Technology

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.

Profiling

Fast

Profitable

Variable

Profiling or roll forming describes the forming of ferrous or non-ferrous metals in successive forming stages (profiling stands) into a finished profile with the desired cross-section. The tools used here are rollers with the appropriate geometries, which gradually shape the sheet metal strip.

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.

Straighten

Higher dimensional tolerance

Higher shape tolerance

Higher quality

Straightening is the forming treatment of sheet metal materials to reduce waviness and other geometric defects. In straightening machines, the semi-finished products are specifically subjected to compressive and tensile stresses by rollers in order to achieve the desired result.

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.

Punching

Flexible design

Core competence

By punching, material openings can be made in the later profile. Assigned to the cutting processes in forming technology, almost any geometry can be realised based on the geometry of the cutting punches used in cooperation with the die.

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.

Separation

High tolerance

Better quality

Separation describes the process of separating the products at the end of the forming production process, as opposed to punching in the roll forming of sheet metal profiles. Separation is a central step in the production of a component from the coil to the end product and can be carried out with the aid of various technologies. Usually, cutting punches or saws are used, but the use of lasers also offers many possibilities.

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.

Welding

Process-safe

High quality

As a joining process, welding is of great importance in industrial applications when it comes to joining components permanently and materially. By applying energy, a molten pool is formed at the joint, which has very high strengths after solidification. The characteristics of the heat-affected zone depend, among other things, on the selected welding process.

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.

Connect

Environmentally conscious

Forming

In addition to welding, there are many other ways to join components together in a material or form-fitting manner in connection technology. Examples of these are clinching, gluing or needling. The aim is to connect two joining partners inseparably.

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.

Automate

Planning security

Efficiency

Automation is playing an increasingly important role in the efficient design of production facilities. It describes the transition from independent manual production steps to networked processes and machine-supported operations.

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.

Embossing

Component identification

Traceability

Embossing not only plays an important role in the production of coins, this technology is also used in the marking of components or the implementation of narrow bending radii in roll-formed profiles. Here, the yield stress of the workpiece material is exceeded locally and the outline of a tool is transferred to the material.

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.

Coating

Individuality

Challenge

Coating is the application of materials, paints, lacquers or films to a substrate. Especially the forming of coated materials poses many challenges with regard to handling and the entire production process.

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.

Foaming

Simple shaping

Beneficial

Foaming refers to the production of plastic materials in connection with gas evolution during the process. A wide range of plastics can be produced as foam and have the associated advantageous material properties.

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.

3D-bending

Efficient

Cost-effective

The bending of ferrous and non-ferrous sheets has a long tradition in manufacturing technology. Many components can be produced efficiently and cost-effectively by bending. By applying tensile and compressive tension, the semi-finished product is brought into shape and the desired product is created.

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.