What is Custom Roll Forming?

Roll Forming is a continuous process in which a strip of metal, usually in coil form, is passed through a series of roller dies and progressively shaped to the desired contour. It eliminates multiple stage production, finishing or sub-assembly operations. Secondary operations such as: notching, punching, tabbing, perforating, edge rolling, bending, deburring, embossing, and mechanical finishing can be combined continuously with the roll forming operation to speed production and reduce assembly costs. By its very nature, roll forming is a process which permits consistent adherence to close tolerances, working in both heavy and lightweight materials. Roll formed shapes can be economically produced from an almost limitless variety of stock that has been preprocessed: painted, vinyl coated, oiled, anodized, embossed, or mechanically surface treated. Practically all metals can be successfully roll formed.

Competitive processes

Extrusion, hot rolling.

Parts produced

HVAC and construction industries are big consumers of rollformed products. These include ductwork as well as doors and wall panels. Rollformed products also find great use on roadways as sign posts and guardrails. Other products include shelving, airframe parts, window and door frames, raceways and troughs, telescoping bleacher seating, electronic enclosures, drawer slides and various types of rails.

Benefits

Should your needs fall to parts with uniform cross-sections, rollforming can make them in high volumes, cutting the parts to the length needed. In-line processes to punch, notch and perform other functions help reduce cost and lead time. Generally, rollformed parts offer a strength advantage over competing processes in structural-rigidity applications.

Capacities

Sizes of parts produced are limited only by shipping and handling concerns. The process typically runs at speeds from about 5 to more than 600 ft./min., depending upon part complexity and use of in-line non-rollforming operations. The type of material worked also affects process speed.

Materials

Any material that can be cold-formed from sheet is a candidate for rollforming.

Should I use it?

The process will yield high volumes of parts, to any length desired. Use it for parts with similar cross-sections throughout. Also, the process is not limited to straight parts—it can sweep material into a continuous radius or a circular ring. Rollforming allows the formation of two different materials simultaneously to produce a clad shape in one operation. Note: Product design is limited to material of constant thickness, and the process does not provide the ability to strengthen bends with fillets.

Article also available on the Custom Roll Forming Institute website. 

Apprenticeships

Developing Apprenticeship Programs

WorkingSolutions designs and develops effective and structured apprenticeship programs based on three approach options:

• The traditional time-based approach – Requiring minimum of 2000 hours of on-the-job training and related technical (knowledge-based) instruction
• The newly approved competency- based approach – Requiring the apprentice to demonstrate competency by successfully completing required on-the-job learning and related technical (knowledge-based) instruction without regard to time (Federal Register, Dept. of Labor/ETA, 29 CFR, Part 29.5)
• Or new “hybrid” approaches – Requiring the apprentice to successfully complete an established minimum of on-the-job learning and related or blended technical instruction hours to demonstrate competency in defined skill, trade or subject areas (Federal Register, Dept. of Labor/ETA, 29 CFR, Part 29.5)

“You can’t make a good part with a bad print” – That also applies when developing training, assessment and apprenticeship programs.  It’s all in the “design!”  Using proven models, techniques and methods, WorkingSolutions can assist you in designing, creating, developing and implementing an effective apprentice program (registered or not registered) to meet your needs and the needs of the apprentice.

Using job/skill analysis techniques, skill-based learning progressions, structured on-the-job training methods, valid competency assessments and/or credentials, skill standards and portfolios, and related knowledge & technical instruction, WorkingSolutions will design your program and weave related technical instruction (coursework), assessments and/or interim credentials into the fabric of your on-job, skill-based learning progression.  Related instruction can include traditional partnerships with an education institution and/or (as recently approved by the Department of Labor) electronic media such as on-line courses, CD/DVD media, distance learning or virtual class work.

Our systematic approach and development strategies provide a valid, defensible and ISO/TS compliant learning and doing program that creates more flexibility for apprentices and employers.  In addition, our program development design provides for increased and innovative choices and options to meet the needs of industries that have traditionally used Registered Apprenticeship programs, as well as connecting with the workforce demands of new and emerging industries.

For more information, contact Bruce Broman at 216-901-8800 or bbroman@pma.org.

Article also available on the Custom Roll Forming Institute website.