Contour Roll Forming

Contour roll forming is a continuous process for forming metal from sheet, strip, or coiled stock into desired shapes of uniform cross section by feeding the stock through a series of roll stations equipped with contoured rolls. This article discusses the materials, roll-forming machines, tooling, and auxiliary equipment used in contour roll forming and its process variables. Tooling used in roll forming includes forming rolls and dies for punching and cutting off the material. The article discusses the additional tooling required in tube mills to weld, size, and straighten the tubes as they are produced on the machine. It describes the roll design for tube rolling and reviews the seam welding operations of pipe and tubing. The article discusses cross-sectional tolerances, the reshaping of round tubing, and factors that affect the quality, accuracy, and surface finish.