When we talk about forming applications, vacuum forming, and they're getting to know about types of roll forming applications Interestingly, roll forming is a very widely used and important metal forming process, with more than 40% of the steel used in various industries such as construction, automobile manufacturing, machinery manufacturing, etc. made from this technique. D ue to this importance, in this section of the Persian Size blog, the largest repository of building information, we'll get into the subject and give you the full details of the field, so stay tuned to us. What is the roll forming process? Interestingly, roll forming is a very widely used process, but at the same time, it is unknown and unknown. In fact, it can be admitted that it is not easy to describe and explain the role formation process; but in general, it can be admitted that the formation of sheet metal strips along straight, longitudinal, parallel bending lines by several pairs of profiling at normal temperature Without changing the thickness of the plate, it is called the roll forming process. About the roll forming process and its related details Overall, it can be acknowledged that roll forming has always been considered a widely used and important process, as it has developed into the most efficient metal forming technique over the past half-century. In fact, it's interesting to note that about 35% to 45% of all steel produced in U.S. factories is produced through the roll forming process, which is more steel than is used in the automotive industry. It can be admitted that hundreds of equipment, automobiles, construction, agricultural machinery, tanks, and other products are produced by the roll forming process every day, but most people who are not in the industry have no knowledge of this known. this industry.
In the 100-year history of roll forming, thousands of tools, equipment, designers, and users have worked and are still working in the industry, but unfortunately, operators, equipment installation engineers, and designers have gained a lot of Part of the experience was never recorded and recorded. Therefore, from all the research articles and reports, only a limited part can be explained and applied to the roll-forming industry. Checking the sheet roll forming process is not an easy task. The international definition of the roll forming process fully illustrates the complexity of the situation; therefore, according to the definition given at the beginning of this article, Persian Sazeh, to understand the process, several important points should be noted, including the following point: • Sheet roll-formed products often have curves. • The angle of the bend line can be 90 degrees. • Curved lines are not always straight, sometimes this is intentional. On the other hand, the bending lines are not always parallel, this is usually done deliberately according to the customer's request. • It should be noted that the thickness of the sheet is always reduced at the bend or bend line. In addition, the rolls of the sheet roll forming machine have special passages that allow the thickness of the sheet to be reduced if necessary. Also, in thinner curved products, the external threads and ridges are formed thinner than the internal ridges. On the other hand, it is mentioned in the above definition that the temperature of the environment does not change during work, but: • Sheet metal is heated prior to roll forming to prevent paint cracking on bend lines. • For sheets that have been welded, annealed, or brazed, the operating temperature should be increased.
The Vacuum Forming Machine and its Types
Vacuum forming is commonly used to form plastic sheets. This operation is related to direct heating or induction heating. In fact, in this operation, after the sheet is put into the sheet holder part of the machine, the heater directly heats the sheet, in this state, the sheet becomes dough, the mold is close to the sheet, and the air in the middle Sheet and forming machine discharge. Of course, it should be noted that this process can be used for soft sheets. In this regard, the types of vacuum forming methods include the following: Vacuum forming Vacuum forming or vacuum forming means that the sheet is softened by heat, and the sheet is shaped like a mold by direct or induction heating and air evacuation between the sheet and the mold. In this process, a heat-sensitive plastic sheet (thermoplastic). is first heated to a certain extent to make it soft and elastic, then this sheet is softened and placed on the mold with the help of an air vacuum and placed in the mold Stretch on the mold, and the shape of the mold is ready. In fact, the thermoforming process is carried out in two stages: heating and forming. is pulled into the mold. After the plastic sheet is formed and hardened, the sheet is finally separated from the mold and the excess is cut.
Air forming in this method, a flexible plastic sheet is applied to the mold plate from above by means of air pressure. In this case, the sheet is pulled into the cavity of the mold. It should be noted that to vent the air trapped between the sheet and the mold, holes must be provided in the mold so that the air forming process can be operated optimally. Mechanical forming in this method, a heat-sensitive plastic sheet is placed between the front and back parts of the mold. Finally, it mechanically squeezes the plastic with direct force from the male part of the mold and pulls the sheet into the cavity of the female mold. In this regard, it should be noted that compared with the other two methods, one of the most prominent advantages of this method is that the dimensional accuracy of the product is better, and the geometric details on both sides of the workpiece are more accurate. The only problem is that this method requires the positive and negative parts are molded, which leads to high production costs.
