Overview
Angle steel roll forming machines are used to continuously bend metal coil into various angle steel sections and profiles for structural construction applications. They form 90-degree angles as well as custom angled corners.
Roll forming uses a series of consecutive pairs of roller dies to gradually bend the strip steel into the desired cross-sectional shape as it passes through the machine. The rollers apply pressure progressively to avoid sudden stresses and fractures in the material.
Compared to other bending methods, roll forming is highly efficient and economical for producing large volumes of angle steel parts in long lengths. It requires minimal material preparation and finishing work. The process is also highly customizable for creating specialized angle sections based on application requirements.
Key Details of Angle Steel Roll Forming Machines:
- Used for mass production of various angle steel sections like equal leg angles, unequal leg angles from coil strips
- Rollers bend the steel gradually through a series of stages into the angle shape
- Automated machines with very high output capacity up to 120 m/min
- Input material is steel coil which is continuously fed into the roll former
- Formed angle steel comes out continuously in long lengths as per order requirement
- Highly customizable roll tooling profiles for making special angle sections
- Better quality and precision compared to other bending methods
- Minimal finishing work required after roll forming process
Angle Steel Roll Forming Machine Types
| प्रकार | विवरण |
|---|---|
| हल किया गया | Basic roll forming system with fixed forming rollers in a linear layout |
| Adjustable | Rollers are adjustable for size changeovers and profile variations |
| Cage | Rollers enclosed in individual housings assembled in sequence |
| Pyramid | Rollers configured in a pyramid arrangement for multi-angle production |
| Portable | Compact and movable roll former for on-site installation |
Fixed: The basic type where the roll forming stands holding the roller dies are fixed in position in a straight-line layout. It can produce a single angle profile in high volumes but requires changing the entire roller sets for new profiles.
Adjustable: This allows adjusting the relative positions of roller stands incrementally to account for material springback and make fine tuning of profiles. Individual rollers can also be adjusted.
Cage: Each roller stand is enclosed in a robust individual housing assembled in the inline forming sequence. This offers protection and safety with flexible adjustment options.
Pyramid: Here the roll forming stands are arranged in a pyramid-like layout so multiple angle configurations can be formed simultaneously by splitting the material flow.
Portable: Lightweight and compact roll formers which can be relocated. Useful for on-site installation and small production runs.
Angle Steel Roll Forming Machine Characteristics
| Characteristics | Details |
|---|---|
| Forming Material | Mild steel, stainless steel, aluminum coils |
| द्रव्य का गाढ़ापन | 0.3 – 3 mm typically |
| Finished Part Length | Up to 40 m long angles |
| Width Capacity | 50 – 800 mm normally |
| Angle Leg Size | Equal or unequal legs from 15 – 180 mm |
| Inside Bend Radius | Typically 1 – 2 x material thickness |
| रोलिंग गति | Up to 100 m/min |
| Production Rate | 10 – 120 meters per minute |
- Coil strips of mild steel, galvanized steel, stainless steel and aluminum can be roll formed.
- Standard thickness capacity is 0.3 to 3 mm but larger thickness is possible.
- Formed angles can be made in lengths of up to 40 meters non-stop.
- Width capacity ranges from 50 mm to 800 mm depending on machine model.
- Both equal leg angles as well as unequal leg angles are possible. Leg sizes range from 15 to 180 mm.
- Inside bend radius is usually 1-2 times the material thickness to avoid cracking.
- High rolling speeds of up to 100 m/min are possible with some tiers.
- Production output rates vary from 10 – 120 m/min depending on the profile.
Angle Steel Profile Types
| Profile Shape | विशेषताएँ | अनुप्रयोग |
|---|---|---|
| Equal leg angles | Legs of equal size at 90 degrees | Structural frames, supports |
| Unequal leg angles | Legs of different sizes | Special connections |
| Lipped angles | One leg extended outward | Sliding contacts, tracks |
| Post angles | One shortened leg | Fencing, railing posts |
| Varying angles | Legs at other angles | Decorative features |
Equal leg angles: Most common type with legs of the same size perpendicular to each other. Used in construction frames, supports, foundations etc.
Unequal leg angles: Have legs of differing lengths to suit specific joint requirements. Used where asymmetric connections are needed.
Lipped angles: One leg is extended outward to form a lip or flange. Used for sliding contact surfaces like door tracks.
Post angles: One leg is shortened to create an offset. Used for fence posts, railing posts sunk into the ground.
Varying angles: Legs can be rolled at any desired angles for special decorative applications.
