Thursday, July 17, 2014

5 Ideas to Consider in Roll Forming - by Jeff Carson

What is roll forming and why do I need it? 

Fundamentally roll forming is defined as a continuous, high-volume, fabricating process in which a desired shape is formed from a flat strip of metal by passing it through a series of matching pairs of contoured rolls.  Only bending occurs in the roll process and does not change the thickness of the metal except for a slight thinning at a bend radius.  Roller forming is a continuous process that is extremely economical and efficient particularly when the job requires shaping sections into extended lengths at high volume.  The advantages of roll forming are widely recognized and include:
  • Processing over 500 feet per minute
  • Consistently formed material
  • Maintaining extremely finite tolerance range
In today's competitive marketplace, it is necessary to have robust equipment that consistently delivers quality product in a consistent pattern.  In addition to sheet leveling units, other forms of roll forming technology include parts leveling, cut to length lines, slitting, embossing, stitching as well as custom-designed process lines.

What are the types of roll materials?

Rolls are generally made from tool steel, the grade being dependent on the expected production and finish of the piece.  For routine applications where a smooth finish strip is to be formed or when shapes are formed from hot rolled, unpickled steel, a High Chrome-High Carbon tool steel (AISI D-2) with about 1.5% carbon and 12% chrome is suggested.  Tool steel has exceptional wear performance and for the average run of light gauge cold formed sections can be expected to roll several million feet or more before........ click the photo to read more on the B&K Framing Blog

Friday, July 11, 2014

Fenstration Roll Forming - Yoder

Several fenestration components are most efficiently reduced by roll forming, particularly, hollow metal door frames, vinyl window stiffeners, trim, balancers, screen frame, and muntin bars.  Whether structural steel or pre-painted aluminum cladding, Yoder designs tooling and machinery specifically for the unique demands of the fenestration industry, supplying complete systems for component distributors or OEMs looking to produce their components for just in time manufacturing.  In order to leverage existing installations, individual machines, tooling and system upgrades are also available to improve productivity and roll forming throughout, such as the addition of inline notching for muntins of the lockbar for door and window latches.

Thursday, June 26, 2014

B&K Light Structrual Framing 2DWR Supermill

The B&K 2DWRSupermill's patented gauge adjustment, punch and shear technology resulting in the most productive steel framing roll forming system available. Adjustment from 25 gauge drywall up to 16 gauge light structural products with variable leg lengths up to 2".

Industry leading production speeds and changeover times, caters to high production distributors as well as small and medium businesses looking for a single machine with the versatility to supply all their steel framing production needs.  For more information on B&K product lines contact us at or call us at 216-292-4460.

Thursday, June 19, 2014

Combination Cutoff Dies - by Paul Williams

Although cutoff dies are available in many variations, one thing most have in common is
their function: cutting a tubular shape to length. In most cases, this is all that is required.
Sometimes, however, suppliers are looking to take the next step and add value to their
products; adding subsequent operations can go a long way.

Determining the right die for the operation is based on the following criteria:

  •   Part Shape
  •  Material Thickness
  •  Die Maintenance
  •  Line Speed
  •  Press Stroke
  • Matchup of Prenotched Areas
  •  Run Lengths

Only experience can tell you what can or cannot be done and what types of part cutoff
operation are achievable. Much depends on the part’s contour, required end condition,
forming operation (welded, lockseam, overlap), and value-added operations such as
adding notches, holes, and forms.

The maximum benefits and profits are achieved when dies are used not only for cutoff,
but also to punch or form the part from the mill, eliminating all secondary operations.

For additional information visit Hill Engineering web page at www.hillengr or contact us at 630-834-4430

Thursday, June 12, 2014

Steel Framing Accessory System Increase Profits - by Jack Pennuto

There are companies that design and engineer production lines from start to finish for steel framing production systems. Due to heavy competition domestically and globally, these organizations focus on providing customized programs to meet a customer’s specific industry goals. Many of the more successful and innovative operations provide equipment programs that include quality, flexibility and productivity with Steel Framing Accessory Straightnerminimal manual adjustment required.  This type of equipment provides the capability to produce a variety of steel framing accessories on a single system with minimum changeover time. As highlighted in the Conventional Mill versus Accessory System chart below, the single changeover advantage dramatically raises the bar on production to bold and aggressive new levels.  

Robust and advanced accessory systems can fabricate multiple profiles (up to eight profiles per system without manual changeover) and easily meet short lead times and manage heavy customer demand.  Systems that offer the addition of a handcrank and mechanical readout accessory can significantly reduce monthly changeover time from 40 hours to as little as 6 ½ hours. This significant savings can equate to nearly 3 months of available production time, annually – valuable time that can be reallocated for new production projects.  Accessory roll forming systems that include fast changeover also increase the amount of profile production.  Depending on the application, an increase of as much as 300,000 feet per month can be realized.  This is a measurable improvement of almost 40% over a conventional mill processing machine. Additional Accessory modules also assist in the expansion of multi-profile offerings and can provide equipment efficiencies that often result in major sales growth along with significant increase of market share.  In addition, high speed productivity and a high speed operation ultimately result in a high performance system that delivers a best-in-class product.  The benefits of an accessory roll forming system not only create huge production efficiencies and sales opportunities, but many times result in another significantly positive impact - that of a strong net promoter score, which can help foster a positive reputation in the market, strengthening an organization’s customer base.

To read more and see an illustration of increased profit opportunity click here to visit the B&K Metal Framing Blog.  Also, watch our video to learn more about Steel Framing Accessory Systems.


Thursday, June 5, 2014

Advanced Roll Forming - Part II: Reduce Cost & Simplify Operations - by Paul Williams

As a follow up to our recent blog examining the potential pitfalls to the roll-forming process, this discussion will focus on how advanced technology has virtually eliminated these costly and aggravating hindrances with recent innovations.

Product Changeover
This is a significant challenge to productivity due to the many processes that take place – from complete removal of a tool set to an entire machine reset. Over the course of time, technological advancements have been made that virtually mitigate or minimize these burdens on time and efficiency.
  • Duplex and telescoping shaft machines: this equipment provides movable banks of inboard and outboard housings to allow for quick changes in part width and eliminate the changing cross section of material thickness
  • Rafted roll forming machines: this machine is typically used to change out an entire bank of roll tooling. The steel plate (known as the “raft”) along with the inboard and outboard housings and roll tooling for one job, is removed from the roll former base and replaced with another containing the tooling for the next job
  • Roll formers featuring 2-side mounted roll tooling: this machine is powered by a single drive and allow product to be made on one set while the other set is changed out. In addition you can find roll formers that have a supplemental set of intermediate passes, which are significantly taller than the others to allow for an upper and lower roll tooling setup
Recent Innovations Yield Impressive Renovations

Manufacturers of roll forming devices have long observed the need to develop systems around specific types or “families” of products used in specific industries. The focal point should always be on the method that delivers the most significant cost savings and efficiencies. Select the process that produces stock in high volume based on the similarity of the product such as geometric characteristics (like items include steel framing, studs, track, joists and other structural building components).  These building items are usually “C” or “U” shaped with variation  the complete blog by visiting the B&K Metal Framing Blog

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