Benefits of a Small Roll Forming Machine
Roll forming allows the shape of components to be maintained throughout a piece. This eliminates secondary processes and saves time and money for manufacturers.
While each manufacturer has a slightly different process, they all follow similar steps. These steps include overall bending, row-roll forming cluster hollow bending, and FFX forming.
Increased Efficiency
Roll forming is the fastest way to produce metal components. It’s a process that offers high consistency from part to part. It’s also an extremely versatile method that can form a variety of cross-section profiles. In contrast, other processes like bending and extruding often require additional processing to get the desired result, which adds time to the overall production cycle.
During the profile design phase, engineers can use CAD or CAM tools to simulate new geometries for the tooling. This small roll forming machine helps them ensure that the rollers will exert the correct amount of pressure and shape force on the material. It’s this precision that gives the manufacturing process its reliability and repeatability.
As a result, it’s possible to achieve shift OEE of 100%, meaning that the machine runs for an entire shift without any downtime and at the maximum machine speed. This is an impressive achievement that demonstrates the productivity benefits of using a small roll forming machine.
One of the key reasons that a small roll forming line can achieve such impressive OEE is through automated calibrations. Typically, each station in the process is set up to produce a specific geometry. This is done by positioning the upper and lower set of tools in a “raft” that’s easily swapped out when the job changeover occurs. This technology allows a single operator to perform what used to take a team of workers several hours to complete.
Lower Production Costs
The increased efficiency of a small roll forming machine allows it to process metal at a much quicker rate than manual operations. This results in fewer waste products and lower overall production costs. Additionally, the quality of the finished product is typically superior to those produced by manually-operated machines. This higher quality can result in reduced repair and replacement costs.
The shortened production time also allows for more parts to be produced in a shorter amount of time. This means that companies can save on labor costs and materials cost as well.
Another way that a small roll forming machine can reduce production costs is through its ability to eliminate the need for secondary processes. For example, the pre-feeding of metals for punching and notching can be done during the rolling process itself, reducing the need for a separate operation. The lubrication of components during the rolling process can also reduce tool wear and panel roll forming machine thus decreases the need for expensive replacements. The precision with which the parts can be formed also helps to reduce the need for machining and finishing.
In addition, the integrated cut-off systems that some small roll forming machines can produce can eliminate the need for separate cutting operations and thereby save on the labor costs associated with them. However, it is important to remember that the addition of these features will typically increase the price of the machine itself.
Lower Maintenance Costs
A small roll forming machine reduces maintenance costs by eliminating the need for a skilled operator, saving money on wages, insurance, and other expenses. It also eliminates the need for secondary operations like punching and notching, which reduces labor and energy costs. Finally, the self-feeding system eliminates waste and scrap, further lowering manufacturing costs.
The initial cost of a rollforming machine may seem high, but it should be evaluated in relation to the production goals and specifications that the business needs to meet. The number of roll stands, complexity of tooling, and the size and design of the machine influence the price. In addition, the business should establish a budget and review its current financial situation to determine whether this equipment is within its capabilities.
After purchasing the equipment, the business should consult its supplier for documentation and technical specifications that help in establishing appropriate maintenance procedures. This helps to ensure the safety and reliability of the machine. The supplier can also help with identifying essential spare parts and setting up an inventory management system to reduce downtime in the event of a breakdown or component failure. Proper lubrication and cleaning reduces wear and tear, cutting down on downtime and improving part quality. Worker training is also important to prevent injuries. These machines contain many heavy components moving at high speeds, and proper procedures must be followed to ensure the safety of workers.
Greater Customization
Roll forming is more flexible than other production processes when it comes to part geometry. In fact, it allows for the creation of shapes such as helixes that may be impossible to make with any other method. This flexibility can also reduce the need for secondary machining or welding steps in some applications.
In addition to flexibility, some small roll forming machines can be equipped with various features that allow for greater customization of products. These can include additional punching and notching capabilities, specific profile dimensions, and embossing units for branding or aesthetics. Some machines can even be built with integrated packing systems to streamline the shipping and handling of finished products.
Lastly, some smaller roll forming machines can be equipped with quick change dies to help reduce changeover times. With these, experienced professionals can switch from one profile to another in as little as 30 to 45 minutes — a significant improvement over the days or hours it could take with a pre-cut line.
Choosing the right roll forming machine can have a significant impact on the overall cost of operations. It’s important to choose a supplier that offers comprehensive maintenance programs, training for new and experienced operators, and ongoing support services. These can help minimize downtime, increase equipment efficiency, and reduce the need for costly repairs and replacements.
