INTRODUCTION TO ROLL FORMING George T. Halmos Introduction to Roll Forming ROLL FORMING MILL George T. Halmos General Mill Types Mill Components References PRESSES AND DIE ACCELERATORS George T. Halmos General Mechanical Presses Pneumatic Presses Hydraulic Presses Information and Dimensions for Press/Die Purchasing and Installation Rotary and Other Cutting, Punching Equipment Flying Die Accelerators SECONDARY OPERATIONS IN THE ROLL FORMING LINE George T. Halmos Secondary Operations Straightening Tight or Loose Line: Cutting Before, In-Between, or After Roll Forming Location of the Secondary Operations Stationary and Flying Dies Punching, Perforating, Notching, and Mitering Piercing and Partial Punching Flanging, Louvering, and Lancing Embossing and Drawing Bending Curving (Sweeping) Marking Swedging (Off Setting) Rotary Dies Mechanical Joining of Different Strips or Parts Adhesive Bonding Soldering and Brazing Resistance Welding Painting Foaming Packaging References ROLL DESIGN George T. Halmos Roll Design Process Cross-Section Product Orientation and Other Operations in the Line Materials Roll Forming Mill Other Tool Design Considerations Spacers and Shims Calculating Strip Width Bend Lines Number of Passes Flower Diagram Roll Design Calculating Roll Dimensions Manually Computer-Aided Roll Design Examples Roll Marking System Roll Orientation Setup Charts References MATERIALS George T. Halmos Design Considerations Mechanical Properties Crystalline Structure of Metals Forming Metals Increasing the Strength of Metals by Cold Working Hot Rolling H.R. and H.R.P.O. Steels Cold Rolled Steel Carbon Steel Alloyed Steel Stainless Steel Metallic Coatings Nonmetallic Coating and Laminating Joining Different Materials in the Roll Forming Process Aluminum Other Metals and Materials Influence of Primary Metal Processes on Roll Forming Guideline to Steel Prices References LUBRICATION Joseph Ivaska Tribology of Lubrication Selection of Lubricants Surface Properties of Formed Material Lubricants for the Secondary Operations Application Techniques Preparation and Maintenance of Lubricants Operating Problems during Production COIL PROCESSING, MATERIAL HANDLING, AND PLANT LAYOUT George T. Halmos and Joseph Horvath Flow of Material Coil Handling and Storage Sheet Handling and Storage In-Line Coil Handling Coil End Welding Strip (Coil) Accumulators Flattening and Leveling In-Line Sheet Handling Finished Product Handling Finished Product Storage Material Handling Equipment Material Handling Accessories Crane Controls Plant Layout References DESIGNING PRODUCTS FOR ROLL FORMING George T. Halmos Developing Light Gage Products Design Considerations Secondary Operations Profiles Manufactured in Different Sizes Design of Specific Products Dimensioning and Tolerancing References EQUIPMENT INSTALLATION, ROLL SETUP, MAINTENANCE, AND TROUBLESHOOTING George T. Halmos Installation of Roll Forming Lines Roll Installation and Setup Maintenance and Spare Parts Troubleshooting and Trouble Prevention BEHAVIOR OF METAL STRIP DURING ROLL FORMING Manabu Kiuchi Various Types of Deformations Causes of Redundant Deformations Effects of Redundant Deformations on Product Defects Mathematical Simulation of the Deformation of a Metal Strip Computerized Design System for Roll Profiles CAE for Roll Forming ACQUIRING ROLL FORMING LINES, EDUCATION, AND TRAINING George T. Halmos Why Roll Form Products? Different Paths to Start Roll Forming Evaluating the Product Selecting Line Components Procuring Roll Forming Tooling Equipment and Tool Specifications Acceptance Test Education and Training Motivation References SAFETY Ashok Shah Safety Common Safety-Related Definitions Safety Design Procedure Determining Limits of the Machinery or System Determining Hazards/Risk Estimation Risk Reduction by Design Safeguarding Selection of Guards and Protective Devices Required Characteristics of Guards and Protection Devices Signals and Warning Devices Personal Protective Equipment Training Summary References INCREASING EFFICIENCY OF ROLL FORMING LINES AND CASE STUDIES George T. Halmos Output, Productivity, and Efficiency Line Utilization Improving Productivity Case Studies Preliminary Tool and Equipment Cost Analysis Preliminary Cost Analysis UNUSUAL, NEW, AND FUTURE ROLL FORMING TECHNOLOGIES George T. Halmos The Last 100 Years The Future of Roll Forming Pull-Through Mills: Nondriven Rolls Tension Roll Forming Combining Roll Forming and Cold Drawing Developing New Roll Forming Methods Roll Forming Tools Reducing the Thickness of the Starting Material Forming at Elevated Temperature Hot Roll Forming Variable Cross-Sections Hot Thickness Reduction along the Length of the Strip Welding Hot Roll Formed Sections Other "Hot" Processes In-Line Soldering, Brazing, and Heat Treating Equipment and Tooling Requirements for Hot Roll Forming Press Tooling for Conventional Roll Forming Lines Computer-Controlled Roll Forming Lines References APPENDICES REFERENCES INDEX