Double deck roll forming machines are an important type of equipment used for rolling and bending metal coils into customized profiles and cross-sections. This comprehensive guide will provide a detailed overview of double deck roll forming technology, including working principles, main components, types of machines, key specifications, parameters, applications, operation and maintenance, how to select suppliers, and pros and cons of double deck roll formers.
Overview of Double Deck Roll Forming Machines
Roll forming is a continuous bending process used to form metal coils into customized open profiles with an array of rollers. It is ideal for producing large volumes of sections efficiently at a low cost compared to extrusion or fabrication.
Double deck roll forming machines utilize two sets of roll forming stations arranged vertically to shape metal coils in two directions as the material passes through. This enables more complex geometries to be formed compared to single deck machines.
Main Advantages of Double Deck Roll Formers
- Increased forming capability for complex shapes and large sections
- Higher production rates due to two forming lines
- Dual directional forming improves profile precision
- Sections can be tapered by adjusting upper and lower rolls
- More rigid frame reduces deflection for accuracy
- Common drive system requires less maintenance
Typical Applications of Double Deck Roll Forming Machines
Double deck roll forming is commonly used to produce:
- Metal roofing and wall panels
- Steel doors and windows
- Rack and shelving posts
- Automotive and HVAC ductwork
- Agricultural silos and storage tanks
- Pre-engineered steel buildings
- Structural frames and support members
- Furniture tubing
How Double Deck Roll Forming Machines Work
Double deck roll forming utilizes a continuous process to shape sheet metal coils into open profiles. Here are the key steps:
- Coil sheets are fed into the de-coiling unit to be straightened.
- The sheet enters the serration rollers to even out thickness.
- Forming rollers progressively bend the strip through a series of stations.
- Top and bottom roller stations form the strip in two planes simultaneously.
- Cutting devices cut the strip to length when it reaches the end.
- Formed sections are collected on the exit conveyor.
Main Components of Double Deck Roll Formers
Double deck roll forming machines consist of the following major components:
Decoiler
- Feeds metal coil sheets into the roll former
- Contains dereeling arms to stabilize coil
- May have hydraulic expansion mandrel
- Often has leveler/straightener
Seriation Unit
- Uses small serrated rollers
- Evens out thickness variations in the strip
Forming Stations
- Contain top and bottom roller sets
- Progressively bend sheet through each stand
- Rollers are machined to required shapes
- Number of stands determines profile complexity
Cutting Device
- Shears, saws, laser, or water jet
- Cuts formed sections to length
- May have flying cutoff for continuous lengths
Controller
- Controls whole line from HMI panel
- Sets roller positions, cut lengths, speed etc.
- Interfaced to sensors and servo motors
Conveyors
- Transports sections from one end to the other
- Entry and exit conveyors may be used
- Transfers parts to next operation
Types of Double Deck Roll Forming Machines
Double deck roll formers are available in several configurations:
Fixed vs. Adjustable Roll Formers
- Fixed roll stations only form pre-set shapes
- Adjustable allows variable profiles within range
- Adjustable uses automated actuators on rollers
Standard vs. Customized Machines
- Standard models for common profiles
- Customized to required shape and size specs
- Customization increases initial cost
Manual vs. Automated Material Handling
- Manual loading/unloading by operator
- Automated transfers sheets in and out
Mobile vs. Stationary Roll Formers
- Mobile units are mounted on wheels or skids
- Stationary machines fixed permanently on foundations
Key Specifications of Double Deck Roll Forming Machines
Double deck roll forming machines are defined by these key specifications:
| Specification | Typical Range |
|---|---|
| Forming Speed | 10 – 100 m/min |
| Maximum Strip Width | Up to 2500 mm |
| Minimum Metal Thickness | 0.3 – 2.5 mm |
| Roller Diameter | 100 to 400 mm |
| Number of Stands | 10 to 50 |
| Main Drive Power | 5 to 100 kW |
| Line Accuracy | +/- 1 mm |
| Roller Adjustment | Manual or Servo Motor |
| Controller | PLC with HMI Touchscreen |
| Structure | Welded Steel Frame |
These parameters determine the size and profiles that can be produced. The number of forming stands required depends on the complexity of the shape. More stands allow more bends but reduce max speed.
