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Notification of Dragon Boat Festival Dear All Friends: We would like to take this opportunity to thank you for your kind support all this while. Please kindly be advised that our office will be temporarily out of duty from June 12nd to June 14th, 2021, in observance of the tradition International Dragon Boat Festival. Any orders will be accepted but will not be processed until June 15, 2021, the first business day after the Dragon Boat Festival Holiday, any urgent things you may contact via my phone: +86--13011740906 or email: sales@rollformingindustry.com. Sorry for any inconvenience may caused. Happy Dragon Boat Festival! From: JINAN RAINTECH MACHINERY INDUSTRIES CO.,LTD

Steps of the Roll Forming Process Uncoiling: Metal coils may become set during storage and have a tendency to stay coiled and become distorted. To correct the problem, the coil is loaded onto the uncoiler, seen below, and fed through a flattener to remove the coil set. The lead end is trimmed to allow for smooth feeding into the pre-press process. Part of the pre-press operation may be a tapering of the beginning of the feed coil to make it easier for it to slide into the forming rollers. Pre-press treatment: Before the metal from the coil is fed into the roll forming rollers, it may need applications added as can be seen in the image below, which can involve adding slots, holes, or slits. Roll forming: At this stage, the material is progressively shaped. A typical roll forming machine can consist of 10 to 24 pairs of roller die stands. The machine is individually or gang driven to force the ribbon of metal through the rollers that gradually shape it to the dimensions of the flower pattern. Cutoff and discharge: Parts are cut to length as they are in motion, which increases the efficiency and speed of the roll forming process. Once they are cut, they are discharged to a run-out table to be placed for shipment or further processing. Secondary processes: There are a variety of ways secondary processes can be performed. Some can be completed as the part comes off the cutoff, while others may have to be performed at another station. The image below has samples of some of the listed secondary processes, which include: Punching Notching Tight tolerance forming Straightening Adding other components Minor assembly Lubricant With any metal forming process, friction plays an important role, which is the resistance produced when two bodies make contact. It is a means of energy dissipating that causes a rise in temperature where two surfaces meet. The temperature is further enhanced by the speed of the process. Lubrication is used in the roll forming process to reduce friction between the rolls and metal to prevent tool wear. Friction is a necessary part of the rolling process and an important part of shifting the metal forward between the rollers. It should not be eliminated or reduced below an appropriate level. The need for friction has to be considered when choosing a lubricant. Roll forming uses fluid lubricants with a low viscosity that include paraffin for non-ferrous metals such as aluminum and copper. Lubricants increase the rate of production, which is determined by the thickness of the material, number of roll stations, and the amount of bending. Below is an example of a roll forming process that uses a chlorine free lubricant. This Rolling Forming Machine Uses a Chlorine Free Lubricant (from etna.com)

RSL-3X1300 Slitting Machine (double Winding Machine) Put Into Production

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Roll Forming Machines There are several varieties of machines used to roll metals. The type depends on the number of spindles that are used. The spindles of the machine are mounted on a base plate that is a base table for the rolling process. Once the rollers are mounted, they are aligned with the spindles, the rotation of which shapes the metal. Spacers hold the rolls in position and allow the spindles to easily act on the metal sheets. Every manufacturer has their own version of a roll forming machine. Listed below are descriptions of a few common versions. Stud and track Stud and track machines produce assembly frames for strong, lightweight partitions, which can be up to 32 feet with varying thicknesses. These machines can form studs or track from 3 5/8" to 8" with 26 to 14 gauge steel and 1 5/8" and 2 1/2" members Angle Angle roll forming machines use high tensile strength steel for form equilateral or unequal perpendicular angles, the most basic of the rolled formed profiles. Framing is the primary use of roll formed angles, but they can also be used for rails, posts, supports, and brackets. Beam Beam roll forming is used to produce box beams for construction. The designs produce fluted beam profiles for floor decking and framing. Beams are made from high tensile strength steel with double thickness flanges and single thickness webbing for additional strength. Seamless The primary use for seamless roll forming is the manufacturing of tubing, which can be square, round, oval, or rectangular. The TIG process is used at the end of the roll forming process to weld the rolled tubing together as can be seen in the diagram. As with many parts from roll forming, tubing is made from a wide variety of ferrous and non-ferrous metals. Wrap Wrap roll forming machines form a wrapped L-shaped edge or flange on sheet metal. Wrap machines are very similar to a long dinner table with a set of rollers running the length of the table. They can reach speeds of fifty feet per minute to create either complex or simple flanges.