Angle Steel Roll Forming Machine Specifications
| विनिर्देश | Typical Values |
|---|---|
| Power | 5.5 – 55 kW motor |
| बनाने की गति | 10 – 120 m/min |
| Roll Stands | 10 – 24 stands |
| Roller Size | Φ100 – Φ220 mm diameter |
| रोलर सामग्री | 45# steel, induction hardened |
| चौखटा | Welded mild steel plates |
| Automation | PLC control, servo motors |
| Machine Size | 8000 x 1200 x 2200 mm (LxWxH) |
| Machine Weight | 8000 – 15000 kg |
- Main drive motor capacity from 5.5 kW to 55 kW
- Maximum rolling speed up to 120 m/min depending on the profile
- 10 to 24 roll stands needed for complete sequential forming
- Roller diameters between 100 – 220 mm normally with hardened surfaces
- Rollers made from 45# steel and induction hardened for durability
- Robust welded mild steel plate frames
- Automated forming process using PLC and servo motor drives
- Machine dimensions approx. 8000 mm long x 1200 mm wide x 2200 mm height
- Weight ranges from 8000 kg for smaller units to 15000 kg for heavy-duty models
Angle Steel Roll Forming Machine Standards
| Standard | Key Points |
|---|---|
| ISO 9001 | Quality management system |
| ISO 14001 | Environmental management compliance |
| सीई | European safety and performance certification |
| §5 of EN 1010 | Safety requirements for design and construction |
| EN 12643 | Tolerances and dimensions |
| EN 10111 | Material grades and compliance |
- International quality standard for design, manufacturing, production and service
- Certified environmental management system responsible disposal and waste reduction processes
- Mandatory certification for safety and performance benchmarks in Europe
- Strict structural safety norms for machine body construction
- Dimensional accuracy and tolerance limits of finished angle steel
- Specifies material grades for coils used and product compliance
Angle Roll Forming Machine Suppliers
| Supplier | Location | मूल्य सीमा |
|---|---|---|
| Botou Xianfa | China | $5000 – $30000 |
| Jouanel | फ्रांस | $10000 – $50000 |
| Gasparini | इटली | $20000 – $100000 |
| LMS Machines | UK | $15000 – $60000 |
| Metform | USA | $8000 – $45000 |
- Botou Xianfa: China based manufacturer offering cost-effective roll forming solutions from $5000 to $30000
- Jouanel: French engineering company providing high-end roll formers from $10000 to $50000
- Gasparini: Italian brand with innovative roll forming machines costing $20000 to $100000
- LMS Machines: British industrial equipment maker with machines between $15000 to $60000
- Metform: American player providing easy-to-use roll formers priced at $8000 to $45000
Angle Steel Roll Forming Machine Pricing
| क्षमता | Motor Power | रफ़्तार | मूल्य सीमा |
|---|---|---|---|
| Small | 5.5 – 7.5 kW | 10 – 20 m/min | $5000 – $15000 |
| Medium | 15 – 22 kW | 40 – 60 m/min | $15000 – $35000 |
| Large | 30 – 55 kW | 80 – 120 m/min | $30000 – $100000 |
- Small: Entry-level roll forming capacity with speeds of 10-20 m/min priced from $5000 to $15000
- Medium: Mid-range roll forming output of 40-60 m/min available from $15000 to $35000
- Large: Heavy-duty high speed roll forming up to 120 m/min priced between $30000 to $100000
Angle Steel Roll Forming Machine Installation
| Activity | विवरण |
|---|---|
| Site preparation | Ensure flat and level floor, 3-phase power supply, sufficient working space |
| Positioning | Use forklift or crane to place machine at desired location |
| Levelling | Adjust machine stands to ensure machine is plumb and horizontal |
| Power connection | Connect machine to suitable 3-phase power supply through isolator |
| Safety check | Verify correct installation of safety guards and devices |
| Machine testing | Test run the machine and make any calibrations needed |
| Trial operation | Run production trials and inspect sample angles to validate quality |
- Prepare site by ensuring a flat and rigid floor, availability of 3-phase electrical supply and enough working space around the machine.
- Use forklift or overhead crane to place the machine unit at the intended operating location.
- Adjust the machine stand legs to level the roll former precisely in a horizontal position.
- Electrical connections have to be made to a suitable 3-phase power supply through an isolator switch.
- Examine safety guards, emergency stops and sensors to confirm correct installation.
- Test run the empty machine and make any roller adjustments needed to achieve design profiles.
- Conduct trial production runs while inspecting the angle quality periodically to verify performance.
Angle Steel Roll Forming Operation
| Activity | विवरण |
|---|---|
| Material loading | Load coil strips at unwinding station ensuring smooth payoff |
| Feeding | Feed leading edge of coil through initial forming stands |
| Parameter settings | Input production speed, size settings, quantity required into the control panel |
| Process monitoring | Monitor forming process and inspect finished angles |
| Output cutting | Cut off formed angles at desired length using end shear |
| Material unloading | Offload finished angles carefully using appropriate means |
- Coil material has to be loaded at the rear unwinding station ensuring its smooth payoff.
- Lead the coil end through the initial forming rollers to start the process.
