Stam Roll Forming Machines

Overview of Stam Roll Forming Machines

Stam roll forming machines are used to form metal sheets into customized profiles through a series of consecutive bending operations. They are versatile equipment capable of producing components for a wide range of applications from roofing and siding to racking systems, solar panel frames, highway products and more.

Roll forming offers several advantages over other metal forming processes:

  • Highly automated production of continuous profiles at fast speeds
  • Ability to form complex shapes with tight tolerances
  • Low tooling costs compared to other processes like stamping
  • Minimal material waste since profiles are formed from coiled flat sheets
  • Flexibility in production volume as roll sets can be changed quickly

Stam has been a pioneering name in roll forming technology for over 50 years. Their roll forming machines range from smaller units for low volume runs to high capacity lines producing over 100 meters of profile per minute.

Some of the key features of Stam roll forming equipment are:

Roll Forming Machines Guide

Production LinesHigh speed, high volume lines with multiple stands and loop control for continuous production
Compact LinesCost-effective lines with lower output volumes but quick changeover ability
Portable Roll FormersLightweight portable units easy to move between sites
Specialty LinesCustomized lines for specialized high-strength profiles or thick gauge material forming
ToolingComplete range of standard and custom roll tooling, punches, dies, etc.

Roll Former Characteristics

Forming StationsUp to 20 forming stands depending on profile complexity
গঠন গতিUp to 100 m/min on high capacity lines
Material ThicknessUp to 8 mm for specialty heavy gauge lines
Material WidthUp to 2100 mm on largest production lines
Roll DesignVarious profiles – round, square, rectangular, trapezoidal etc.
AutomationLoop control, programmable PLCs, quick die change systems
OptionsDecoilers, straighteners, pre-punches, cutoff saws, stackers etc.

Applications of Stam Roll Formers

IndustryTypical Profiles Produced
ConstructionRoofing sheets, wall panels, cornices, studs, purlins
AutomotiveWindow frames, mudguards, pillars, exhaust components
AppliancesPanels, housings, frames, door components
FurnitureRacks, frames, shelves, table legs
AgricultureSilo panels, drainage profiles, cow mats
InfrastructureStructural profiles, highway crash barriers, utility poles
Stam Roll Forming Machines
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Specifications Overview

Roll forming technology involves gradual bending of strips or coils of sheet metal into desired cross-sectional shapes. This is done by passing the sheet through consecutive sets of contoured rolls. Each set incrementally forms the shape a little more until the final profile is achieved.

Common design standards and structural specifications of Stam roll forming machines include:

  • Number of roll stations – Typically between 6 to 20 depending on profile type
  • Roll station type – Breakdown stations for initial forming and sizing stations for final precision
  • Roll shaft diameter – Higher rigidity needed for heavy gauge forming so diameters up to 180 mm may be used
  • Roll adjustment design – Quick and precise roll gap settings are key for quality profiles
  • Roller bearings – Heavy duty bearings required for rolling high strength steels
  • Roll materials – Alloy steel or hardened steel rolls needed for long service life
  • Roll geometry – Sophisticated CNC grinders used to create precise roll contours
  • Roll parallelism – Maintaining parallelism between top and bottom rollers critical for control of material flow
  • Material feed system – Robust direct drives with electronic controls preferred over chain/sprocket drives
  • Strip guidance control – Multi-roller systems or edge guider rolls to maintain centering of strip
  • Horsepower capacity – Higher HP motors and gearboxes mandatory for fast cycle times and heavy gauge rolling
  • Frame and base – Stable C-frame in high tensile steel with concrete foundation for minimising vibrations
  • Safety features – Emergency stop buttons, roll guards, light curtains, access interlocks etc.

Guide for Choosing Stam Roll Forming Equipment

Selecting the appropriate Stam roll forming machine depends on assessing production requirements and choosing equipment capabilities accordingly:

Part volumesHigh speed lines for over 50,000 pieces/year. Compact lines for 5,000-50,000 pieces/year
Material typeMild steel up to stainless steel, aluminium, copper etc. Specialty alloy competency required
Material thicknessThinner gauges can use smaller diameter rolls. Thicker gauges need heavier duty roll tooling
Part dimensionsNarrower widths need lesser forming stations than wider profiles
Profile complexityIntricate shapes need more forming stations and may run at slower speeds
Quick changeoverMinimise setup time between jobs with quick change forming heads and rollout stands
Line automationHigher automation for continuous high volume production. Semi-auto lines for low volume batch production
Total line costConsider TCO including ancillary equipment like decoilers, straighteners, cutoff saws etc.
Production environmentCleanroom specification possible for electronics/medical applications
SafetyAdditional safeguarding as per safety norms in respective countries
ServiceResponsive aftersales support for maintenance and spare parts supply

Roll Forming Machine Buyer’s Guide

Some tips for customers planning to purchase Stam roll forming equipment:

  • Clearly define annual production volumes and product mix to be run on the machine
  • Calculate maximum material width, thickness, yield strength to determine machine capacity needed
  • Factor in any secondary operations like punching, notching, hole cutting to be done inline
  • Engage with technical sales engineers early on for design consultancy and project planning
  • Request reference lists of customers producing similar profiles to assess track record
  • Ask for actual line layout drawings based on space constraints at your factory
  • Review options for automation – PLCs, servo controls, sensors for monitoring
  • Specify ancillary equipment modules – decoilers, straighteners, inspection tables etc.
  • Consider aftersales service response time to minimize production downtime
  • Compare life cycle costs offered by various manufacturers
  • Negotiate for performance trials of machine at manufacturer’s demo center
  • Ensure adequate training of operators is included in the machine purchase

Roll Forming Process Overview

DecoilingSheet coil mounted on powered decoiler. Adjustable tension control for various gauges
FeedingRollers or motorized feed tables used to feed metal sheet into first station
FormingSheet passes through consecutive forming stations to gradually attain profile
CutoffEnd cutoff device – rotating shear or saw cuts profile to required length
Exit tableFormed pieces placed on exit table for inspection and offline operations

Standard Roll Forming Equipment Configuration

  • Decoiler or uncoiler unit
  • Feed or straightening rolls
  • Accumulator or loop control device
  • Forming stations with top/bottom contour roll sets
  • Punching or notching station if needed
  • Shear and cutoff machine for cutting to length
  • Exit table for collection of formed pieces
  • Electrical panel for controls and automation

Inline vs Batch Production Methods

Inline Roll FormingBatch Production
Continuously forms profiles from coilForms pre-cut sheet blanks
Higher production ratesLower production rates
Needs fewer operatorsNeeds manual loading of blanks
Close tolerance control between piecesMore variability between pieces
Automated size cutoffManual cutting to size
Suited for long production runsBetter for lower volume runs
Compact layoutWork flow may be spread out

Choosing Between New and Used Roll Forming Lines

New Roll Forming LinesUsed Roll Forming Machines
Fully warranted equipmentNo warranty coverage
Latest technology and safety featuresMay lack newer safety features
Customized to your product needsLimitations in adjusting to different profiles
Predictable repair and maintenance costsHigher risk of unanticipated breakdowns
Minimized workflow disruptionsMore prone to downtime
Higher initial capital investmentSignificant cost savings over new equipment
Ideal for high precision or critical applicationsAcceptable for less precision applications
Reduced risk of retrofitting issuesMay need some upgrades or refurbishing
Easier to get operational support from OEMOEM support may not be available
stam roll forming machine
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Operating Guide for Roll Forming Lines

Material loadingUse overhead crane or forklift to load coil on decoiler. Ensure steady rest at rear is set.
Decoiler setupPosition coil on mandrel and secure rear end. Set decoiler tension and straightener rolls pressure.
Forming setupInstall correct forming rolls in each station as per tooling layout drawings. Check parallelism and set gaps.
Trial runningRun initial pieces at slow speed while monitoring forming process. Check profile dimensions.
Full speed runningRamp up to full operating speed once trial step is passed. Confirm part quality.
Roll maintenancePeriodically inspect roll surfaces for wear. Grind/rechrome rolls if surface defects appear.
LubricationApply lubricating oil on forming rolls periodically to prevent corrosion and improve surface finish.
SafetyEnsure light curtains, access guards and emergency stops are functional at all times. Require hearing protection for operators.

Roll Tooling Maintenance Guidelines

  • Visually inspect rolls once per shift for damage or wear
  • Measure roll diameters periodically to identify any uneven wear
  • Lightly grind roll surfaces if fine cracks or pitting observed
  • Re-chrome forming rolls if chroming has worn excessively
  • Replace rolls if severe indentations, galling or scoring is present
  • Check roll parallelism and re-adjust if tolerance exceeds 0.02 mm
  • Confirm roll materials match the sheet material specifications
  • Protect rolls from corrosion by oil coatings when line is idle

Troubleshooting Common Roll Forming Defects

DefectPossible CausesCorrective Actions
Profile distortionRolls out of parallelism, worn rolls, strip misalignmentRe-align rolls, replace badly worn rolls, adjust strip guidance
Surface marksRoll surface damage, foreign particle ingress, unsuitable lubricantDress roll surface, improve filtrations, change lubricant
Profile springbackElastic recovery of metal, excessive roll gapsIncrease bottom roll diameter, minimize roll gaps
Burrs on edgesRoll gaps too narrow, damage to roll edgesOpen roll gaps slightly, file/dress damaged roll edges
Thickness variationsNon-uniform coil hardness or gauges, worn rollsImprove coil quality control, timely roll grinding/replacement

Cost Breakdown of Roll Forming Lines

ComponentShare of Total Cost
Forming stations with rolls25-30%
Decoiler and feed section15-20%
Cutoff saw and exit tables10-15%
Electricals and controls10-15%
Frames and enclosures10-15%
Design and installation10%
Ancillary equipment5-10%
Logistics and freight5%

As can be seen, the forming rolls and stations account for the largest share of the total line cost. The frame, controls, and material handling equipment together account for almost half the expenditure. Customers should align their budget to the production volumes and level of automation needed.

