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Roll Forming
Roll forming, also spelled roll-forming or rollforming, is a type of rolling (metalworking), rolling involving the continuous bending (metalworking), bending of a long strip of sheet metal (typically coiled steel) into a desired cross-section (geometry), cross-section. The strip passes through sets of rolls mounted on consecutive stands, each set performing only an incremental part of the bend, until the desired cross-section (profile) is obtained. Roll forming is ideal for producing constant-profile parts with long lengths and in large quantities. Overview A variety of cross-section profiles can be produced, but each profile requires a carefully crafted set of roll tools. Design of the rolls starts with a ''flower pattern'', which is the sequence of profile cross-sections, one profile for each stand of rolls. The roll contours are then derived from the flower pattern profiles. Because of the high cost of the roll sets, Finite element analysis, computer simulation is often used ...
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Work Hardening
Work hardening, also known as strain hardening, is the process by which a material's load-bearing capacity (strength) increases during plastic (permanent) deformation. This characteristic is what sets ductile materials apart from brittle materials. Work hardening may be desirable, undesirable, or inconsequential, depending on the application. This strengthening occurs because of dislocation movements and dislocation generation within the crystal structure of the material. Many non-brittle metals with a reasonably high melting point as well as several polymers can be strengthened in this fashion. Alloys not amenable to heat treatment, including low-carbon steel, are often work-hardened. Some materials cannot be work-hardened at low temperatures, such as indium, however others can be strengthened only via work hardening, such as pure copper and aluminum. Undesirable work hardening An example of undesirable work hardening is during machining when early passes of a cutter inadver ...
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Drawer Slides Roll Forming Machine
A drawer slide roll forming machine is a cold roll forming machine used to manufacture drawer slides. They have similarities with roofing roll formed products, but require a higher performance and skills in profile forming. These machines are also known under various names such as slide rail making machine, slide make machine and telescopic channel roll forming equipment. Process of slide roll forming The basic production flow of drawer slide machine is roll forming, punching, and cut off to length. Processes of drawer slides roll forming is a continuous cold rolled steel strip passing through a plurality set of upper and lower shaped rollers, and then punching, embossing, straightening, and cut off to length. Straightening is an important part to avoid material twisting or curling. A roll forming line is often provided with straightening mechanism to make sure the material is nicely formed in a predetermined shape to meet the original design. Every slide rail varies in so ...
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Roll Bender
A roll bender is a mechanical jig having three rollers used to bend a metal bar into a circular arc. The rollers freely rotate about three parallel axes, which are arranged with uniform horizontal spacing. Two outer rollers, usually immobile, cradle the bottom of the material while the inner roller, whose position is adjustable, presses on the topside of the material. Roll bending may be done to both sheet metal and bars of metal. If a bar is used, it is assumed to have a uniform cross-section, but not necessarily rectangular, as long as there are no overhanging contours, i.e. positive draft. Such bars are often formed by extrusion. The material to be shaped is suspended between the rollers. The end rollers support the bottomside of the bar and have a matching contour (inverse shape) to it in order to maintain the cross-sectional shape. Likewise, the middle roller is forced against the topside of the bar and has a matching contour to it. Operation After the bar is initial ...
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Tube Beading
Tube beading is a metal forming process that forms a bead on the end of a tube. Tube beads can be used to help hold a hose on the end of a tube or to strengthen the end of the tube.Gregory Miller, "Tube Forming Processes: A Comprehensive Guide," 2002 There are two forming processes: ''internal roll forming'' and ''ram forming''. Internal roll forming Internal roll forming is generally slower than ram forming but it holds tight tolerances. Serrated clamp jaws are used to hold the tube while radial pressure is applied by an internal roller to form the bead. Ram forming Ram forming is quicker and usually preferred when speed of production is a concern. The automotive industry The automotive industry comprises a wide range of company, companies and organizations involved in the design, Business development, development, manufacturing, marketing, selling, Maintenance, repairing, and Custom car, modification of motor ve ... usually uses this process over internal roll-forming. ...