Type of Roll Forming Processes Every roll forming manufacturer uses a unique set of rolling processes to create their products. Some specialize in tubing, while others produce roofing and siding. The most common types of rolling are: Shape Rolling Ring Rolling Roll Bending Flat Rolling Plate Rolling Below is a discussion of these methods: Roll Forming Methods A) Roll Bending Roll bending can be used for thick large metal plates. Three rollers bend the plate to produce the desired curve. The placement of the rollers determines the exact bend and angle, which is controlled by the distance between the rollers. B) Flat Rolling The basic form of roll forming is when the end material has a rectangular cross-section. In flat rolling, two working rollers rotate in opposite directions. The gap between the two rollers is slightly less than the thickness of the material, which is pushed through by the friction between the material and the rollers, which elongates the material due to the decrease in material thickness. The friction limits the amount of deformation in a single pass making several passes necessary. C) Shape Rolling/Structural Shape Rolling/Profile Rolling Shape rolling cuts different shapes in the workpiece and does not involve any change in the thickness of the metal. It produces molded sections such as irregular shaped channels and trim. Shapes formed include I-beams, L-beams, U channels, and rails for railroad tracks. D) Ring Rolling In ring rolling, a ring of small diameter workpiece is rolled between two rollers to form a ring of larger diameter. One roller is the drive roller, while the other roller is idle. An edging roller ensures that the metal will have a constant width. The reduction in width of the ring is compensated for by the diameter of the ring. The process is used to create seamless large rings. E) Plate Rolling Plate rolling machines roll sheets of metal into tightly shaped cylinders. The two different varieties of this type of equipment are four roller and three roller. With the four roller version, there is a top roller, pinch roller, and side rollers. The three roller version has all three rollers producing pressure with two on the top and one on the bottom. The diagram below is a four roller systems forming a cylinder.

Metals Used in Roll Forming Roll forming can shape any ferrous or non-ferrous metals and their alloys. The types of metals used by manufacturers determines the adjustments that must be made to each bending stage of the roll forming process. The key factors are thickness and ductility as well as the flow stress, which determines the amount of force necessary to shape the metal. The yield point, the point at which a metal bends, is higher at a lower temperature necessitating an increase in the amount of force, which has to be factored into the roll forming machine. Listed below are seven metals that are commonly used in roll forming separated into ferrous and non-ferrous metals. Ferrous metals – Contains iron Steel: Made of iron Malleable below its melting point without requiring special heat treatment. Free from slag Contains small amounts of silicon and manganese Has trace quantities of sulfur and phosphorus Stainless Steel: Has a high percentage of chromium Strain and corrosion resistant Resistant to weak mineral acids, oxidation, organic acids, and caustic materials Galvanized Steel: Coated with zinc Is a heat treated metal Has a bonded coating of zinc-iron alloy Non-Ferrous metals – Does not contain iron Aluminum: Malleable Lightweight Resistant to corrosion Has a layer of aluminum oxide Brass: Copper and zinc alloy Corrosion resistant Bronze is another type Malleable Copper: Has electrical conductivity. Primary component in non-ferrous alloys Lead: Has high density Low melting point Tarnishes slowly Ductile Poor electrical conductor Resistant to corrosion