Choosing the Right Double Deck Roll Former
Selecting the optimal double deck roll forming machine depends on these key factors:
- Metal type and thickness – affects choice of roll materials, drive power, and press capacity
- Part sizes and profiles – determines number of stands, roller diameters, widths
- Production volume – higher volumes need heavier duty and automated models
- Dimensional accuracy required – tighter tolerances need rigid frames and precision components
- Budget – initial cost is higher for larger, customizable, or automated machines
- Future expansion plans – consider ability to add more stands later or change tooling
- Available space – check area needed for machine length and material handling
Work closely with suppliers to match the roll former capabilities to your production requirements.
Double Deck Roll Forming Process Design
In order to achieve quality roll formed parts, the process must be designed properly. Here are some best practices:
- Model part geometry using CAD to visualize formed shapes
- FEA analysis determines stress points and guides tool design
- Design roll tooling profile using specialized software
- Iteratively adjust roller positions to optimize forming
- Simulate material flow through all stations
- Build in tolerance stacks from parts to rollers
- Write detailed forming sequence instructions
- Inspect initial sample parts and validate process
- Refine tools based on quality checks and feedback
- Document validated forming process for repeatability
Careful roll design, simulation, prototyping, and refinement ensures optimal roll formed part quality and process control.
Applications and Uses of Double Deck Roll Formers
Double deck roll forming is utilized to produce a wide array of part profiles across many industries:
Building and Construction
- Roofing, siding, wall panels
- Structural frames and supports
- Door and window sections
- Solar panel frames
- Flooring and decking profiles
- Drainage systems
- Scaffolding, safety barriers
Transportation
- Chassis, frames, and body panels
- Truck trailer side walls
- Railway car sections
- Shipping container frames
- Aerospace ducting and panels
Storage, Material Handling
- Racks, shelving uprights
- Silo wall panels
- Conveyor housings
- Equipment guards, safety barriers
- Ducting, hoppers, chutes
Furniture and Appliances
- Desks, cabinets, shelving frames
- Office cubicles, partitions
- Refrigerator liners
- Oven and dishwasher cavities
- Tubular furniture legs and arms
The flexibility to form virtually any open cross-section makes double deck roll forming suitable for producing a huge range of components across diverse industries.
Typical Double Deck Roll Formed Profiles
Here are some examples of common profiles produced using double deck roll forming machines:
C-Channels
Used for frames, supports, tracks, guides.Symmetrical shape provides strength.
Structural Tube Sections
For structural support systems. Hollow tube with flat sides
Sigma Sections
Sigma sections used for beams and columns. High second moment of area.
Zeds / Zee Sections
Zed profiles for roofing, cladding, structural use. Interlocking shape.
Angles / L-Sections
Angle profiles used for frames, supports, bracing. Provides rigidity.
Choosing a Double Deck Roll Forming Machine Supplier
Selecting the right supplier is crucial to get a high-quality double deck roll former. Here are important factors to consider:
- Technical expertise – Experienced in roll tooling design and process engineering
- Roll forming focus – Specialists dedicated to roll forming equipment
- Customization capabilities – Able to customize to your requirements
- Quality and precision – High accuracy standards and tolerances
- Reliable components – Uses reputable brands of motors, hydraulics, etc.
- Responsive service – Quick support for breakdowns or issues
- Knowledge transfer – Provides operator training and documentation
- Upgrade capabilities – Ability to add features, automation, or stands later
- Delivery reliability – On-time delivery record and lead times
- Longevity and reputation – Established suppliers with proven track record
- Value for money – Competitive pricing for quality equipment
- Local presence – After-sales support available in your region
Selecting an experienced roll forming specialist with design expertise, high build quality, responsive service, and proven reputation ensures you get capable and reliable equipment.
