احبتى فى الله معى اليوم كتاب
Roll Forming Handbook
Contents
1 Introduction to Roll Forming George T. Halmos ........................................................................1-1
1.1 Introduction to Roll Forming .....................................................................................................1-1
2 Roll Forming Mill George T. Halmos ............................................................................................... 2-1
2.1 General .........................................................................................................................................2-1
2.2 Mill Types .....................................................................................................................................2-1
2.3 Mill Components .......................................................................................................................2-18
References ................................................................................................................................................2-32
3 Presses and Die Accelerators George T. Halmos ........................................................................... 3-1
3.1 General .........................................................................................................................................3-1
3.2 Mechanical Presses .......................................................................................................................3-6
3.3 Pneumatic Presses ......................................................................................................................3-10
3.4 Hydraulic Presses ........................................................................................................................3-12
3.5 Information and Dimensions for Press/Die Purchasing and Installation .............................3-15
3.6 Rotary and Other Cutting, Punching Equipment ...................................................................3-15
3.7 Flying Die Accelerators ..............................................................................................................3-20
4 Secondary Operations in the Roll Forming Line George T. Halmos ....................................4-1
4.1 Secondary Operations ..................................................................................................................4-2
4.2 Straightening ................................................................................................................................4-3
4.3 Tight or Loose Line: Cutting Before, In-Between, or After Roll Forming ..............................4-9
4.4 Location of the Secondary Operations ..................................................................................... 4-14
4.5 Stationary and Flying Dies ........................................................................................................4-14
4.6 Punching, Perforating, Notching, and Mitering .....................................................................4-16
4.7 Piercing and Partial Punching ..................................................................................................4-19
4.8 Flanging, Louvering, and Lancing ............................................................................................ 4-20
4.9 Embossing and Drawing ............................................................................................................4-20
4.10 Bending ......................................................................................................................................4-22
4.11 Curving (Sweeping) ...................................................................................................................4-24
4.12 Marking ......................................................................................................................................4-46
4.13 Swedging (Off Setting) ...............................................................................................................4-46
4.14 Rotary Dies ........................................................................................4.15 Mechanical Joining of Different Strips or Parts ......................................................................4-56
4.16 Adhesive Bonding .......................................................................................................................4-60
4.17 Soldering and Brazing ................................................................................................................4-60
4.18 Resistance Welding .....................................................................................................................4-60
4.19 Painting ......................................................................................................................................4-62
4.20 Foaming .....................................................................................................................................4-62
4.21 Packaging ...................................................................................................................................4-62
References ................................................................................................................................................4-62
5 Roll Design George T. Halmos ............................................................................................................5-1
5.1 Roll Design Process ......................................................................................................................5-2
5.2 Cross-Section ...............................................................................................................................5-4
5.3 Product Orientation and Other Operations in the Line ........................................................5-13
5.4 Materials .....................................................................................................................................5-19
5.5 Roll Forming Mill ......................................................................................................................5-28
5.6 Other Tool Design Considerations ........................................................................................... 5-40
5.7 Spacers and Shims ......................................................................................................................5-48
5.8 Calculating Strip Width .............................................................................................................5-52
5.9 Bend Lines ..................................................................................................................................5-55
5.10 Number of Passes .......................................................................................................................5-64
5.11 Flower Diagram ..........................................................................................................................5-73
5.12 Roll Design .................................................................................................................................5-78
5.13 Calculating Roll Dimensions Manually ....................................................................................5-94
5.14 Computer-Aided Roll Design ....................................................................................................5-95
5.15 Examples ..................................................................................................................................5-100
5.16 Roll Marking System ................................................................................................................5-103
5.17 Roll Orientation .......................................................................................................................5-107
5.18 Setup Charts .............................................................................................................................5-107
References ..............................................................................................................................................5-111
