Design of Roll Forming Mill

International Journal of Mechanical Engineering

© 2021 by SSRG - IJME Journal

Volume 8 Issue 4

Year of Publication : 2021

Authors : Kondusamy V, Jegatheeswaran D, Vivek S, Vidhuran D, Harishragavendra A

10.14445/23488360/IJME-V8I4P101

How to Cite?

Kondusamy V, Jegatheeswaran D, Vivek S, Vidhuran D, Harishragavendra A, "Design of Roll Forming Mill," SSRG International Journal of Mechanical Engineering, vol. 8,  no. 4, pp. 1-19, 2021. Crossref, https://doi.org/10.14445/23488360/IJME-V8I4P101

Abstract:

Sheet metal forming is widely used by the industries in the current scenario. Bending, Spinning, Deep drawing, Stretch forming & Roll forming is the major sheet metal forming processes. In this, roll forming is a unique continuous forming process, where 2D sheet metal is formed into various profiles like Rooftops, Window frames, Storage columns, etc., by using series of mated rollers. This project focuses on design considerations of roll forming tools and process parameters for a roll forming line. This design consideration discusses certain issues in the design of the roll forming tool, which includes Unfold length calculation, Flower pattern design, and Roller design by using an analytical solution. The constant bend allowance (arc) method of flower patterning was used to find the dimensions for the 2D die design. This dimension includes web length, flange length, and radius at each bend for both upper and lower roller. The roller design includes the proper shaft selection, key & keyway selection. This design was done based on force calculation. Major forces are considered to find the torque and bending moment.

Keywords:

Bending, Spinning, Deep drawing, stretch forming, Roll forming, Stretch forming, Hydroforming, Explosive forming, K – factor, Bend allowance and deduction, Unfold length, Bending moment, Rolling friction, Spring back force, Flower pattern.

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