Installation and Commissioning of Double Deck Roll Lines
Proper installation and start-up of double deck roll lines is key to smooth operation. Here are some guidelines:
- Offload components carefully using forklifts, cranes, jacks
- Assemble machine sections according to marked plans
- Check alignments, clearances, and tolerances
- Perform static balancing of forming rollers
- Verify correct rotational directions of motors
- Install hydraulic power packs and piping
- Wire up control cabinets and I/O modules
- Interface encoder feedbacks to controllers
- Load tooling profiles and test roller positioning
- Thread pilot sheet through entire line slowly
- Monitor sheet flow, sensors, and clearances
- Make adjustments to guides, supports, and stations
- Gradually increase speed to rated production
- Confirm that all stations form part correctly
- Validate dimensional accuracy of end parts
- Make final adjustments for process optimization
- Document machine settings and process data
Careful installation, debugging, trial runs, and process documentation ensures the double deck roll line starts up smoothly and produces quality right from the beginning.
Operation and Maintenance of Double Deck Roll Lines
To achieve consistent production and throughput from double deck roll formers, proper operation and preventive maintenance is critical:
Operation:
- Monitor line speed, coil payoff, and strip flow
- Watch for flutter, jamming, or strip tracking errors
- Verify cut lengths, hole punching, part features
- Conduct regular quality checks on formed parts
- Measure key dimensions at defined intervals
- Check for wear on rollers, bearings, and guides
- Lubricate machine per maintenance schedule
- Inspect hydraulics, electrics, and safety devices
Maintenance:
- Establish routine maintenance schedule and checklists
- Train technicians on safety procedures
- Inspect roll tooling regularly for wear and damage
- Realign/replace worn rollers and guides
- Lubricate bearings and sliding components
- Verify hydraulic power pack operation
- Check motors, gearboxes, and drive couplings
- Monitor PLC, HMI, and electrical cabinets
- Perform machine calibration to original specs
- Document all maintenance activities
- Plan major overhauls during shutdowns
Following structured operation protocols and preventive maintenance activities ensures continuous and safe functioning of the roll forming line over its service lifetime.
How to Choose the Right Double Deck Roll Former
Selecting the optimal double deck roll forming machine depends on carefully evaluating your production requirements, part parameters, business objectives, and supplier capabilities. Here are key steps:
Define Production Requirements
- Profile shapes to be produced
- Metal material (steel, aluminum etc.)
- Material thickness and strip widths
- Annual volume per profile
- Tightness of tolerances
- Level of automation needed
Determine Key Machine Specifications
- Number of forming stations
- Roller size and adjustment type
- Line speed and accuracy
- Cutting method (shear, saw etc.)
- Coil handling method
- Drives, controls, and sensors
Evaluate Supplier Capabilities
- Experience with similar applications
- Design expertise
- Equipment quality and precision
- Customization flexibility
- Responsiveness to issues
- Operator training provided
- Future upgrade capabilities
Assess Value Proposition
- Compare proposals from shortlisted suppliers
- Evaluate quality, throughput, and reliability
- Consider total cost of ownership
- Weigh capital cost versus operating costs
- Review maintenance and service costs
- Discuss possible future expansions
Taking a structured approach to gathering requirements, outlining specifications, assessing suppliers, and evaluating total value ensures you select the optimal double deck roll former for your needs.