6 Materials George T. Halmos ................................................................................................................6-1
6.1 Design Considerations .................................................................................................................6-1
6.2 Mechanical Properties ..................................................................................................................6-2
6.3 Crystalline Structure of Metals ...................................................................................................6-7
6.4 Forming Metals ............................................................................................................................6-7
6.5 Increasing the Strength of Metals by Cold Working ...............................................................6-10
6.6 Hot Rolling ................................................................................................................................6-10
6.7 H.R. and H.R.P.O. Steels ...........................................................................................................6-12
6.8 Cold Rolled Steel ........................................................................................................................6-12
6.9 Carbon Steel ...............................................................................................................................6-12
6.10 Alloyed Steel ...............................................................................................................................6-13
6.11 Stainless Steel ..............................................................................................................................6-15
6.12 Metallic Coatings ........................................................................................................................6-16
6.13 Nonmetallic Coating and Laminating ...................................................................................... 6-17
6.14 Joining Different Materials in the Roll Forming Process .......................................................6-18
6.15 Aluminum ..................................................................................................................................6-18
6.16 Other Metals and Materials .......................................................................................................6-20
x........................................4-466.17 Influence of Primary Metal Processes on Roll Forming .........................................................6-20
6.18 Guideline to Steel Prices ............................................................................................................6-24
References ................................................................................................................................................6-24
7 Lubrication Joseph Ivaska ...................................................................................................................7-1
7.1 Tribology of Lubrication ..............................................................................................................7-1
7.2 Selection of Lubricants ................................................................................................................7-5
7.3 Surface Properties of Formed Material ...................................................................................... 7-8
7.4 Lubricants for the Secondary Operations ................................................................................ 7-10
7.5 Application Techniques ..............................................................................................................7-11
7.6 Preparation and Maintenance of Lubricants ........................................................................... 7-12
7.7 Operating Problems during Production .................................................................................. 7-18
8 Coil Processing, Material Handling, and Plant Layout
George T. Halmos and Joseph Horvath .....................................................................................................8-1
8.1 Flow of Material ...........................................................................................................................8-2
8.2 Coil Handling and Storage ..........................................................................................................8-3
8.3 Sheet Handling and Storage ........................................................................................................8-6
8.4 In-Line Coil Handling .................................................................................................................8-9
8.5 Coil End Welding .......................................................................................................................8-14
8.6 Strip (Coil) Accumulators .........................................................................................................8-16
8.7 Flattening and Leveling ..............................................................................................................8-19
8.8 In-Line Sheet Handling .............................................................................................................8-22
8.9 Finished Product Handling .......................................................................................................8-23
8.10 Finished Product Storage ...........................................................................................................8-31
8.11 Material Handling Equipment ..................................................................................................8-34
8.12 Material Handling Accessories ..................................................................................................8-38
8.13 Crane Controls ...........................................................................................................................8-40
8.14 Plant Layout ...............................................................................................................................8-41
References ................................................................................................................................................8-43
9 Designing Products for Roll Forming George T. Halmos .........................................................9-1
9.1 Developing Light Gage Products ................................................................................................ 9-1
9.2 Design Considerations .................................................................................................................9-2
9.3 Secondary Operations ................................................................................................................9-10
9.4 Profiles Manufactured in Different Sizes .................................................................................. 9-20
9.5 Design of Specific Products .......................................................................................................9-22
9.6 Dimensioning and Tolerancing .................................................................................................9-22
References ................................................................................................................................................9-29
10 Equipment Installation, Roll Setup, Maintenance, and Troubleshooting
George T. Halmos ....................................................................................................................................10-1
10.1 Installation of Roll Forming Lines ............................................................................................ 10-1
10.2 Roll Installation and Setup ........................................................................................................10-8
10.3 Maintenance and Spare Parts ..................................................................................................10-14
10.4 Troubleshooting and Trouble Prevention ..............................................................................10-3211 Behavior of Metal Strip during Roll Forming Manabu Kiuchi ...........................................11-1
