Last time we took a closer look at the problems in the roll forming process and found that the work material is usually not the culprit.
If material is excluded, what could be the problem?No changes were made, and the operator and setup claim they didn’t do anything different.Well…
In most cases, the problem can be traced back to machine setup, maintenance or electrical issues.Here are some items you might want to include in your checklist:
It might surprise you that most material problems are directly related to machine problems or incorrect settings in the roll and punch tooling.Ensure operators and setup staff maintain and maintain good setup charts across all shifts.
Don’t put up with those infamous pocket books of secret settings!Troubleshooting opinions can be very costly, especially with regard to tooling and machine settings.
Now let’s talk about the toughest roll forming problem – lubrication.You want to eliminate lubrication problems permanently because in most operations you will find the purchasing department in control of this aspect of roll forming.
Usually, aside from material, this is the first line item the red pen hits.But wait!Why is it necessary to use any type of lubrication and then take it off?Why would anyone spend time, effort and money on this?Then why are we spending our hard-earned money on special lubricants?
Steel mills usually coat the coil with some kind of oil to prevent rusting.However, this oil was not developed for molding.
Physics Briefing.Simply accessing the physical properties of a material’s surface, we know that a metal surface is fairly rough, even though it appears smooth to the naked eye.
Picture peaks and valleys to better understand how polished surfaces look under the microscope.We also know that, according to Hertz’s formula for the pressure between elastomers, a harder material penetrates a softer material.Add friction to the equation and you get shear at the peak.
Over time, the summits are eroded and pressed into the coil material as they fracture.As you may already know, this effect is the deposition of material on the roll surface, especially on the high wear grooves.Obviously, this has an impact on product quality and tool life.
hot.In addition, the heat generated by the roll forming process comes from friction and forming energy and does not affect the microstructure of the material; however, in some cases, such as in-line welding, the heat can cause shape changes and other problems in the cross-section.A large amount of roll lubricant acts as a coolant.
Consider the final product.When choosing a roll forming lubricant, you must consider the finished product and its application.
There may be a slight wax residue on hidden parts, but what would happen if you used the same lubricant in a roofing application?Your credibility will drop, and that’s it.It’s best to discuss the application with an expert and remember that the right lubricant can have huge benefits; however, the wrong lubricant can cost you dearly in a number of ways.
Create a waste management plan.Also, you should think of lubrication as a complete system.This means you need to consider the environment, OSHA and local regulations to reap the benefits of lubricants and avoid hassles.
Most importantly, you need to establish a waste management plan.This program not only ensures that you are in compliance with the law, but also increases the efficiency of the process.The next time you walk through the factory, look around.You may find the following:
The point is that your efforts to improve and maintain your roll forming operations need to extend to lubricants.Don’t forget to focus on the maintenance aspect of lubrication – continuous use of molding lubricants and their proper disposal, or better yet, recycling.
FABRICATOR is North America’s leading metal forming and fabrication industry magazine.The magazine provides news, technical articles and case histories that enable manufacturers to do their jobs more efficiently.FABRICATOR has been serving the industry since 1970.
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Post time: Mar-18-2022