Custom roll forming is the process of custom shaping strip metal by passing it through a series of specially designed rolls.
From initial concept through to final approval, here’s an outline of our custom roll forming process:
Decoiling Metal strip passing through a decoiler. High quality metal strip – ranging from 0.5-6mm thickaccording to the customer specification – is loaded onto the decoiler and fed through the entry guide.
Pre-Piercing Metal strip being pre-pierced. The strip is fed through our pre-piercing machine where holes can be pierced as specified.
Roll Forming 1 Metal strip being fed through forming rolls. The strip is then fed through to the forming rolls, which gradually change the shape of the strip to generate the desired profile.
Roll Forming 2 Each roll performs only an incremental part of the bend. Each roll performs only an incremental part of the bend, until the desired cross-section profileis achieved.
Roll Forming 3 The profile gradually begins to take shape. Step by step, with every forming roll, the profilegradually begins to take shape, providing superb dimensional accuracy and a smooth finish.
Induction Welding 1 A closed profile approaches the induction welder. If a closed profile is required ourinduction welding process provides an almost flat weld seam with strength superior to the yield of the parent material. We then use eddy current testing to ensure weld integrity.
Induction Welding 2 The tube is sealed by the induction welder. The tube is sealed, generating a complete profile with a flat, almost invisible, seam and a weld strength superior to the yield of the parent material.
Flying Cut Off The flying cut off cuts the profile into individual lengths. The profile is then fed through to our flying saw, which cuts it into individual lengths. Theindividual profiles are then released and stacked together, ready for final packing and dispatch or to move on for secondary operations.
In addition to the profile manipulation service, we also offer a range of additional processes to enable us to provide a finished item, and remove the need for you to carry out secondary processes. From drilling to laser profiling, the range of processes we offer is shown below:
For components where standard holes are required drilling and punching is the simplest operation. Formore complex holes patterns automatic drill rigs and laser processes can be developed in-house.
Where the tolerances are critical and concentricity of the hole or holes is a key factor in the process, rotor broaches can be used to produce a quality finish. Again this can be a singular manual process or built into an automated jig for more complex developments.
Fabrications and production of sub-assemblies consisting of manipulated or straight parts is a fundamental part of day to day supply chain. Dedicated fabrication cells have been created to ensure that we can provide our customers with the most efficient and flexible service which can be tailored to the customer’s needs through a joint development process.
Complex fabrications can be developed and manufactured using dedicated jigs and tooling designed and produced in house by our technical department, this attention to detail ensures that bothquality and continuity from assembly to finished product meets the customers requirements and the highest quality standards.
To create accurate angles or high tolerance products during or after the forming or fabrication processes the Manipulation division has the capability through dedicated equipment to add specific cutting detail.
Through standard or bespoke jigs and fixtures either prototype parts or large batch volumes can be produced at the highest quality levels and tolerance standards with excellent repeatability.
Laser profiling has become an economical high tolerance controlled method of producing components where previously a number of machining operations would have been employed to achieve the same result.
The Profile Manipulation Division utilises 5 axis and Flat Bed laser technology to allow our customers the flexibility to have high quality customised bespoke endconditions. It also allows us to produce complex hole configurations on standard or complex manipulated components.
The specification of 3-Dimensional end cut conditions and complex hole configurations for ease of fabrication has seen the Metsec Profile Manipulation Division significantly increase the use of 5-Axis laser technology to provide complex component parts to our customers exacting requirements.
The Profile Manipulation division specialises in the process of cold bending, forming and sweeping of metal sections or tubes. At the cutting edge of metal forming we have the capability to produce virtually any manipulated product from a limitless range of profile shapes, tubes and standard sections. For applications such as: safety and roll over protection systems for agricultural vehicles, excavators, construction vehicles and fork lift trucks.
The process of mandrel bending is used when the geometry of the profile is to remain consistent during and after bending.
A precision mandrel of the same profiles is held within the profile during bending to prevent the profile from collapsing, whilst external tooling is applied to prevent the profile from distorting.
Mandrel bending allows tubes to be bent to ever decreasing radii without deformation.
Sweep bending is used for producing a continuous sweep within part or all of a profile. This can be performed as a single operation or in conjunction withmandrel bending.
Sweep bending requires a former to be used for the profile to follow the desired curve.
Ring Rolling is generally the simplest form of bending profiles and tubes. The ring rolling process relies on a set of three rolls whereby the middle roll is used toapply pressure against the other two, inducing a curve as the profile is passed through.
Ring rolling can be used to produce consistent curves on parts of profiles and/or complete circular hoops.
High frequency induction welding allows us to produce an irregular or regular shaped tube with a flat, almost invisible, weld seam and a joint that is actually stronger than the parent material and are suitable for safety critical applications. Material thicknesses from 2mm – 6mm can be used and the welding process can also be combined with in-line piercing, if desired.
Unique to Metsec within the UK high frequency induction welding uses electromagnetic induction to heat the parent materials during the manufacturing process. While still ductile the weld seam is scarfed to remove excess material and unwanted burrs to create a uniform, flat and clean weld seam.
Weld integrity is verified using in-line eddy current testing, as part of our comprehensive quality assurance procedures.
The ability to manufacture a high quality, safety critical, welded product, offers designers a solution to create the perfect profile shape for their end product. This allows the development of real market winning solutions.
Our in-line piercing facilities give us the ability to deliver almost limitless hole shape, size and pattern requirements, accurately and with no need for expensive secondary processes.
Our equipment allows us to perforate both complex and standard features including notching, counter forming, swaging, lancing and other standard and non-standard hole designs and patterns.
Our in house design and support team can help with any technical questions and design ideas required within your product range. This support function will help you develop the best possible solution into your product range at the concept stages of design.
Tel: +44 (0) 121 601 6000
Fax: +44 (0) 121 601 6119
We pride ourselves on offering a total solutions package.
Literature, Brochures, Software and Certificates.
An introduction to Custom Roll Forming including key features and benefits.
Our quality engineers review the product specification at every stage.
Cold roll formed metal profiles are used in a multitude of applications and markets.