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Active Contributor

Join Date: Jan 2010
Posts: 18

Cold Roll Forming

05/18/2012 4:43 AM

Hello Everyone.

I have a cold roll forming machine, The width of material is 530 mm with thickness on 1.2 mm mild steel and hardness of around 180 BHN. The finished size required is 520 mm. 24 nos of 6.5 mm depth groves have to be formed. We have a hydraulic arrangement to push the roller vertically down. The diameter of rollers is 252 mm made of OHNS material hardened to 32 HRC. Hydraulic pressure can go upto 150 Tons. The distance between male and female groves is 1.6 mm. Both the male and female rollers have been checked for run out and even high spots have been take care of.

The problem is, when we roll the material we are unable to get the desired depth and also there is a wrinkle formation is the sideways collar of the material.

We would like to get some solution for this problem.

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Guru

Join Date: Jun 2010
Posts: 1296
Good Answers: 104
#1

Re: Cold Roll Forming

05/18/2012 8:12 AM

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.

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Guru

Join Date: Jan 2011
Posts: 668
Good Answers: 3
#2

Re: Cold Roll Forming

05/18/2012 9:54 PM

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

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Participant

Join Date: May 2012
Posts: 4
#3

Re: Cold Roll Forming

05/19/2012 1:52 AM

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)

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Guru

Join Date: Jan 2011
Posts: 668
Good Answers: 3
#4
In reply to #3

Re: Cold Roll Forming

05/19/2012 2:13 AM

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

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Active Contributor

Join Date: Jan 2010
Posts: 18
#5
In reply to #4

Re: Cold Roll Forming

05/19/2012 2:37 AM

nope thickness of the metal does not change

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Associate

Join Date: Feb 2010
Location: Spain
Posts: 33
#6

Re: Cold Roll Forming

05/20/2012 12:43 PM

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

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Guru

Join Date: Mar 2007
Location: City of Light
Posts: 3943
Good Answers: 183
#7

Re: Cold Roll Forming

06/17/2012 3:35 PM

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.

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