When factory manufacturers need to continuously bend a long strip of metal, typically coiled steel, they need a rollform equipment to perform this task. This procedure is called rollforming whereby coiled steel is passed through consecutive sets of rolls, or stands, each performing only an incremental part of the bend, until the desired cross-section profile is obtained. Rollforming is ideal for producing parts with long lengths or in large quantities.
A metal forming machine can be complex because each profile requires a carefully crafted set of roll-tools. Because of the high cost of the roll sets, simulation using the Corpra FEA software is often used to validate the designed rolls and optimize the forming process to minimize the number of stands and material stresses in the final product.
Sophisticated duplex rollformer can even change from one product to the next on a rollforming line without any downtime. All it takes is a touch of a button for the inboard and outboard portions of the mill glide towards or away from each other. These mills can be designed to have the inboard side of the mill in a fixed inboard position and the outboard side doing the gliding; or it can be centerline-compatible as seen in most of the steel stud and track lines used in the steel framing industry.