Getting to Know the Types of Roll Forming
Learn about the types of rolls forming systems as you may have read in other Persian Sazeh articles, the most important member of a roll forming line is the roll press. The metal is shaped because the rolling machine applies the necessary force and support to the rollers. Interestingly, the design variety of rolling machines in this field is limitless, but they can be divided into the following categories, which include suspended, tandem, combined tandem, standard and flatbed machines. It should also be noted that devices that do not fall into any of the above categories may be considered special scrolling devices. Familiar with various sheet roll forming methods to get an effective and functional product, we always see different procedures in each process to get the output. In this regard, there are many kinds of rolling forming methods for sheets. According to this problem, the types of rolling forming methods can be considered as follows: 1. Cold bending forming method from a more general perspective, it can be said that the smallest thickness sheets produced by hot rolling are usually pickled, thinned, or deformed by a cold rolling process. In fact, it can be said that the application of cold rolling is to reduce the thickness at the required dimensional accuracy of the steel sheet. In addition, in this cold-bending process, it is also possible to mention that the sheet is straightened during the operation, so that the rolls comprising two small-diameter rolls eliminate the curvature of the sheet produced in the previous process, and it is removed from the It came out smooth in the roller. In fact, the purpose of cold forming is to reduce the thickness of the sheet under very high pressure, which is usually carried out at room temperature and up to 200 degrees Celsius. In this cold working method, factors such as the characteristics of the sheet roll forming machine, the skill of the tool designer, the quality and performance of the designed tool, the skill of the operator, the manner of the tool, etc. are elements that affect the process's success.
Placement, and the formability of the slats has an impact. The application of this process in the sheet metal industry is so diverse that it covers the range from less precise parts to sensitive and precision parts. 2. Hot rolling forming method Thermal methods are used to form sheets of high thickness. Generally, in this method, the temperature of the metal sheet is raised to a very high level to help form the thick sheet. Hot rolling has fewer fans than cold rolling, and products produced by this method have limited practical use. Products such as beams, angles, or thick plates such as sheets are rolled by hot rolling. Roll forming of sheet metal with hot rolling methods requires the very precise setting of the desired temperature, as temperature variations, and low and high temperatures can all lead to product damage. Therefore only a few mills use the hot rolling method. What is the forming process of the galvanized sheet? As you know, a galvanized sheet with zinc metal coating on the surface can be produced in various colors. Galvanized sheet, on the other hand, is painted using a sprayer or placed in a special oven. Galvanized sheet thicknesses from 6 to 18 mm are formed using forming machines of various designs. In this regard, one of the traditional ways to shape this product is a sinusoidal design. Sinusoidal designs have a shape like ocean waves and are often used in the construction of gable roofs or false ceilings. It should also be mentioned that another method of forming a galvanized sheet is a trapezoidal design. In general, this plan is more suitable for places with high traffic and humid weather. Of course, there are three different types of this method itself.
Galvanized sheet for covering the interior of roofs or walls. Facades are designed to build sloped surfaces and façades are designed to be used for exterior surfaces or sheds. Galvanized sheet with very attractive colors and designs is also popular among customers due to their high resistance to environmental factors. While shaping the beauty of the building's appearance, the product is light in weight, increases earthquake resistance, facilitates transportation and implementation, and reduces costs. And forming machines the machines used in the forming process also have different types according to their use, and in this section, we will introduce each of these machines: 1. Sinusoidal forming device In general, the dimensions of the full-line sinusoidal forming machine are 1 meter and 70 centimeters wide and 8 meters long with a 100 mm chain gear and can be transported with a trolley. This type of system has 11 gates with a mold diameter of 180 mm and a motor power of 50 rpm. 2. Trapezoid forming machine the dimensions of the device are 10 meters long and 1 meter 70 cm wide with a 100 mm chain gear that can be easily transported with a trolley. This type of system has a 75 mm trans main shaft and two 75 mm gearbox dynamos with 50 rpm engine power. 3. Shadow line forming machine Shadow line forming machine has 11 gates with 75 trans main shaft and 50 rpm engine power.
This type of system is combined with a 75 mm shaft gearbox dynamo with two twin gears, 170 mm deep, 30 mm deep, with a 100 mm chain gear, and they are among the optimal devices in this process. 4. Steel deck forming machine the steel deck forming machine has 26 gates along with the main shaft, 90 mm trans and has 2 1200 mm chain gear gearbox dynamos. The steel deck forming machine has a length of 15 meters and the width of the machine is 1 meter 70 centimeters. In addition, this device is approved by the municipal monitoring device and is made of roll sheet with a thickness of 80% and up to a thickness of 1.25 mm. 5. Small sinusoidal forming Small sinusoidal forming has 22 longitudinal gates with a 65 mm trans shaft with nearly 950 molds with a length of 13 meters and a width of 1 meter 50 centimeters. It should also be noted that the motor power of this device was 40 rpm. This forming machine is very sensitive and if you want to form a roll sheet with a width of one meter, the design can be done with 18 gates. Of course, it should be noted that the last two edges of the sheet are turned down and only a one-meter-wide roll sheet can be formed with fine rib. ConclusionOur vision is to be a standard for customized products and quality services so that we can build a good brand image of our company in the national and international market with competitive prices and cheap shipping services. We are eager to do what we do and strive to further the needs of our customers by providing quality products and services. For more information kindly visit our site.