Benefits and Advantages of Roll Forming Machine Roll forming is a cost effective process for shaping metal coils into custom designed profiles. It is used by several industries to produce components for automobiles and appliances to aircraft and construction industries. Listed below are some of the benefits and advantages roll forming offers. Efficiency The speed of roll forming is due to the long coils of metal it uses that are rapidly fed into the forming machine. Since the machine is self-feeding, there is little need for human monitoring, which lowers the cost of labor. Punching and notching during pre-feeding avoids the need for secondary operations. Cost savings Metals do not need to be heated for roll forming, which significantly lowers energy costs. The careful control and lubrication of moving parts reduces tool wear and the cost of component replacement. The smooth finishes of completed parts removes the need for secondary processes such as deburring or trimming of flash. Parts are produced in large quantities reducing the cost of the final product. Flexibility Complex and intricate cross sections can easily be produced using ferrous and non-ferrous metals. In some processes, it is not possible to shape a metal that has been painted, plated, or coated. Roll forming can easily shape them regardless of the type of finish. Quality Products are more uniform and consistent across a complete run. Tolerances are very tight with extremely precise dimensions. Sharp, clean contours are maintained with the absence of die marks or deformities. Length of parts Since the metal is fed into the machine, any length can be produced using the same tooling for any part. Less scrap Roll forming produces one to three percent scrap for each production run, which is far less than any other metal working process. The lower amount of scrap lowers the cost of working with expensive metals. Repeatability A major problem with bending metal is residual stress, which negatively affects repeatability. The rapid processing of roll forming helps metals retain their residual stress as well as any loss of weld seam control.

Roll Forming Process Each roll forming manufacturer has a different set of steps for their roll forming process. Regardless of the variations, there are a set of basic steps all producers use. The process begins with a large coil of sheet metal that can be from 1 inch to 30 inches wide with a thickness of 0.012 inch to 0.2 inch. Before a coil can be loaded, it has to be prepared for the process. The above diagram represents each step of roll forming from the feeding of the coil to the cutoff and discharge at the end of the process. Below is a description of each step.

What is the Roll Forming? Roll forming is a process that uses a set of precisely placed rollers to perform incremental bending to a continuously fed strip of metal. The rollers are mounted in sets on a consecutive stand with each roller completing one small step of the process. Rollers are carefully crafted using a flower pattern, which identifies the sequential changes to the metal strip. The shape of each roller is created from the individual sections of the flower pattern. Each of the colors in the above flower pattern illustrates one of the incremental bends used to complete the part. The individual colors are a single bending operation. CAD or CAM renderings are used to simulate the roll forming process so that errors or flaws can be prevented prior to production. Using software applications, engineers can select calibrations and profiles for folding or bending angles to create new geometries by clicking their mouse.

Analysis Of Domestic Cold Roll Forming Technology In China, since the beginning of the construction of cold-formed units in the late 1950s, it has experienced a tortuous process of development and adjustment. There were only 6 at the end of the 1970s. In the 1980s, China`s cold-formed steel developed rapidly, and by 1982, the output was only 16,000 tons. By 1989, more than 20 manufacturers across the country had an output of more than 300,000 tons and a design capacity of more than 600,000 tons. Among them, 14 key plants in the metallurgical system, 45 sets of units, and cold-formed steel varieties and specifications are also increasing. There are more than 800 species. Under the favorable form of reform and opening up, the national economic construction has put forward new requirements on the variety and quality of steel. The advantages of cold-formed steel have gradually been recognized and accepted by people, and the production of cold-formed steel has achieved greater development. So far, there are more than 100 sets of cold bending units, with an annual production capacity of 1.5 million tons and a total of more than 1,000 varieties and specifications. For example: Shanbaotou Design and Research Institute developed a medium-Φ219mm medium-diameter welded pipe forming unit, which is a new type of roll forming unit, developed by Shanbaotou Design and Research Institute to digest and absorb some advanced foreign technologies and the specific conditions of the domestic market, namely the CR unit (composite roll mill). The characteristics of the unit are: (1) The rough forming section of cold bending forming adopts a combination of shared rolls and replacement rolls. When changing product specifications, the rolls of some stands do not need to be replaced, which can save some rolls in reserve. (2) The combined roll sheet for flat rolls, the rough forming section is six racks, the vertical roll group rolls are arranged obliquely, the volume of the car roll is small, the weight of the roll is more than 1/3 less than the traditional roll forming machine, and the equipment structure is more compact. (3) The roll profile is simple, easy to manufacture and repair, and the roll repetition rate is high. (4) The cold bending forming is stable, the rolling mill has strong applicability to the forming of thin-walled tubes and rear wall tubes, and the product specifications range are wide. The first set of CR-Φ219 forming unit designed by the institute was officially put into production in Tianjin Jinhai Joint Steel Pipe Plant in August 1992. However, no matter in terms of output, quality, variety, consumption and application fields, or in terms of equipment level and technological level, there is a big gap with foreign developed countries, and it is extremely disproportionate to the status of a country with an annual output of nearly 100 million tons of steel. It can be predicted that cold-formed steel will have a greater development in my country.

