The process of roll forming uses successive sets of roller dies to bend a strip of steel progressively until the desired shape is achieved. However, roll forming has many functions instead of just bending the metal, it also lends itself well to prepunching, midpiercing, and postpunching all inline, as well as sweeping before cutoff.
Roll forming is a complex but versatile process that allows design innovation. Setting up a roll forming line requires the expertise of a skilled roll form designer and cooperation between the vendor and manufacturer in developing a successful product. But with the right preparation and special software simulation, the transition can be painless. Sophisticated rollformers are made and equipped to change from one product to another without any downtime.
Carefully choosing the proper roll forming equipment, skillfully designing the product and tooling, properly training the operators, and adequately maintaining the production line make roll forming easier. Additional methods such as hemming, slitting, filing, grinding, squashing, and embossing can make the edges less hazardous to the workers.