The work efficiency of the cold roll forming machine mainly depends on the roll shape and structure of the production tool. The most widely used production tool is the forming roll. The most complicated problem in cold roll forming is the determination of the shape of the forming roller. As the requirements for the stability of the strip and the quality of the profile increase, and the forming speed of the cold roll forming machine increases, higher and higher requirements are placed on the forming roll.
The basic principles for determining the number of passes and the shape of the roller of cold roll forming equipment are as follows:
1. In the case of using the least number of passes, the shape of the roller should make the material have uniform and most reasonable deformation.
2. According to the selected central axis which is constant in each pass, the vertical and horizontal dimensions of the roller profile are determined and calculated. For asymmetrical shape, this axis is the axis of symmetry.
3. Divide the profile section into sections and calculate the length of each section. The total degree of each segment on the left and right sides of the selected centerline remains unchanged in all passes.
4. The turning angle of the arc at the bottom of the profile cannot exceed 45° in a pair of rollers.
5. The bending of the vertical wall does not proceed simultaneously with the arc bending of the bottom.
6. It is suggested that the inclination angle of the upper roller is 1.5 to 2 degrees larger than that of the lower roller.
7. When the bending inner diameter is very small, in order to make the material bend easily and to be able to mark the position of the bending line, a groove recessed into the contour can be cold-rolled on the strip in advance.
8. The shape of the last pair of cold-formed steel machine should take into account the elastic rebound data.
9. In order to prevent the axial deviation of the roller, it is recommended to make a flange to cover the flange or protrusion of the corresponding roller.
10. In order to prevent the manufactured profile from twisting or bending after escaping from the last roller, a discharge guide is installed to straighten the profile.
11. The factors that should be considered when designing the roll profile of a cold roll forming machine for the production of specific products include forming passes, strip width, roll design, forming roll parameters, forming roll materials and so on.