The Development of Overseas Cold Roll Forming Technology The foreign roll forming technology has a history of more than 100 years and is roughly divided into three stages. The first stage (1838-1909) is the exploration and trial production stage. At this stage, the research on roll forming theory and cold-formed steel is progressing slowly. With the rapid development of the industrial transportation industry, the cold-formed steel produced by the roll forming process can no longer meet user requirements. The second stage (1910-1959) is the stage of establishing and gradually popularizing the roll forming process. The third stage (from 1960 to the present) is the stage of rapid development of roll forming production. The development trend of foreign cold-formed steel production can be summarized in several aspects: 1). Production continues to increase Since the 1960s, the output of foreign cold-formed steel has increased rapidly. This is the general trend. According to the statistics of cold-formed steel in various countries over the years, the output of cold-formed steel and the output of steel have been relatively stable at a certain ratio. It is 1.5:100 to 4:100. For example, the development plan formulated by the former Soviet Union in 1975 stipulated that the output of cold-formed steel in 1990 will account for 4% of steel output. With the improvement of the production process of cold-formed steel, product specifications and varieties continue to increase, and product quality continues to improve The scope of application is expanding. The former Soviet Union was re-regulating the original development plan in 1979, stipulating that it will reach 5% in 1990. Some other countries also plan to increase the output of cold-formed steel. Now the output of foreign cold-formed steel is about 10 million tons per year. It accounts for 3% of the world's total steel. 2). Research work is deepening The research work on roll forming theory, forming process and forming equipment is in-depth abroad, and a series of progress has been made in the research on the practical application of cold formed steel. For example, the former Soviet Union and the United States have used electronic computers to study the force and energy parameters in cold bending forming and explore the deformation method with the lowest energy consumption. 3). New processes continue to appear Since the roll forming process was successfully studied in the United States in 1910, after decades of improvement and perfection, the forming process has become more mature. As the technical and economic effects of cold-formed steel in practical applications are increasingly recognized, cold-formed steel is widely used in various fields of the national economy. Users have more and more stringent requirements for the quality of cold-formed steel, and they require diversification of varieties and specifications. This promotes the continuous improvement of roll forming processes to meet user requirements. Foreign countries have adopted roll forming processes and developed corresponding equipment. Vertical roll forming machine with plug-in type, forming unit with centralized adjustment of forming rolls is referred to as CTA unit (Central Tool Adjustment), straight edge forming unit. 4) The product variety is constantly increasing, and the product structure is constantly updated. With the development of cold-formed steel production and the expansion of the scope of application, the variety of cold-formed steel continues to increase, product structure is constantly updated, and product standards are gradually improved. With the continuous emergence of new technologies, the range of billet materials and specifications is expanding. Now there are more than 10,000 varieties and specifications of cold-formed steel produced abroad. The specifications of cold-formed steel range from 10mm to 2500mm, and thickness 0.1 mm~32mm. From the perspective of the material of cold-formed steel, it was mainly carbon steel before the 1970s, which accounted for more than 90%. Since the 1970s, through the technical and economic comparison of practical applications, the use of high-strength low-alloy steel, alloy steel and Stainless steel makes the proportion of ordinary carbon steel products decrease year by year, and the proportion of alloy steel, high-strength low-alloy steel and stainless steel products increases year by year.