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Structural Shape Rolling
Structural shape rolling, also known as shape rolling and profile rolling, is the rolling and roll forming of structural shapes by passing them through a rolling mill to bend or deform the workpiece to a desired shape while maintaining a constant cross-section. Structural shapes that can be made with this metal forming process include I-beams, H-beams, T-beams, U-beams, angle iron, channels, bar stock, and railroad rails. The most commonly rolled material is structural steel, including carbon steel and stainless steel. Other metals, plastic, paper, and glass can also be rolled. Common applications include railroads, bridges, roller coasters, art, and architectural applications. It is a cost-effective way of bending these materials because the process requires less set-up time and uses pre-made dies that are changed according to the shape and dimension of the workpiece. This process can roll workpieces into full circles. Process Structural shape rolling uses profile rolling techn ...
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Skin-pass
In metalworking, rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness, to make the thickness uniform, and/or to impart a desired mechanical property. The concept is similar to rolling pin, the rolling of dough. Rolling is classified according to the temperature of the metal rolled. If the temperature of the metal is above its recrystallization (metallurgy), recrystallization temperature, then the process is known as hot rolling. If the temperature of the metal is below its recrystallization temperature, the process is known as cold rolling. In terms of usage, hot rolling processes more tonnage than any other manufacturing process, and cold rolling processes the most tonnage out of all cold working processes... Roll stands holding pairs of rolls are grouped together into rolling mills that can quickly process metal, typically steel, into products such as structural steel (I-beams, angle stock, channel stock) ...
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Sheet Metal
Sheet metal is metal formed into thin, flat pieces, usually by an industrial process. Thicknesses can vary significantly; extremely thin sheets are considered foil (metal), foil or Metal leaf, leaf, and pieces thicker than 6 mm (0.25 in) are considered plate, such as plate steel, a class of structural steel. Sheet metal is available in flat pieces or coiled strips. The coils are formed by running a continuous sheet of metal through a roll slitting, roll slitter. In most of the world, sheet metal thickness is consistently specified in millimeters. In the U.S., the thickness of sheet metal is commonly specified by a traditional, non-linear measure known as its Sheet metal gauge, gauge. The larger the gauge number, the thinner the metal. Commonly used steel sheet metal ranges from 30 gauge (0.40 mm) to about 7 gauge (4.55 mm). Gauge differs between ferrous (Iron, iron-based) metals and nonferrous metals such as aluminum or copper. Copper thickness, for example ...
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Crazing
Crazing is a Yield (engineering), yielding mechanism in polymers characterized by the formation of a fine network of microvoids and fibrils. These structures (known as ''crazes'') typically appear as linear features and frequently precede brittle fracture. The fundamental difference between crazes and cracks is that crazes contain polymer fibrils (5-30 nm in diameter), constituting about 50% of their volume, whereas cracks do not. Unlike cracks, crazes can transmit load between their two faces through these fibrils. Crazes typically initiate when applied tensile stress causes microvoids to nucleate at points of high Stress (mechanics), stress concentration within the polymer, such as those created by scratches, flaws, cracks, dust particles, and molecular heterogeneities. Crazes grow normal to the principal (tensile) stress, they may extend up to centimeters in length and fractions of a millimeter in thickness if conditions prevent early failure and crack propagation. The ref ...
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Rolling (metalworking)
In metalworking, rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness, to make the thickness uniform, and/or to impart a desired mechanical property. The concept is similar to the rolling of dough. Rolling is classified according to the temperature of the metal rolled. If the temperature of the metal is above its recrystallization temperature, then the process is known as hot rolling. If the temperature of the metal is below its recrystallization temperature, the process is known as cold rolling. In terms of usage, hot rolling processes more tonnage than any other manufacturing process, and cold rolling processes the most tonnage out of all cold working processes... Roll stands holding pairs of rolls are grouped together into rolling mills that can quickly process metal, typically steel, into products such as structural steel (I-beams, angle stock, channel stock), bar stock, and rails. Most steel mills ...
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Steel Frame
Steel frame is a building technique with a "skeleton frame" of vertical steel columns and horizontal I-beams, constructed in a rectangular grid to support the floors, roof and walls of a building which are all attached to the frame. The development of this technique made the construction of the skyscraper possible. Steel frame has displaced its predecessor, the iron frame, in the early 20th century. Concept The Rolling mill, rolled steel "profile" or cross section (geometry), cross section of steel columns takes the shape of the letter "". The two wide flanges of a column are thicker and wider than the flanges on a Beam (structure), beam, to better withstand compressive stress in the structure. Square and round tubular sections of steel can also be used, often filled with concrete. Steel beams are connected to the columns with bolts and threaded fasteners, and historically connected by rivets. The central "web" of the steel I-beam is often wider than a column web to resist the ...
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