- Input the production parameters like speed, size settings and required order quantity via the machine control panel.
- Keep observing the roll forming process and inspect quality of finished angles at outlet.
- Cut off completed angle lengths at the specified dimension using the end shear.
- Carefully unload the finished angle pieces using lifting equipment or conveyors.
Angle Steel Roll Forming Maintenance
| Activity | Frequency |
|---|---|
| Inspection | Daily |
| सफाई | Weekly |
| स्नेहन | Monthly |
| Adjustment | As needed |
| Roller change | Yearly |
| Hydraulics service | Yearly |
| Machine overhaul | 3-5 years |
- Inspect the machine daily checking for any abnormal noises or malfunctions
- Clean the accumulating dirt and metal dust on a weekly basis.
- Lubricate the machine components like bearings using appropriate lubricants monthly.
- Make any adjustments to rollers or forming process as needed.
- Replace rollers at least annually as per wear and tear during production.
- Service hydraulic power pack and pistons annually for smooth functioning.
- Complete machine overhaul recommended every 3-5 years by the manufacturer.
How to Choose Angle Steel Roll Forming Machine
| Factor | Guidelines |
|---|---|
| Production needs | Consider current and future production volume requirements |
| Angle profiles | Types of angle sections and sizes to be produced |
| Material type | Grade of steel coil strip to be roll formed |
| Automation needs | Level of automation features desired for ease of operation |
| Budget | Optimize specifications as per budget constraints |
| Manufacturing standards | Ensure international quality and compliance certification |
| After-sales service | Review availability of technical support for maintenance |
- Analyze present and projected production volume needs and angle steel demand
- Choose machine capable of delivering the required angle profiles and sizes
- Consider the grade of input steel coil to be used – mild, stainless, etc.
- Determine automation needs for minimizing operator intervention
- Optimize specifications to get best value equipment within budget limits
- Verify international quality and safety standards compliance
- Ensure manufacturer provides responsive after-sales service support
Angle Steel Roll Forming Machine Pros and Cons
लाभ
- Highly efficient continuous bending operation
- Consistent and precise angle sections in long lengths
- Minimal secondary processing required after roll forming
- Customizable profiles by adjusting roller dies
- Automated for high productivity with less manpower
- Compact layout requires less space than other bending processes
- Lower tooling costs than other bending methods
Limitations
- Not economical for small production quantities
- Limited thickness and size capacities
- Roll tooling needs changing for new profiles
- Skilled personnel needed for maintenance and operation
- High initial capital investment for machine and tooling
- Limited capability for specialized bending applications
Angle Steel Roll Forming vs Other Methods
| Method | Comparison |
|---|---|
| Press Brake Bending | – Slower batchwise operation <br> – Limited length parts <br> – Higher tooling cost <br> – More secondary finishing <br> – Lower automation suitability |
| Section Bending | – Discontinuous production <br> – Inconsistent bend quality <br> – Size limitations <br> – Higher operational labor |
| Rotary Draw Bending | – Sequential batch production <br> – Material gripping marks <br> – Difficult oval corrections <br> – Only short to medium lengths |
- Press Brake: segmented batch production. Roll forming faster and lower cost.
- Section Bending: inconsistent bends requiring more correction. Automated roll forming superior.
- Rotary Draw: sequential bending leads to marking. Roll forming better for long angles.
सामान्य प्रश्न
Q: What are the different types of angle steel profiles that can be produced?
A: The common profiles include equal leg angles, unequal angles, lipped angles, post angles and custom angles of varying dimensions. Roll tooling can be designed to produce different profiles.
Q: What level of precision and tolerance can be achieved?
A: Roll formed angles can achieve a dimensional accuracy up to ±0.5 mm and angular tolerance of ±1° along 20 m length. The tolerance depends on material grade and machine rigidity.
Q: What is the typical inside bend radius of roll formed angles?
A: The inner radii are usually 1 to 2 times the material thickness. A smaller radius increases the chances of cracking during bending.
Q: How frequently are the roll dies changed for different profiles?
A: Roll dies may need changing weekly, monthly or yearly depending on production variety. Quick roll change designs reduce profile changeover time.
Q: What safety measures are incorporated in these machines?
A: Standard safety features include emergency stop buttons, electrical safety cut-outs, overload protection, safety guards, sensors and alarms.
Q: What maintenance activities are required?
A: Major tasks are daily inspection, regular lubrication, cleaning, roll replacement, hydraulic system overhaul and full machine refurbishing every few years.
Q: What is the typical production capacity of these machines?
A: Production output ranges from 10 to 120 meters of finished angle per minute. Higher capacities of above 100 m/min are possible with advanced roll formers.
Q: What expertise is needed to operate angle roll forming machines?
A: Operators require basic technical training to master control settings, material feeding, visual inspection skills and routine maintenance activities.