devchand had a similar problem: http://cr4.globalspec.com/thread/77969/Problem-of-Wrinkle-Formation See the comments given him/her

I'm not a roll-forming expert, but I suspect you are trying to get too much deformation in one stand.

compare the clearance between the male/female swage against the roller clearance.

Dear Friend,

• I understand that all the 24Nos. of grooves are formed simultaneousy. If this is the case, there is restriction of flow / elongation of metal while forming metal to shape and results into wrinkles. It would help trying one , two, three groves at a time and see result.
• Use of Deep Drawing / Extra Deep Drawing quality of steel will hepl further.
• Hope, sharp corners are avoided, by providing radius at corners.

N N Shah

Baroda(India)

does the swaging process reduce the thickness of the metal;? i would think so.

nope thickness of the metal does not change

For cold forming you need to account for the elastic behaviour (so as for the plastic) of the material, and together with that, be sure to press the sides with the appropiate pressure, in case you only see wrinkles there. For further help, please send your grooves and rolling conditions to us at, javier@atecid.com

Could you please make a sketch of the groves ? Or a picture to show a bit more specific information? The more we have as input the more chances to give a good answer.