Roll Forming Is Used in a Variety of Industries
Roll forming is the process of bending flat steel stock into a specific shape using powered rolls or dies. It is used in a wide range of industries, including automotive, agriculture, and solar energy.
Rack systems are available in both structural and roll-formed steel, but how do you know which is best for your operation? Watch this tutorial to learn the differences.
Versatility
Roll formed sheet metal is used to create a variety of products and structures. Typical applications include shelving, storage racks, and other racking systems.
In the forming process, a coil or long strip of metal is fed through a series of roll forming stations that convert it into a specific cross-sectional shape. The forming machine then bends and folds the material to its final contour, and can also notch, emboss, shear, or punch it with holes in the process.
This is a highly efficient process because it can quickly form metal into complex shapes with minimal waste and requires less labor than other processes. It also allows for strict tolerances, which is important in the manufacturing of sheet metal-based components.
Another benefit of roll forming is that it can be used to shape any type of sheet metal. It’s especially useful in the production of long lengths of metal. It also allows for secondary processes to be integrated into a single line, which reduces overall costs.
These factors make roll forming an ideal solution for a wide range of products and applications. For example, it’s the main component in many solar power distribution systems, and it’s used to build the skeleton of cargo trailers, delivery trucks, and even some 18-wheelers.
It’s also widely used for custom railings in high-end restaurants and commercial retail stores. The metal is often painted or anodized to prevent rusting, and it has excellent abrasion resistance and can be produced with very low residual stress.
A CAD/CAM system enables the forming machine to work at maximum efficiency, which helps lower the cost of labor. The process also produces only one to three percent scrap for each production run, compared to other methods. This allows for significant economies of scale in the production of large quantities of parts.
This versatility allows manufacturers to produce a wide range of products, including complex structures, which can be difficult to create with other methods. Because it’s an efficient and effective method of manufacturing, roll forming is used in many industries, from healthcare to electronics and everything in between.
Durability
Roll formed racking is a cost-effective, durable option for warehouses. This system is also more scalable and adaptable than structural racking.
Roll forming is a rack roll forming process that uses rolling dies to shape metal into an engineered shape. This process is used to create components for a variety of applications, including racks and conveyor systems.
Steel is a popular material for roll forming because it is malleable below its melting point by at least one temperature range without needing special heat treatment. This makes it a great choice for creating complex structures.
It is possible to create almost any cross section with roll forming. This includes intricate shapes that may not be possible with other processes, such as welding or punching.
In addition, the process is very efficient. Long lengths of metal can be produced and cut in a single production line, reducing overall costs.
The speed of the forming process allows for more complex parts to be created, and the smooth finish of the finished product eliminates the need for secondary processes such as deburring or trimming flash.
This makes it a highly efficient way to create complex structures for your warehouse. It is also a great way to create products that are made from non-ferrous metals, such as stainless steel, copper, and aluminum.
Another advantage of using roll forming is the ability to produce custom sizes and shapes for unique application needs. This can be useful when designing a warehouse layout that has unique needs, such as a need for narrow aisles or a desire for extra height.
Typically, roll-formed racks install faster due to teardrop connections that allow beams to snap into uprights quickly and securely, without the need for bolts. This type of connection is also safer than bolts, as safety clips help prevent beams from dislodging or lifting during loading and unloading by a forklift.
Structural racking is a more expensive option for warehouses, but it can be highly customizable to meet your unique needs. This system is durable and can withstand heavy loads, making it the right choice for large warehouses that need to be able to handle high levels of product movement.
Flexibility
When it comes to racking systems, warehouse solutions companies need options that are durable, light, and versatile. With global shifts in the way goods are shipped and delivered, a growing need for e-commerce services, and supply chain challenges, a more customizable approach to storage racking is becoming a must have for many businesses.
Roll-formed racking offers versatility, which makes it an excellent solution for a variety of applications. In addition to a wide range of pallet racks, it can also be used to create complex structures like catwalks or walkways.
Flexibility is a key consideration when choosing a storage system for a warehouse or distribution center, and roll-formed steel racks offer that flexibility in rack roll forming abundance. They can be set up quickly and easily, and they’re easier to change than structural racks because of their connecting system.
Unlike structural racking, which is made by pouring molten steel into molds and forming the components with a die, roll formed rack is produced from cold sheet metal that has been coiled and bent into various shapes before being sent through a roll forming machine. This process is highly repeatable, which translates to less waste for the producer.
A variety of materials are utilized for the manufacturing of a roll-formed rack, which allows for custom solutions to meet any needs. The main advantage of this type of system is that it can be used in numerous applications – including material handling, warehousing, production line, and cold and dry storage.
The pliability of racks is a major factor in their popularity among warehouse solutions companies. The ability to bend or modify a component without compromising the strength of the product can be incredibly beneficial in the long term, especially when it comes to damage from forklifts or other warehouse vehicles.
While a lot of companies prefer structural racks in heavy load capacity applications and environments, roll-formed racks are increasingly preferred by companies with lighter load capacities because they’re much lighter and more flexible to install and change configurations.
A roll-formed racking system is made with a variety of light gauge, high yield, and high-strength steel that is shaped in a roll forming machine. The steel is cooled and then coiled into various shapes, allowing for the construction of a wide range of complex structures that can be modified as needed.
Cost
Cost is one of the most important considerations for any type of metal forming process. It can make or break your bottom line, depending on the type of product you’re producing and how much of it you’re able to sell.
The key to controlling your roll forming costs is to make sure you’re working with a manufacturer who can create efficiency through process optimization. This includes common-sense organization, easy retrieval of roll dies and consistent methods for loading the machines.
Moreover, selecting an experienced partner who can eliminate downtime during setup and run cycles is also a great way to keep your costs under control. An organized facility means fewer errors, faster set up times and lower costs on raw material and labor.
Another key to keeping your costs down is to select a metal supplier that can help you optimize the design of your product for roll forming. This can save you money on tooling as well as help you reduce the number of forming passes your part requires to get it to its final shape.
Structural rack is typically heavier and stronger than roll formed rack, and can be used for a wider variety of applications, including pushback, drive-in, and cantilever systems. It’s typically used in high-density, high-traffic areas such as warehouses and pick modules.
A structural system can also be built at the project site, which means that freight costs will be reduced. However, installation may be more labor-intensive than roll form racking.
Installing a structural system requires bolting beams to upright frames, which can require tools and be time-consuming. In contrast, roll formed components are dropped into slots on the uprights and secured with safety clips. This process helps prevent the beams from dislodging and lifting during forklift loading or unloading.
Additionally, you can use electrical controls and computer technology to integrate your roll former operation with your business’s MRP system so that lengths, quantities and hole patterns are automatically directed to the machine. With this functionality, you can ensure that your production is always on schedule and in line with your inventory needs.