11.1 Various Types of Deformations .................................................................................................11-1
11.2 Causes of Redundant Deformations ......................................................................................... 11-3
11.3 Effects of Redundant Deformations on Product Defects ........................................................11-6
11.4 Mathematical Simulation of the Deformation of a Metal Strip ..........................................11-19
11.5 Computerized Design System for Roll Profiles .....................................................................11-29
11.6 CAE for Roll Forming ..............................................................................................................11-34
12 Acquiring Roll Forming Lines, Education, and Training George T. Halmos ...................12-1
12.1 Why Roll Form Products? .........................................................................................................12-1
12.2 Different Paths to Start Roll Forming ...................................................................................... 12-2
12.3 Evaluating the Product ..............................................................................................................12-3
12.4 Selecting Line Components .......................................................................................................12-4
12.5 Procuring Roll Forming Tooling ............................................................................................... 12-7
12.6 Equipment and Tool Specifications .......................................................................................... 12-7
12.7 Acceptance Test ...........................................................................................................................12-7
12.8 Education and Training .............................................................................................................12-7
12.9 Motivation ...............................................................................................................................12-11
References ..............................................................................................................................................12-11
13 Safety Ashok Shah ...............................................................................................................................13-1
13.1 Safety ..........................................................................................................................................13-1
13.2 Common Safety-Related Definitions ........................................................................................ 13-2
13.3 Safety Design Procedure ............................................................................................................13-2
13.4 Determining Limits of the Machinery or System ...................................................................13-3
13.5 Determining Hazards/Risk Estimation ..................................................................................... 13-3
13.6 Risk Reduction by Design .........................................................................................................13-8
13.7 Safeguarding ...............................................................................................................................13-9
13.8 Selection of Guards and Protective Devices ...........................................................................13-13
13.9 Required Characteristics of Guards and Protection Devices ................................................13-13
13.10 Signals and Warning Devices ..................................................................................................13-14
13.11 Personal Protective Equipment ............................................................................................... 13-14
13.12 Training ....................................................................................................................................13-14
13.13 Summary ..................................................................................................................................13-15
References ..............................................................................................................................................13-16
14 Increasing Efficiency of Roll Forming Lines and Case Studies George T. Halmos ........14-1
14.1 Output, Productivity, and Efficiency ........................................................................................ 14-1
14.2 Line Utilization ...........................................................................................................................14-2
14.3 Improving Productivity .............................................................................................................14-3
14.4 Case Studies ...............................................................................................................................14-4
14.5 Preliminary Tool and Equipment Cost Analysis ...................................................................14-10
14.6 Preliminary Cost Analysis .......................................................................................................14-10
15 Unusual, New, and Future Roll Forming Technologies George T. Halmos ......................15-1
15.1 The Last 100 Years ......................................................................................................................15-2
15.2 The Future of Roll Forming 15.3 Pull-Through Mills: Nondriven Rolls ....................................................................................... 15-5
15.4 Tension Roll Forming ................................................................................................................15-6
15.5 Combining Roll Forming and Cold Drawing ..........................................................................15-7
15.6 Developing New Roll Forming Methods ................................................................................. 15-7
15.7 Roll Forming Tools .....................................................................................................................15-9
15.8 Reducing the Thickness of the Starting Material ..................................................................15-10
15.9 Forming at Elevated Temperature .......................................................................................... 15-11
15.10 Hot Roll Forming Variable Cross-Sections ............................................................................15-11
15.11 Hot Thickness Reduction along the Length of the Strip ......................................................15-12
15.12 Welding Hot Roll Formed Sections ........................................................................................ 15-12
15.13 Other “Hot” Processes .............................................................................................................15-13
15.14 In-Line Soldering, Brazing, and Heat Treating ......................................................................15-13
15.15 Equipment and Tooling Requirements for Hot Roll Forming .............................................15-14
15.16 Press Tooling for Conventional Roll Forming Lines .............................................................15-16
15.17 Computer-Controlled Roll Forming Lines ............................................................................15-16
References ..............................................................................................................................................15-17
Appendices ............................................................................................................................................ A-1
References .............................................................................................................................................. R-1
Index ........................................................................................................................................................ I
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