If you would like to purchase a complete copy of the Cold Rolled Handbook or a chapter of your choice the prices are listed below:

Transcription

1 If you would like to purchase a complete copy of the Cold Rolled Handbook or a chapter of your choice the prices are listed below: A complete copy is VAT A chapter is 40+ VAT Please note prices for non members will differ. To purchase or for further information please contact Adrian Nicklin on or adrian.nicklin@britishmetalforming.com To view what each chapter contains please scroll down.

2 Chapter One (Section A & B) Chapter one covers the basics of Rollforming operations and guides the operator from the initial sheet in-feed through to the final sheet cut off and inspection. Each stage covers problems that may occur and suggestions on how to overcome them. A lot of everyday problems are common to most Rollforming machines and some can be easy to handle but some are dependant on the experience and wisdom of the operator. The layout is set out to guide the operator through each stage of the forming sequence as laid out below. This is intended for both beginner and those less experienced. Rollforming overview. Difficulty in pulling sheet from Decoiler. Sheet is tight/loose when entering entrance table. Leading edge of sheet is hitting shafts. Sheet creases and buckles when running through first set of rolls. As the sheet rolls through the Rollformer the Decoiler snatches. Crease marks appear across the width of the sheet. Sheet pulls to one side and twists. The sheet is noisy as it runs through the mill. On box profile sheet the sheet shows ripples in the forms. Oil canning ripples / Herringbone effect. Double bend lines on corners of the forms. Marks or dents in the corners of the bends line A half moon crescent shape appears in the large pans of a box profile. There is a ripple down the edge or edges of the sheet. Intermittent side kink on edge. When running coated material the coating starts to peel or blister. Problems with running painted or PVF2 material. Running Galvanised or other protective material coatings. Aluminium, Stainless steel or High temper steels Roll stands adjustments. As sheet enters the cut off die they are out of alignment The cut sheet is deformed by the shearing action. Sheet jams on cut and run mode. Length measurement and associated problems Realignment of the side profile shape or edges Profile inspection General inspection points.

3 Chapter Two (Section C) In most Rollforming companies the operator has not only to operate but also to reset and adjust rolls for different materials and gauges or other sections of the Rollformer, this is not always easy and without experience or some guidance this can lead to expensive and time consuming effort. This chapter will assist and give solutions to some of the common everyday problems. Setting out and positioning Decoiler. Setting sheet in-feed guide position. Roll alignment. Resetting rolls for gauge changes. Resetting rolls to solve profile variations. Resetting rolls to solve forming and flow problems. Roll shapes. Bottom rolls positioning. Resetting alignment of shear-blades. Shears-Blades and Blade Clearance. Chapter Three (Section D & E) This chapter gives an overall view and information on profile sections and forms. From the basic Roofing or Cladding profile there can be simple modifications made to alter the overall appearance of the section from its basic form. There is also descriptions of the simple liner section to the more complex and structurally designed Decking profiles. Away from the familiar profiles the secret fix and standing seam sections are explained. Corrugated Profiles Development and modification of the basic Profile shape Internal Liner Profiles. Decking Profiles. Secret Fix Profiles. Over- bending and side forming. Standing Seam.

4 Chapter Four (Section F) From the basic Rollforming machine design there are processes that are either necessary to its successful efficient operation or add-ons that compliment the process or help with everyday problems to increase the machines efficiency. Some suggestions are listed below. Additional items to the Rollforming Process Coil Loading systems. Coil storage system. Sheet cut off facilities at completion of order. Strip film or special material application. Sheet lubrication. Stacking and conveyor systems. Short sheet conveyor. Coil sheet storage and accumulator systems. In-line coil edge slitting. Carry-over table. Wrapping and bearer insertion units. Coil edge guidance systems. Sheet identification marking. Assisted sheet in feed and exit. Straightening & Corrective Levelling Chapter Five (Section G) In this chapter an overall description is given of the many and varied forms of Rollformers available for a multitude of uses and efficiencies of use. This will be of use to those who are unfamiliar with any other machine types other than the basic design and could possible help with the choice of the next machine. Sheet feed. Coil feed. Stop to cut. Flying shear. Fixed head-single purpose. Roll change. Rafted. Multi Level / Dual / Triple Deck Rotary / Revolver / Profile. Duplex. Tile effect Rollformers. Mobile / Static operation Specialist Rollforming lines. Drive Systems.

