Roll forming also has other advantages over braking and extruding. Compared to brake forming, roll forming can produce more parts with greater uniformity and consistency throughout the length of the part. Roll forming also eliminates multiple stage operations, trim scrap, and slitting burrs.
Advantages of roll forming relative to extrusion methods include: practically all metals can be roll formed, not just aluminum. Also, roll forming can eliminate secondary operations – multiple stage operations such as notching, punching, and post-painting – by combining them in the roll forming process.
Prepainted steel can be substituted for post-painting methods and the metal can be perforated prior to roll forming or, if the hole pattern is close to the beginning or end of the part, the formed part can be perforated in the cut-off die. The ability to fabricate decorative parts from precoated, prepainted, or pre-plated metal is a distinct feature of roll forming.Samson Roll Formed Products Company is one of the oldest and largest contract roll formers in the U.S., located in Chicago in a large industrial facility that houses 40 roll forming lines and an array of ancillary equipment. Stamping, bending, parting, and assembly are some of the other services in Samson’s arsenal of value-added options. Samson has stock tooling for more than 2,000 shapes, many of which are featured at other roll-formed shapes.
Samson Roll Formed Products Company provides our customers with distinct advantages of roll forming.
Two distinct parts can be run together to form one assembly.
Two different materials can be formed simultaneously to produce a clad shape in one operation.
Efficiency Roll forming is an energy efficient process usually requiring no process heat to be added.
Forming can produce superior surface finishes. Sharp, clean contours can be maintained. The absence of die marks on the material often eliminates the need for additional finishing.
Hole and Slot
Patterns Pre-punching in-line allows holes or slots that cannot be done as a secondary operation because of their location or features of the part to be included in the shape.
Hollow or semi-hollow shapes can be produced with thinner walls than are possible by competing processes.
Almost unlimited lengths can be roll formed. The only limitations are due to material handling equipment, space constraints, and shipping capabilities.
Almost any bendable material can be roll formed.
The high speed, continuous nature of roll forming lends itself to economic production of large volumes of parts.
Many additional operations, such as punching, notching, welding and bending, that otherwise would have to be performed as secondary operations can be incorporated into the roll forming process, thus reducing handling and processing costs. Even labels giving installation instructions can be applied to the shape as an in-line process.
Roll formed materials generally have a strength advantage over competing processes in structural rigidity applications.
Roll forming can achieve closer tolerances than are possible with most competing processes.
The same tooling can be used to roll a shape out of different materials.
Roll forming produces symmetrical parts with uniform dimensions that assure precision fits, simplify production, and that speed assembly and minimize rejects.