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We are pleased to announce that the

ROLL FORMING HANDBOOK

 

edited by George Halmos

                published by Taylor & Francis Group is now available

The link to the publisher’s, CRC Web site is

 http://www.crcpress.com/shopping_cart/products/product_detail.asp?sku=DK1201

 For more details on the website please click on the “Contents” tab

CONTENTS:

INTRODUCTION TO ROLL FORMING; George T. Halmos

Introduction to Roll Forming

ROLL FORMING MILL; George T. Halmos

General

Mill Types

Mill Components

References

PRESSES AND DIE ACCELERATORS; George T. Halmos

General

Mechanical Presses

Pneumatic Presses

Hydraulic Presses

Information and Dimensions for

Press/Die Purchasing and

Installation

Rotary and Other Cutting,

Punching Equipment

Flying Die Accelerators

SECONDARY OPERATIONS IN THE ROLL FORMING LINE; George T. Halmos

Secondary Operations

Straightening

Tight or Loose Line: Cutting

Before, In-Between, or After

Roll Forming

Location of the Secondary

Operations

Stationary and Flying Dies

Punching, Perforating, Notching,

and Mitering

Piercing and Partial Punching

Flanging, Louvering, and Lancing

Embossing and Drawing

Bending

Curving (Sweeping)

Marking

Swedging (Off Setting)

Rotary Dies

Mechanical Joining of Different

Strips or Parts

Adhesive Bonding

Soldering and Brazing

Resistance Welding

Painting

Foaming

Packaging

References

ROLL DESIGN; George T. Halmos

Roll Design Process

Cross-Section

Product Orientation and Other

Operations in the Line

Materials

Roll Forming Mill

Other Tool Design

Considerations

Spacers and Shims

Calculating Strip Width

Bend Lines

Number of Passes

Flower Diagram

Roll Design

Calculating Roll Dimensions

Manually

Computer-Aided Roll Design

Examples

Roll Marking System

Roll Orientation

Setup Charts

References

MATERIALS; George T. Halmos

Design Considerations

Mechanical Properties

Crystalline Structure of Metals

Forming Metals

Increasing the Strength of Metals

by Cold Working

Hot Rolling

H.R. and H.R.P.O. Steels

Cold Rolled Steel

Carbon Steel

Alloyed Steel

Stainless Steel

Metallic Coatings

Nonmetallic Coating and

Laminating

Joining Different Materials in the

Roll Forming Process

Aluminum

Other Metals and Materials

Influence of Primary Metal

Processes on Roll Forming

Guideline to Steel Prices

References

LUBRICATION; Joseph Ivaska

Tribology of Lubrication

Selection of Lubricants

Surface Properties of Formed

Material

Lubricants for the Secondary

Operations

Application Techniques

Preparation and Maintenance of

Lubricants

Operating Problems during

Production

COIL PROCESSING, MATERIAL HANDLING, AND PLANT LAYOUT; George T. Halmos and Joseph Horvath

Flow of Material

Coil Handling and Storage

Sheet Handling and Storage

In-Line Coil Handling

Coil End Welding

Strip (Coil) Accumulators

Flattening and Leveling

In-Line Sheet Handling

Finished Product Handling

Finished Product Storage

Material Handling Equipment

Material Handling Accessories

Crane Controls

Plant Layout

References

DESIGNING PRODUCTS FOR ROLL FORMING; George T. Halmos

Developing Light Gage Products

Design Considerations

Secondary Operations

Profiles Manufactured in Different Sizes

Design of Specific Products

Dimensioning and Tolerancing

References

EQUIPMENT INSTALLATION, ROLL SETUP, MAINTENANCE, AND TROUBLESHOOTING; George T. Halmos

Installation of Roll Forming Lines

Roll Installation and Setup

Maintenance and Spare Parts

Troubleshooting and Trouble Prevention

BEHAVIOR OF METAL STRIP DURING ROLL FORMING; Manabu Kiuchi

Various Types of Deformations

Causes of Redundant Deformations

Effects of Redundant Deformations on

Product Defects

Mathematical Simulation of the Deformation

of a Metal Strip

Computerized Design System for Roll

Profiles

CAE for Roll Forming

ACQUIRING ROLL FORMING LINES, EDUCATION, AND TRAINING; George T. Halmos

Why Roll Form Products?