5 Chapter Six (Section H) Apart from the production of the basic Roll formed section there are many ways that the sheet can be post formed to give a wider variety of uses to the customer with the additional benefit of an increase in the value of the product. From the simplest and oldest forms of curving a corrugated profile to the more sophisticated crimp curve and the even more difficult curving of a standing seam & clip fix system this chapter gives detailed information of these processes. Smooth curving corrugated sinusoidal profiled sheet. Smooth curving trapezoidal profile sheet. Stretch forming smooth curving. Self- curving. Crimp curving trapezoidal sheet. Types of crimp curved sheet. Crimp curving details & calculations. Curve dimensions & calculation data. Roll crimping trapezoidal sheet. Tapered Standing seam and Clip fix sheet Smooth curved standing/ clip fix seamed sheet. Vented sheet. Specialist cutting system. Chapter Seven (Section J, K, L & M) Not all production staff are aware of the production tolerances that are required of the industry, variations may be necessary for specific uses that the sheet may be used for. Tolerances are also required from the supplier and they should be known by the purchaser. All materials have there own specific inherent properties and when using these materials the user should be aware of these. Some may be unsuitable for there intended use. Within any industry there are specific names and terminology used, this section of the chapter lists and describes the most widely used. Commercial & Accepted Rolling Tolerances Material specification of material properties General notes on material properties Profile terminology Some commonly used terminology Chapter Eight (Section N) This covers a general description of various types sheeting, where and how they are fixed and the types of fixings used. This will be of use to those who may not have had the advantage of seeing the sheet in its final position on the building. Roofing /Cladding & Decking Sheet. Sheet fixing systems Bracket & bar spacer systems Some additional spacer systems Examples of typical fixings Examples of various other types of Roofing & Cladding Sheeting

6 Chapter Nine (Section P) From the initial outlines and operations of Rollforming given earlier this chapter will deal with more technical details from general principals of Rollforming to material details and some inherent problems with these materials. Also the types materials used within insulated panels and material's used to combat condensation. General Principals of roll design. A selection of the various profile sections. Galvanised steel and white rust staining Electrolytic action of dissimilar materials Coated materials. Life span of coated materials. Aluminium and staining Structural insulation panels. Composite panel insulation materials R-Value Insulation. Anti Condensation fleece Chapter Ten (Section Q, R, S & T) Unfortunately a lot of machinery purchased is not always up to the job they were originally intended for. A lot of manufactures or agents give a colourful description of a machine and its capabilities without really knowing exactly what is required by the customer, and the customer may not have the experience to judge the best machine for them. This section will give a guide to the way the purchasing process should be laid out for both new and used equipment, and for those intending to install the machine themselves a guide to its installation. General notes on machinery purchasing. Purchase of used equipment Rollformer installation Rollforming machinery & associated equipment manufacturers. Part Two: Metal Cutting and Forming to Compliment Rollforming To compliment most Rollforming operations manufacturers will provide flat sheet either directly from coil or cut to width, with or without protective film applied. This chapter covers the various methods and machines used to do this, there is also technical details on how to produce Flat Sheet from coil and the various problems associated with producing flat sheet from coil. A section is also included on slitting and the application of protective strip film Cut to length lines & Flat Sheet Slitting Film application Guillotine/Shears

7 Associated products such as flashings etc. will be usually supplied alongside Roll formed sheeting and this chapter covers the many aspects of this operation. The forming of flashings etc. is relatively simple and straightforward but this section gives a more overall description of the processes involved with the machinery and technical details of all of these machines. The selection of the right machine and its tooling along with the correct method of operation is critical to obtain the maximum use out of any machine. Punching piercing Press Brakes Press Brake Tooling Material positioning systems Folding Machines Roll Bending Hand forming machinery Joining Techniques