Roll forming

Roll forming is ideal for producing constant-profile parts with long lengths and in large quantities.

Roll formed parts may be much lighter, with thinner walls possible than in the extrusion process, and stronger, having been work hardened in a cold state.

Variations in size are achieved by making the distances between the rolls variable by manual adjustment or computerized controls, allowing for rapid changeover.

These specialized mills are prevalent in the light gauge framing industry where metal studs and tracks of standardized profiles and thicknesses are used.

For example, a single mill may be able to produce metal studs of different web (e.g. 3-5/8" to 14 inches), flange (e.g. 1-3/8" to 2-1/2") and lip (e.g. 3/8" to 5/8") dimensions, from different gauges (e.g. 20 to 12 GA) of galvanized steel sheet.

Roll forming lines can be set up with multiple configurations to punch and cut off parts in a continuous operation.

The production rate depends greatly on the material thickness and the bend radius; it is however also affected by the number of required stations or steps.

[3] In general, roll forming lines can run from 5 to 500 feet per minute (1.5 to 152.4 m/min) or higher, depending on the application.

The main hazards that need to be taken into consideration are dealing with moving work-pieces (up to 800 feet per minute (240 m/min)), high pressure rolls, or sharp, sheared metal edges.