Cold roll forming for industrial production

PM Forming machines are characterized by the specialized and hyper-technological processing of profiles. These machines are also created to guarantee a complex product in large quantities, and above all customized.

We have studied and innovated the cold method to apply it to the roll forming machines that we create in PM Forming. In this way, our machines already provide "upstream" the possibility of integrating ancillary processes in line to obtain a completely tailor-made profile, without having to implement further steps.

In our production system continuity and progressiveness are the guidelines that respectively allow speed and quality in construction. This is why we ensure extremely durable, resistant, highly specialized and technologically advanced machines.

What is the cold roll forming?

It is a process in which the sheet metal, usually coil-shaped, is bent at room temperature, without using heat, until the desired form is reached. This ‘bending’ process is carried out continuously and on a large scale to form different sections of profiles. The advantage is to produce a large number of customized metal profiles with processing times and costs significantly lower than the standard ones.

Our numbers

Workable Thicknesses

From 0,2 to 12 mm

Coil Dimensions

min 600 / max 2.000 mm

Max working Speed

20 ÷ 150 m/min

Profile Lengths

200 ÷ 14.000 mm

PROCESS STAGES FROM A TO...I

A • Decoiling

This is the first part of the cold roll forming process in which the coil is smoothed and prepared for the next step.

B • Straightening

This step allows the sheet to arrive at the pre-cutting area as flat as possible.

C • Pre-cutting

Before the strip enters the progressive roll forming stations, it is pre-punched and pre-cut as required in a continuous manner, without slowing down the system.

D • Roll Forming

The sheet metal strip passes continuously between suitably shaped pairs of rolls which give the profile its shape. With each step it gradually begins to take shape, until it reaches its desired form. The roll forming process also allows the processing of pre-painted and pre-galvanised material, saving additional time in subsequent processing stages.

E • Welding

Here we are at the heart of the process: by means of seam welding we obtain closed, resistant profiles, also with high levels of precision (thanks to the use of laser fibre welding machines) where other tools fail.

F • Straightening - calander heads

Installed immediately after the roll forming machine, they adjust the profile precisely and allow corrections to be made. They have an all-metal structure on which the straightening rolls are installed. As an alternative it is possible, in continuity with the cold roll forming process, to insert final bending and straightening processes to give the product variable and programmable bends.

G • Cutting-off

It is only after the roll forming that the separation into cut-to-length pieces takes place by means of flying cut-off units. This is possible as the cold forming process deforms the sheet without deteriorating the condition of the source material.

H • Additional processing

At this stage we carry out any additional processes on the profile or the robotic insertion of auxiliary components to complete it. In this way we obtain a finished product without the need for subsequent re-works.

I • Unloading

The final stage is the unloading process, which can be done either manually, robotically or semi-automatically.

Integration of special machines and equipment

Cold roll forming is a complete but standard process. Within PM Forming lines we can integrate machines and special equipment to add value while maintaining a continuous process:

Levellers • Shot blasting machines • Foaming machines • Washing machines • Assembling machines • Riveting machines • Spot welding machines • Painting plants • Skinpass • Vision systems for geometric control and piece measurement

ADVANTAGES OF COLD ROLL FORMING PROCESS

01

Profiles of various sections, open or closed, are obtained.

02

Production is quick, high quality yet at low cost.

03

The management is numerically controlled and highly automated.

04

The rolls are designed with extreme precision by PM engineers.

05

Integrating auxiliary processes is possible.

06

The design of the entire line is tailor made.

Do you need an industrial partner for your roll forming machines?
Contact us for a consultation!

Speak with one of our experts, together we find the best suited solution for the needs of your company.

Contact PM Forming