The Anatomy of a Roll Forming Line: Complete Process from Coil to Crate

The roll forming process beings with a coil of metal and ends with a finished part in a shipping crate. This video explains each step along the way. The complete process includes 4 parts:

0:00-3:23 Coil & Uncoiler
3:24-7:58 Straightening & Pre-punch Press
7:59-13:19 Roll Forming Mill & Roll Forming Tool Setup
13:20-16:43 Cutoff and Secondary Operations

Part 1 of 4: The first step in the continuous roll forming line is loading a metal coil onto the uncoiler machine. The uncoiler operation is controlled by a laser loop system that detects slack in the strip and feeds downstream machines at the optimum speed. Dahlstrom Roll Form’s specialized uncoiling capabilities: powered uncoilers, unpowered uncloilers, dual spindle uncoilers, and coil cradles can accommodate the full range of materials, gauges, and weights. Industry-leading AMS controls ensure the process is always running at maximum speed and precision.

Part 2 of 4: The second step in the continuous roll forming line is leveling and straightening the metal with coil processing equipment. The straightener removes defects such as bow, camber, and twist. After coil straightening, a pneumatic punch press feeder pulls the strip into a pre-punch press. The servo controlled feeder is accurate to 0.001”. In the pre-punch press, a die punches specifically designed holes through the strip. The holes punched by the die will be used to detect cutoff times down the line.

Part 3 of 4: The third step in the continuous roll forming line is setting up the roll forming mill and tooling. The roll forming machine setup is the most important part of the process and often takes 5-9 hours to complete. The roll forming tools are placed precisely in the machine with feeler gauges. Electric motors and gearing drive the force through the tooling shafts to form the strip.

Part 4 of 4: The final step in the continuous roll forming line is the cutoff process and secondary operations. A linear encoder records the speed of a metal strip through the roll form mill. The speed is synced with a sensor, which detects pre-punched holes and triggers the cutoff press. Once the strip is cut, end bending or other secondary operations take place. The completed roll formed part is then packaged in a crate for shipping.

Dahlstrom Roll Formed Parts & Decorative Metal Mouldings

[bartek_o-zz]

Thank you Mr. White for showing the important aspects of the roll forming process. Nice to see the Company Owner has no problem to makes a hands dirty. Big respect.

[wikizheng]

This is the best explanation I have ever heard!

[HeathJenkins-fdxo]

This was very well done, thank you for taking the time to put this together!

[austinfox]

This helps a lot with understanding the roll forming process for my manufacturing processes class! Thank you for sharing!

[bobjohnson]

Fantastic explanation, makes me want to do business with Dahlstrom Roll Form. Thank you.

[tareqwalid]

Great clear explanation, definitely from long experience.

[jasonwarsalla]

This is not taught in classes, and heads up companies now use tapered material. Thanks for the video.

[shakejones]

Well done, great video! Thank you for sharing mate 🙏🏻

[petelopetelo]

very informative thank you...better than other videos too technical lol

[ArashSadr]

I did my Ph.D.
on cold-formed hollow sections, and I enjoyed every little bit of this video. it was very well-explained. Now I'd like to do a research on Open section as well :))

[AvinashPatil-igyj]

What is the typical line speed for roll forming

[thewatchmen]

If young people who stop playing videogames and learn other trades just maybe they wouldn't have that lame excuse I don't know how. But if parents don't get involved WHY should the kids. Easier to commit crimes just sometimes the pay off is a MTHFK