility and thickness. These factors can affect the forming stages and the amount of force required to form a certain part.
This is why it is important to choose a quality Beam Roll Forming Machine that will be able to handle the material being used. This will ensure that the product produced is of high quality and will last for a long period of time.
Another way to reduce the cost of a Beam Roll Forming Machine is to use software applications that can simulate the roll forming process before it actually happens. This will help the manufacturer avoid mistakes or flaws that could be caused by human error.
One of the most popular ways to do this is by using a computer-aided design (CAD) program. CAD can be used to create complex designs with multiple component parts. It can also be used to test the appropriateness of a particular metal for a project without the need for production runs or prototypes.
CAD can also be used to generate flower patterns that are created from a series of incremental bending operations. This helps minimize strain localization and compensate for springback during the bending process.
A Beam Roll Forming Machine can also be used to form welded profiles, which are formed by joining materials that have similar melting points and compositions together. This is a process that is growing in popularity and can be used to make a wide range of products including rails, stairs, and ladders.
Benefits
The Beam Roll Forming Machine is one of the most versatile and efficient forms of metal forming. Its ability to shape metals with complex cross sections and dimensional tolerances makes it an ideal choice for a variety of applications from aerospace to construction.
The process is highly flexible, allowing a single set of tools to produce almost any length of the same cross-section. This allows a large variety of product sizes to be produced in an economical manner.
Another benefit of roll forming is the ability to produce a wide range of shapes and angles. This can be useful in a number of applications, including tubing and structural components.
It is also a very cost-effective way to produce high-quality components with very tight radii. This makes it a great choice for tubing and other thin-walled, lightweight products.
Unlike other bending processes, which often use a die to shape the end piece, roll forming uses two or three rollers to elongate and deform the material. This produces a curved surface without the need for dies and can be done with many different types of materials.
Other benefits of the process include the ability to produce complex parts and a low amount of scrap, which lowers production costs. This is a major advantage for industries that produce high-quality, expensive parts.
A variety of lubricants are used in the roll forming process, including fluids with very low viscosity that can reduce tool wear and extend tool life. This allows the machine to run faster, which in turn increases output.
The forming process is also extremely efficient and reduces energy costs. This is because the coils of metal are fed rapidly into the forming machine. This reduces the need for monitoring and human interaction.
The forming process is also efficient because it can be run in-line with other operations such as punching, notching, and welding. This reduces labor costs and eliminates secondary operations, reducing the cost of producing a part.
Costs
Roll forming is a process of bending long metal strips into desired shapes. The strip is passed through a series of rolls where each set of fixed rollers gradually bends the metal until it reaches the ideal cross-section profile. This progressive method of bending minimizes the risk of breakage and produces a high-quality, consistent end product.
This bending process can be used to shape nearly any type of metal, from ferrous to non-ferrous. It can also be integrated with secondary processes to maximize production efficiency.
The type of metals used in the bending process determines the resulting strength and stiffness of the finished product. It is also important to know the yield point, a temperature at which the metal is malleable. The amount of force required Beam Roll Forming Machine to achieve a specific bend can vary depending on the yield point and thickness of the material.
In general, the more ductility a metal has, the less force is needed to form it. This allows for greater flexibility in forming shapes, especially complex profiles.
A Beam Roll Forming Machine is a mechanical device that is used to form metal beams. Beams are typically made from steel, but can be made from other materials as well.
Beams are often used in construction and in the transportation industry, including highway guardrails. Brother Union Machinery manufactures a range of beam forming machines that can be customized according to the customers’ needs.
These machines can be used to produce a wide range of rolled formed shapes, including angle and box beams. A variety of metals are used in this process, including steel, aluminum, and stainless steel.
The cost of Beam Roll Forming Machines varies depending on the size of the equipment, its design and the types of materials being used in the production. A small-scale Beam Roll Forming Machine costs around $15,000, while larger models can be several hundred thousand dollars.
If you have a high volume of parts, it may be more economical to outsource your bending work to a contract roll former. This can increase your profit margins and reduce stress levels.