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ROLL FORMING HANDBOOK

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: Non-driven 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
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Copyright © 1997 Delta Engineering Inc.
Last modified: January 05, 2006