Different Paths to Start Roll Forming

Evaluating the Product

Selecting Line Components

Procuring Roll Forming Tooling

Equipment and Tool Specifications

Acceptance Test

Education and Training

Motivation

References

SAFETY; Ashok Shah

Safety

Common Safety-Related Definitions

Safety Design Procedure

Determining Limits of the Machinery or

System

Determining Hazards/Risk Estimation

Risk Reduction by Design

Safeguarding

Selection of Guards and Protective Devices

Required Characteristics of Guards and

Protection Devices

Signals and Warning Devices

Personal Protective Equipment

Training

Summary

References

INCREASING EFFICIENCY OF ROLL FORMING LINES AND CASE STUDIES; George T. Halmos

Output, Productivity, and Efficiency

Line Utilization

Improving Productivity

Case Studies

Preliminary Tool and Equipment Cost

Analysis

Preliminary Cost Analysis

UNUSUAL, NEW, AND FUTURE ROLL FORMING TECHNOLOGIES; George T. Halmos

The Last 100 Years

The Future of Roll Forming

Pull-Through Mills: Nondriven Rolls

Tension Roll Forming

Combining Roll Forming and Cold Drawing

Developing New Roll Forming Methods

Roll Forming Tools

Reducing the Thickness of the Starting

Material

Forming at Elevated Temperature

Hot Roll Forming Variable Cross-Sections

Hot Thickness Reduction along the Length

of the Strip

Welding Hot Roll Formed Sections

Other “Hot” Processes

In-Line Soldering, Brazing, and Heat Treating

Equipment and Tooling Requirements for

Hot Roll Forming

Press Tooling for Conventional Roll Forming

Lines

Computer-Controlled Roll Forming Lines

References

APPENDICES

REFERENCES

INDEX

The book contains about 584 pages

 

        (For in-house roll forming training courses see home page)

 Factors for roll forming success

There's a lot to know about roll forming. That's why the Fabricators & Manufacturers Association, International (FMA), developed this Roll Forming Tutorial with one of the most experienced professionals in the industry, George Halmos.

Spend two days under his tutelage and you'll come away with a comprehensive understanding of current roll forming practices and technology. Learn how factors such as product design, equipment selection, materials, troubleshooting, and managerial concepts play a critical role in the success for your roll forming operation.

 
About your instructor

George T. Halmos, P. E. President, Delta Engineering  Inc. Toronto, Ontario, Canada

As president of Delta Engineering, George Halmos' responsibilities include supplying equipment and tooling, consulting, product design, feasibility and cost reduction studies, computer-aided roll design, and conducting roll former operator training courses. He has more than 50 years of experience in the roll forming industry and has authored nearly 40 technical papers on the subject, including numerous articles for The FABRICATOR® magazine.

Halmos has performed research on the formability of metals, taught at the university level, and has spoken at dozens of FMA conferences.

Who should attend?

Production personnel

Product designers

Equipment purchasers

Engineering staff

Tool engineers

Foremen

Production managers

 About your sponsor

The Fabricators & Manufacturers Association, International (FMA), is the leading educational association serving the metal forming and fabricating industry FMA's primary mission is to present the latest metal fabricating technology through technical conferences, expositions such as FABTECH® International, and publications like The FABRICATO~. Other services include industry wage surveys, networking opportunities, and much more. To begin your FMA membership benefits-starting with a discount to attend this conference-simply mark the box on the registration form inside. To receive additional membership information, call FMA customer service at 815399-8775.
Introduction to Roll Forming
  • Definition of roll forming
  • Typical roll formed products
  • Basic requirements for a successful roll forming operation

Product Design

  • Small and large bending radii Influence of the width of flat sections
  • Influence of roll forming technology on product design
  • Drawings, communication between engineering and manufacturing
  • Product tolerances-length, dimensions, angles, surface appearance, and deviations from straightness and flatness

Materials

  • How mechanical properties, thickness, width, and surface characteristics influence the roll forming process
  • Problems with steel, stainless steel, aluminum, prepainted, and other metals

Line Components and selecting Equipment

  • Coil handling cars, uncoilers
  • Flatteners and feeders
  • Prepunching, prenotching, precutting, postcutting
  • Mill drives and auxiliary components Different types of mills
  • Presses-mechanical, pneumatic, and hydraulic
  • Dies-prepunch, prenotch, rotary, cutoff
  • Other operations in roll forming lines
  • Lubrication
    •

Roll Design

  • Flow of material through the mill
  • Selecting the number of passes
  • Influencing factors on springback, flare, and waviness
  • Section orientation
  • Constant arc and constant radii design
  • Computerized roll design
  • Roll setup procedure
 Troubleshooting
  • How to determine the primary cause of troubles
  • How to troubleshoot material, equipment, tool, and operator problems

Managerial Concepts

  • Calculating production requirements
  • Increasing productivity
  • Material handling and efficient plant layout
  • Roll forming line maintenance
  • Educating personnel at all levels

Roll Forming in the 21st Century

  • Motorized, computer controlled mills
  • Faster lines and presses
  • Improved tolerances
  • Roll forming variable cross sections
  • Hot roll forming
  • Automated tolerance control

Q & A Session:

Your Questions Answered

During the course, our expert will devote time to answering your specific questions. Simply fax your question, problem, or idea to  Kathy Lederhause, FMA education coordinators, at 815-399-7279 prior to the course. Be sure to include your name and the date of the course you plan to attend, and George Halmos will respond to your question at your conference. Bring samples, drawings, your roll forming problems to the tutorial.

Registration and Information

By Mail:          FMA Customer Service Department, P.O. Box 388309, Chicago, Il 606638-8309

By Fax:            FMA, 815-399-7679

By Phone:       FMA, 815-399-8775

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Last modified: January 04, 2006