The design of a profiling system requires a lot of experience and detailed knowledge of the technical possibilities. But the optimal solution only emerges when new ideas and an intelligent combination of the right processing steps are added. Here we present some of the technologies that are built into our systems.
Roll-formed profiles have clear advantages over extruded and edged profiles. Profiling by roll forming is fast, economical and variable. In addition, it is possible to process higher-strength and ultra-high-strength materials and production is more environmentally friendly. High processing accuracy and low tolerances ensure that the workpiece can also be processed very well automatically.
Even coated and painted sheets can be processed without damage and with the highest precision. In the case of a heat-conducting sheet for solar collectors, it was even possible to improve the absorption properties by profiling on one of our systems. In this way, the finished solar collector achieved higher energy efficiency through even better heat transfer to the energy carrier.
Higher dimensional tolerance
Higher shape tolerance
Straightening is usually one of the first processing steps in roll forming. It is essentially intended to help achieve a high dimensional and shape tolerance in the finished sheet metal profile. This happens, for example, when strip material is unwound from the coil and is to be fed into a roll forming machine as free as possible from internal stresses. The tensile and compressive residual stresses present in the material before straightening would negatively influence the forming processes and reduce the component quality.
High-quality strip straightening units are installed in Profilmetall Engineering’s roll forming lines. This means that the best possible forming result can be expected and the quality demands of our customers can be met.
These geometries can serve as functional elements or joints in finished components and enable the user to design products flexibly. Due to the short cycle times in punching, the process design is particularly important here. In particular, the removal of the separated material parts must be taken into account early in the process planning.
Technology testing and design in the area of pre-punching of sheet metal profiles is one of Profilmetall’s core competences. Please feel free to contact us regarding current challenges or planned products.
If further finishing operations are required on the end faces of the separated profile for special components, the separating device can be used after the forming process of the strip edges. Thus, the finishing of the end faces is possible by further bending operations in special tools.
Our separation modules are robustly designed and can be equipped with a wide variety of actuators according to customer requirements.
Laser welding can be used to create high-quality connections in roll-formed profiles with process reliability and even at high feed rates of the workpieces. The comparatively low heat-affected zone and thus low residual stress connection of the components is to be emphasised here.
Different processes can be integrated into Profilmetall’s systems. Especially when using lasers for joining, the safety of the entire system is very important to us and we work together with renowned experts in the industry.
Joining technology plays an important role in the full consideration of the product life cycle, especially with regard to recyclability. For example, the forming of similar materials is beneficial and an important argument for environmentally conscious customers.
Forming joining processes can be integrated into Profilmetall Engineering’s production facilities. We will be happy to help you master the technological challenges and provide you with advice and support.
The seamless process and the “meshing of all cogs” is to be achieved through the integration of control and regulation options. This not only reduces the workload for people, but also creates planning reliability and efficiency.
At Profilmetall, the focus is on people. Automation is not intended to make anyone replaceable, but to take ergonomics and everyday work to the next level. We would be happy to support you in the implementation of automated production solutions in the field of forming technology.
The advantages are not only obvious in component marking and tracing, but also positively influence the material properties due to work hardening. Roll-formed products can be equipped with a distinctive marking inline and thus facilitate further handling.
At Profilmetall, the technology is used at various points in the manufacturing process of your components. Contact us and we will find a solution to your challenges.
For example, in the case of products in the visible area, great importance is attached to the appearance of the surface in terms of freedom from scratches and existing gloss, and this is reflected in customer satisfaction. Furthermore, products can be individualised by coating.
Contact us if you have any questions or ideas about implementing coating and decoating solutions in your production facilities. Together we will be able to realise the requirements.
Due to their low density, foams are very light and easy to shape. In profile production in particular, they can be used to greatly improve the mechanical and material properties of hollow chamber profiles. For example, the stiffness of a profile can be increased by foaming or an insulating effect can be achieved.
Modules for foaming profiles can be integrated perfectly into Profilmetall Engineering’s production facilities. Please feel free to contact us with your ideas regarding implementation in your production environment.
In general, good material utilisation can be achieved with bending forming processes and environmental aspects make the process attractive compared to primary forming (e.g. casting) and machining (e.g. milling). In addition, the work hardening induced by the forming process has a positive effect on the component properties.
In Profilmetall’s production lines, bending stations with independent tools can be implemented in addition to roll forming. This enables further features to be added to the resulting products and can save subsequent work steps in the process chain and support joining operations.