The rolls in roll forming equipment are a crucial component. Their design and manufacturing features include: even force distribution across all passes to ensure balanced wear and extend roll life. Rolls are typically made of C12MoV material due to its excellent wear resistance; however, the balance between hardness and strength must be carefully considered.
The upper and lower rolls, or cross rollers, should be effectively protected by confinement. Otherwise, problems may arise during use. For example, the guide rails may exhibit blurred tracks, deformation, and uneven force distribution, further shortening their lifespan. Roll forming equipment must consider rolling stability during the rolling process.
If the material wobbles laterally in the roller track, appropriate measures must be taken. For instance, during assembly, the gaps between different areas of the rollers can be kept consistent. Furthermore, a guide bevel can be installed before the material is engaged to prevent this problem. If bending or twisting occurs during production, the main cause is unbalanced force distribution. Therefore, the design should ensure balanced force distribution for accurate processing. A fundamental principle of roll forming equipment is that the strip bends longitudinally in a straight line. However, the pressure generated during bending deformation, combined with residual stress in the strip, often causes the strip to deviate from the equipment. To address this issue, a straightening mechanism should be used at the end of the roll forming equipment.
The basic principle of the straightening mechanism is that for profiles with defects such as lateral bending or warping, sufficient pressure is applied in the opposite direction to induce deformation. If the deformation in the opposite direction is appropriate, the profile can be fully straightened after springback. If the formed profile has undergone torsional deformation in a certain direction, the straightening mechanism sequentially rotates the profile in the opposite direction, thereby producing plastic deformation. If the rotation angle is appropriate, the profile will no longer twist after springback.