Pros and Cons of Double Deck Roll Forming Machines
| Pros | Cons |
|---|---|
| Higher production rates than single deck | More expensive initial cost |
| Increased forming capability and complexity | Larger space requirement |
| Dual directional forming improves precision | Design and tooling is more complex |
| Ability to taper and curve profiles | Needs preventive maintenance for uptime |
| Common drive reduces maintenance | Limited adjustment range in fixed models |
| Rigid frame gives better accuracy | Higher skill needed for operation |
| Wide range of profiles can be produced | Significant make-ready time for profile changeovers |
| Lower cost for high volumes than other processes | Limited for short production runs |
Double Deck Roll Former Costs
| Machine Type | Typical Price Range |
|---|---|
| Manual Fixed Roll Former | $40,000 to $60,000 |
| Automatic Fixed Roll Former | $60,000 to $150,000 |
| Manual Adjustable Roll Former | $60,000 to $100,000 |
| Automatic Adjustable Roll Former | $100,000 to $250,000 |
| Custom Roll Former | $150,000 to $500,000 |
Prices vary widely depending on:
- Number of forming stations
- Level of automation
- Customization requirements
- Additional features
- Production volumes
- Supplier reputation and quality
Higher process capabilities and production rates make double deck roll formers well suited for large production volumes despite the higher initial machine cost compared to single deck machines.
FAQ
What materials can be formed on double deck roll forming machines?
- Most commonly low carbon steel and stainless steel coils
- Also capable of forming aluminum, copper, and brass alloys up to certain hardness
What thickness of metal strip can be roll formed?
- Typical thickness range is 0.3 to 2.5 mm
- Thicker materials up to 7 mm can be formed with enough power
- Minimum bending radius limits material thickness
What profiles are best suited for double deck roll forming?
- Open profiles with multiple bends in two planes
- Sections up to 8 inches high and 3 inches thick
- Profiles with return flanges for strength and rigidity
How many roller stands are needed for typical profiles?
- 8 to 15 stands for simple C and U channels
- 15 to 25 stands for complex structural shapes
- More stands provide more forming capability
How to calculate if a profile can be roll formed?
- Model profile and simulate material bending
- Use roll design software to develop tooling profiles
- Adjust roller positions iteratively to form shape
- Build tooling and test forming process on machine
What are common problems in roll forming?
- Strip tracking errors, fluttering, jamming
- Roller wear, deflection causing shape deviations
- Scratches, deformities in formed parts
- Vibration and noise indicating alignment issues
- Hydraulic leaks or electrical faults
How long do roll forming machine tools last?
- With proper use and preventive maintenance, tools can last 12-18 months
- Carbide rollers provide longer working life
- Tool life depends on metal hardness and thickness
How to improve quality in roll formed parts?
- Ensure precision ground tooling profile
- Maintain tight tolerances in roller stands
- Frequently calibrate machine
- Control strip flow and feed rate
What safety precautions are important for roll forming?
- Enclose dangerous moving parts in shrouds
- Interlock access doors to power off machine
- Use safety mats and light curtains around machine
- Provide proper machine guarding mechanisms
- Require personal protective equipment for operators
What factors affect the line speed of a roll former?
- Metal thickness – thinner metal can run faster
- Number of forming stations – more stands reduce max speed
- Forming complexity – simpler profiles can run faster
- Available driving power – higher power allows higher speed
How to calculate machine straightness for roll forming?
- Establish a straightness baseline by running a tight wire
- Measure deviations from wire to machine elements
- Total indicator runout should be within 0.002 in/ft
- Shim and align machine elements as needed
What are common roll former malfunctions?
- Feed problems like skipping, jamming, flutter
- Roller misalignment causing profile errors
- Worn or damaged rollers and forming dies
- Drive and gearbox failures
- Hydraulic system leaks or electrical faults
How is roll tooling changed for quick die changeovers?
- Manual changeovers use hand tools to swap rollers
- Quick-change systems use cartridges or cassettes
- Powered roll change carts automatically swap stations
- Minimizes production downtime for die changes
What regular maintenance is required?
- Daily: visual inspection, lubrication, cleanup
- Weekly: check alignments, hydraulics, electrical
- Monthly: inspect rollers, bearings, gears
- Yearly: calibration, major overhaul, part replacement