What is Roll forming?

Roll forming on our Rollotronic® systems is a chipless manufacturing process for rotationally forming of rotationally symmetrical hollow parts such as thin-walled tubes sections or deep-drawn parts. By controlling the radial movement of internal and/or external shape-defining tools – the rollers – and continuously rolling them over and or inside within the workpiece, circumferential beads or grooves can be produced. With suitable tool designs, continuous threads can also be formed through the wall, while interrupted features such as knurls or perforations can be imparted. The process can also be used for trimming, chamfering, folding by flanging the tube edge. With appropriate process and tool design this can also enable form-fit joining of different component parts.

The raw-material- and energy-efficient roll-forming process is used in particular for high-quality, rotationally symmetrical mass-produced components in the automotive, measurement technology, sanitary, consumer-goods and packaging industries. Typical semi-finished products are simple deep-drawn parts or tubes. Applications range from the mass production of “simple” cosmetic jars in the consumer-goods and packaging sector to the highly demanding manufacture of safety-critical shock-absorber components for the automotive industry. Because the geometry is always reproduced from contour discs or rollers, the process ensures high forming precision and excellent repeatability. In addition to conventional steels, stainless steels and non-ferrous metals such as copper, aluminum and their alloys can also be processed.

Depending on the application, we have access to a range of Rollotronic® machines in different designs supplied by our mechanical-engineering partner Max Simmel Maschinenbau GmbH. Our current machine and tooling concept can cold-form wall thicknesses of up to 2.5 mm without difficulty. Local preheating of the component can further increase the permissible wall thickness and the complexity of the rolled contour. In addition to development, testing and prototype manufacture, we offer contract manufacturing from small batches through to high-volume series. Depending on the component and forming task, fully automated cycle times range from a few seconds to well below one second.