Technology
The design of a roll forming line requires a lot of experience and detailed knowledge of the technical possibilities. The optimal solution is created as soon as 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 roll forming lines.
3D Bending
Functional x Extendable
3D bending of ferrous and non-ferrous sheets has a long tradition in manufacturing technology. Many components can be manufactured efficiently and cost-effectively by bending. By applying tensile and compressive stresses, the semi-finished product is brought into shape and the desired product is created.
In general, good material utilization can be achieved with bending forming processes, and environmental aspects make the process attractive compared with 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 roll forming lines, 3D bending stations with independent tools can be implemented in addition to roll forming. This allows further features to be added to the profiles being created, saves work steps in the process chain and supports joining operations.
Coating
Individuality x Challenge
Coating is the application of substances, paints, lacquers or films to a substrate. The forming of coated materials in particular presents 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 gloss, and this is reflected in customer satisfaction. Furthermore, profiles can be individualized by coating.
Contact us for individual and process-integrated coating and decoating solutions in your production facilities. We will be happy to implement the right process for you.
Digitize
Planning Reliability x Efficient
Automation and digitization are playing an increasingly important role in the efficient design of production facilities. It describes the transition from independent manual manufacturing 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 humans, but also creates planning reliability and efficiency.
Profiling 4.1 – At Profilmetall, the focus is on people. One stands for the person who likes to work successfully with our profiling systems. Because in the end, profiles are only as good as the synergy between man and machine.
Thats smart profiling!
Emboss
Component Identification x 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 tight bending radii in roll-formed profiles. Here, the yield stress of the workpiece material is exceeded locally and the contour of a tool is transferred to the material.
The advantages are not only obvious in component identification and traceability, but also positively influence the material properties due to work hardening. Roll-formed profiles can be equipped with a distinctive marking inline, thus facilitating further handling.
At Profilmetall, embossing technology is used at various points in the manufacturing process of your components. Contact us and we will find a solution for your challenges.
Roll forming
Fast x Economical x 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 for this purpose are rollers with corresponding 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. It is also possible to process higher- and ultra-high-strength materials, and production is more environmentally friendly. High processing accuracy and low tolerances ensure that the workpiece can also be further processed very well by automation.
Even coated and painted sheets can be processed without damage and with maximum precision. In addition, desirable material properties can also be increased in the roll forming process: In the case of a heat conducting sheet for solar collectors, the absorption properties are even optimized by roll forming on our roll forming lines. In this way, the finished solar collector achieves higher energy efficiency through even better heat transfer to the energy carrier.
Straighten
Higher Dimensional Tolerance x Higher Shape Tolerance x Higher Quality
Straightening is the forming treatment of sheet materials to reduce waviness and other geometric defects. In straighteners, 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 rollforming line as free as possible from residual stresses. The tensile and compressive residual stresses present in the material before straightening would negatively influence the forming processes and reduce component quality.
High-quality strip straightening units are installed in Profilmetall Engineering’s roll forming lines. Thus, the best possible forming result can be expected and the quality requirements of our customers are met.
Foaming
Simple Shaping x Advantageous
Foaming refers to the production of plastic materials in conjunction with gas evolution during the process. A wide variety of plastics can be produced as foam and exhibit the associated advantageous material properties.
Due to their low density, foams are very light and easy to form. Particularly in the production of roll-formed profiles, they can be used to greatly improve the mechanical and material properties of hollow sections. For example, the stiffness of a profile can be increased by foaming or an insulating effect can be achieved.
Modules for foaming metal profiles can be optimally integrated into Profilmetall Engineering’s profiling lines. Take advantage of our many years of experience in process-integrated foaming of roll-formed profiles.
Welding
Process Reliable x High Quality
As a joining process, welding is of great importance in industrial applications when it comes to joining components permanently and materially. Energy is applied to form a molten pool at the joint, which exhibits very high strength after solidification. The characteristics of the heat-affected zone depend, among other things, on the selected welding process.
Laser welding can be used to produce high-quality joints in roll-formed profiles with process reliability and even at high feed rates of the workpieces. The comparatively small heat-affected zone and thus low residual stress connection of the components is worth emphasizing here.
Different welding processes can be integrated into Profilmetall’s roll forming lines. Particularly when using lasers for joining, the safety of the overall system is very important to us. Our plants are therefore certified by renowned experts in the industry.
Punching
Flexible Design x Core Competence
Material openings are made in the subsequent profile by punching. Assigned to the cutting processes in forming technology, almost any geometries can be implemented 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 stamping, we attach great importance to process design. The removal of separated material parts is also taken into account at an early stage in process planning.
Technology testing and design in the area of pre-punching of sheet metal profiles is one of Profilmetall’s core competencies. Please feel free to contact us regarding current challenges or planned products.
Separate
High Tolerance x Better Quality
Separation, as distinct from punching in the roll forming of sheet metal profiles, describes the separation of the products at the end of the forming production process. Cutting is a central step in the production of a component from coil to end product and can be carried out with the aid of various technologies. In most cases, cutting punches or saws are used, but the use of lasers also offers many possibilities.
If further finishing operations on the end faces of the separated profile are required for special components, the separating device can be used after the forming operation 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 equipped with a wide variety of actuators according to your customer requirements.
Connect
Environmentally Conscious x Forming
In addition to welding, there are many other ways of joining components with a material or form fit. Examples include clinching, adhesive bonding and needling. The aim is to join two joining partners inseparably.
Joining technology plays an important role in the full consideration of the product life cycle, particularly with regard to recyclability. Here, for example, the forming of similar materials is advantageous and an important argument for environmentally conscious customers.
Forming technology joining processes can be integrated into Profilmetall Engineering’s production facilities. We will be happy to master the technological challenges with you and provide advice and support.