Designing for rollforming

times   2015-11-27
Before production begins, carefully evaluate assembly drawings, part geometry and mating components, and identify ways to simplify the product. Eliminate excess notches or multiple bends in a part, and consider ways to reduce the need for fasteners or laser-cut components.

Designing for rollforming also presents new opportunities that challenge other production methods.
Complex sections often require multiple hits and several production processes to achieve a desired profile. Rollforming often eliminates much of this excess due to its ability to form complex linear shapes and perform secondary operations inline. Rollforming also is well-suited for parts requiring edge conditioning as well as long parts—the process accommodates part lengths beyond 50 ft.

Tooling costs often deter fabricators from traveling the rollforming road, but options exist to reign in this expense.
Evaluating how a part’s design can be simplified and optimized for rollforming will reduce costs down the line, and improve efficiency and product quality.
Material selection for a new part or product comprises a crucial element of cost control and design integrity. For rollforming to be most effective, opt for light-gauge high-strength low-alloy or structural steel—material whose physical condition can be manipulated during the rollforming process without losing strength.
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