DK1201 FL

A volume in the series

New! Manufacturing Engineering and Materials Processing

Edited by
George T. Halmos CONTENTS
Delta Engineering Inc., Toronto, Ontario, Canada INTRODUCTION TO ROLL Spacers and Shims
FORMING; George T. Halmos Calculating Strip Width
Practical Knowledge for Immediate Introduction to Roll Forming Bend Lines
ROLL FORMING MILL; Number of Passes
Implementation George T. Halmos Flower Diagram
General Roll Design
Roll forming is one of the most widely Mill Types Calculating Roll Dimensions
used processes in the world for form- Mill Components Manually
ing metals. Most of the existing knowl- References Computer-Aided Roll Design
edge resides in the minds of those who PRESSES AND DIE Examples
have learned from experience or in ACCELERATORS; Roll Marking System
various journal articles. Providing a George T. Halmos Roll Orientation
vehicle to systematically collect and General Setup Charts
share this important knowledge, the Mechanical Presses References
Roll Forming Handbook presents the Pneumatic Presses MATERIALS; George T. Halmos
first comprehensive, dedicated treat- Hydraulic Presses Design Considerations
ment to all facets of roll forming, sup- Information and Dimensions for Mechanical Properties
plying references to more in-depth Press/Die Purchasing and Crystalline Structure of Metals
Installation Forming Metals
information to fill in the gaps.
Rotary and Other Cutting, Increasing the Strength of Metals
This book spans from conception of the roll forming operation, Punching Equipment by Cold Working
purchasing and specifying equipment, and roll design to main- Flying Die Accelerators Hot Rolling
tenance, troubleshooting, safety, and operator training. SECONDARY OPERATIONS IN H.R. and H.R.P.O. Steels
Detailed discussions reveal how material, equipment, tooling, THE ROLL FORMING LINE; Cold Rolled Steel
and operator factors affect overall efficiency and product qual- George T. Halmos
Carbon Steel
ity. Expert contributors share insights based on many years of Secondary Operations
Alloyed Steel
hard-won experience, including effects of secondary operations Straightening
Stainless Steel
such as punching, embossing, curving and cutting in the line; Tight or Loose Line: Cutting
Before, In-Between, or After Metallic Coatings
designing products for efficient roll forming; mechanical prop- Nonmetallic Coating and
Roll Forming
erties of metals, lubrication and the influence of coatings on roll Location of the Secondary Laminating
design and forming; and mathematical simulations of various Operations Joining Different Materials in the
deformations that occur during processing to determine their Stationary and Flying Dies Roll Forming Process
causes and find a solution. Punching, Perforating, Notching, Aluminum
and Mitering Other Metals and Materials
Outlining a practical approach to select, set up, and operate roll
Piercing and Partial Punching Influence of Primary Metal
forming lines, the Roll Forming Handbook combines scien- Processes on Roll Forming
tific background and practical know-how that enables you to Flanging, Louvering, and Lancing
Embossing and Drawing Guideline to Steel Prices
set up cost-effective and high-quality roll forming lines with References
confidence. Bending
Curving (Sweeping) LUBRICATION; Joseph Ivaska
Marking Tribology of Lubrication
FEATURES Swedging (Off Setting) Selection of Lubricants
Rotary Dies Surface Properties of Formed
• Includes real-world case studies, recommendations Material
for efficient plant layout and material handling Mechanical Joining of Different
Strips or Parts Lubricants for the Secondary
as well as hundreds of illustrations and references Operations
Adhesive Bonding
• Explains the principles and methods of manual Application Techniques
Soldering and Brazing
and computer-aided roll design and tool setup Preparation and Maintenance of
Resistance Welding Lubricants
• Supplies equations to calculate number of passes, Painting Operating Problems during
shaft diameters, and bending factors, published Foaming Production
here for the first time Packaging COIL PROCESSING, MATERIAL
References HANDLING, AND PLANT LAY-
• Presents guidelines for training personnel as well ROLL DESIGN; OUT; George T. Halmos and
as for performing troubleshooting and maintenance George T. Halmos Joseph Horvath
Roll Design Process Flow of Material
Cross-Section Coil Handling and Storage
Product Orientation and Other Sheet Handling and Storage
Operations in the Line In-Line Coil Handling
Materials Coil End Welding
Roll Forming Mill Strip (Coil) Accumulators
Catalog no. DK1201, November 2005, 584 pp. Other Tool Design Flattening and Leveling
Considerations
ISBN: 0-8247-9563-6, $169.95 / £97.00 See reverse for continuation of contents and ordering information
 Contents continued — Roll Forming Handbook
In-Line Sheet Handling ACQUIRING ROLL FORMING LINES, Improving Productivity
Finished Product Handling EDUCATION, AND TRAINING; Case Studies
Finished Product Storage George T. Halmos Preliminary Tool and Equipment Cost
Material Handling Equipment Why Roll Form Products? Analysis
Material Handling Accessories Different Paths to Start Roll Forming Preliminary Cost Analysis
Crane Controls Evaluating the Product UNUSUAL, NEW, AND FUTURE ROLL
Plant Layout Selecting Line Components FORMING TECHNOLOGIES;
Procuring Roll Forming Tooling George T. Halmos
References The Last 100 Years
DESIGNING PRODUCTS FOR ROLL Equipment and Tool Specifications
The Future of Roll Forming
FORMING; George T. Halmos Acceptance Test Pull-Through Mills: Nondriven Rolls
Developing Light Gage Products Education and Training Tension Roll Forming
Design Considerations Motivation Combining Roll Forming and Cold Drawing
Secondary Operations References Developing New Roll Forming Methods
Profiles Manufactured in Different Sizes SAFETY; Ashok Shah Roll Forming Tools
Design of Specific Products Safety Reducing the Thickness of the Starting
Dimensioning and Tolerancing Common Safety-Related Definitions Material
References Safety Design Procedure Forming at Elevated Temperature
EQUIPMENT INSTALLATION, ROLL Determining Limits of the Machinery or Hot Roll Forming Variable Cross-Sections
SETUP, MAINTENANCE, AND System Hot Thickness Reduction along the Length
TROUBLESHOOTING; George T. Halmos Determining Hazards/Risk Estimation of the Strip
Installation of Roll Forming Lines Risk Reduction by Design Welding Hot Roll Formed Sections
Roll Installation and Setup Safeguarding Other “Hot” Processes
In-Line Soldering, Brazing, and Heat Treating
Maintenance and Spare Parts Selection of Guards and Protective Devices Equipment and Tooling Requirements for
Troubleshooting and Trouble Prevention Required Characteristics of Guards and Hot Roll Forming
BEHAVIOR OF METAL STRIP DURING Protection Devices Press Tooling for Conventional Roll Forming
ROLL FORMING; Manabu Kiuchi Signals and Warning Devices Lines
Various Types of Deformations Personal Protective Equipment Computer-Controlled Roll Forming Lines
Causes of Redundant Deformations Training References
Effects of Redundant Deformations on Summary APPENDICES
Product Defects References REFERENCES
Mathematical Simulation of the Deformation INCREASING EFFICIENCY OF ROLL INDEX
of a Metal Strip FORMING LINES AND CASE STUDIES; ORDER ONLINE AT
Computerized Design System for Roll George T. Halmos
Profiles Output, Productivity, and Efficiency
CAE for Roll Forming Line Utilization
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