Buying Criteria When Comparing Roll Forming Machine Suppliers

Years in business15+ years idealUnder 5 years risky
SpecializationDedicated roll forming machinery companiesTraders or resellers without technical expertise
Production scaleIn-house manufacturing preferredTraders or assemblers reliant on outsourced components
Design capabilitiesSophisticated 3D modeling analysis idealManual or outdated design practices
Quality accreditationISO-certifiedNo quality systems certification
Customer baseReferences from established companiesReferences from small/unknown companies
Aftersales serviceQuick response workshops near youManufacturers situated remotely overseas
Commercial termsWillingness to offer trials and demonstrationsPressure sales tactics without proper demonstrations

As a strategic investment, customers would do well to partner with established roll forming machinery brands that offer the complete end-to-end solution.

Stam Roll Forming Machines
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Q: What types of profiles can be produced on Stam roll forming machines?

A: Stam roll formers can produce a wide variety of profiles from simple geometries like angles, rails, channels to complex shapes like solar panel frames, highway guardrails, engineered structural sections etc. Common applications include roofing and wall panels, racks, highway components, shelves, door and window sections etc.

Q: How fast is the roll forming process?

A: Production speeds vary based on part complexity. Typical speeds are 10-15 m/min for simpler profiles and 60-100 m/min for high speed lines producing basic C/U channels continuously. Specialty alloys may be limited to 30 m/min ranges.

Q: What size coils can be used for roll forming?

A: Many standard Stam roll forming lines accept 1500 to 2100 mm width coils with thicknesses from 0.5 up to 8 mm. Coil I.D. ranges from 508 mm to over 1500 mm while coil O.D. can go over 2100 mm on high capacity decoilers. Coil weight capacities are normally 10 to 30 tons.

Q: How does roll forming compare to press braking or bending sheet metal?

A: Roll forming is faster and more economical than brake pressing for producing linear parts in long lengths. It also enables close tolerance control across the full profile length. Press braking is better suited for short length components in small batches.

Q: What is the advantage of servo motor driven roll forming over mechanical drives?

A: Servo drive based Stam roll forming machines allow programming of speed variations at different stations to optimise forming. This avoids overloading by dynamically controlling tooling speeds, reducing cone/bow defects.

Q: What level of operator skill is needed for roll forming?

A: Stam roll forming lines are designed for quick setup by semi-skilled operators. CNC controls, recipe storage, and automatic features minimise manual intervention needed. Some training is still required for activities like roll change, maintenance, troubleshooting etc.

Q: How often are roll changes needed on a multi-profile roll forming line?

A: On typical Stam flexible roll forming lines used for the construction industry, roll changes may be needed once every 1-2 days when switching between profiles like roofing sheets, girts, studs etc. Quick change tooling and automated preset recall helps fast changeovers.

Q: What kind of testing or inspection is done on profiles coming off a roll former?

A: Inspection tables allow checking of critical dimensions like depth, width, straightness and angularity. Wall thickness gauges may be used to sample thickness at regular intervals. Visual inspection for surface defects is also done before packed for dispatch.

Q: Can a roll forming machine be used for prototyping and short production runs?

A: Yes, manual and semi-automatic Stam roll forming lines are well suited for small scale production. With quick roll changes and offline cutting, they offer an economical solution for prototyping and pilot batches for new custom profiles.

Q: Does Stam provide roll design software for developing new tooling profiles?

A: Stam offers ProfileRoll Design software to help customers develop and simulate new roll forming profiles. It optimizes the number of stands required and roll geometry to produce profiles within specified tolerances. The software models help reduce empirical guesswork and development time.

Q: What maintenance activities are required on roll forming machines?

A: Activities like roll grinding, roll chrome plating, bearing lubrication,belt tensioning, visual inspection of components for wear/damage, and keeping the machines clean are part of standard preventive maintenance. This is required at prescribed intervals for reliability.

Q: How long does it take to change between different profiles on the same machine?

A: On manual lines, roll change time can range from 20 to 90 minutes depending on the complexity. On fully automatic quick change lines with easy split forming heads, complete roll changes are accomplished in 15 minutes or less making frequent profile changes feasible.

Q: Can other metal fabrication operations like punching or cutting be integrated with roll forming?

A: Yes, it is common to have punching stations or end of line cutting processes integrated inline with roll forming for processing efficiency. Other secondary operations like stamping, shearing, milling can also be combined depending on the production process flow.

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