High Production Roll Forming

Roll forming is one of the most widely used processes in the world for forming metals. Most of the existing knowledge resides in various journal articles or in the minds of those who have learned from experience. Providing a vehicle to systematically collect and share this important knowledge, the Roll Forming Handbook presents the first comprehens

The principal method of learning either design skills or machine operator skills of roll form tooling and its design has been on-the-job training. As the only book of its kind available on the subject, this insightful and handy reference acts as a supplement to on-the-job-training by presenting the fundamentals of roll tool design through theory and illustrative examples which include detail of the design calculations. Additionally, it identifies design decisions that are judgment calls and have no correct answers in design examples that depict certain ideas and conceptshelping users develop a feel for the process. It is sure to be useful as a teaching aid for setup personnel and roll form machine operators, as well as a basic reference for tool design personnel.

This report represents a portion of the information contained in the March, 1967, revised edition of the 'Aircraft Designer's Handbook for Titanium and Titanium Alloys' which was prepared by the Defense Metals Information Center under the joint sponsorship of the U.S. Air Force Research and Technology Division, and the Federal Aviation Agency. The important techniques discussed include; (1) brake forming, (2) stretch forming, (3) deep drawing, (4) trapped-rubber forming, (5) tube bulging, (6) bending, (7) drop-hammer forming, (8) roll forming, (9) roll bending, (10) spinning, (11) shear forming, (12) dimpling, (13) joggling, and (14) hot sizing. Auxiliary metalworking operations, preparation for forming, blank heating methods, lubricants for forming and tooling materials are discussed. Other data available in the open literature have been summarized and referenced to present a comprehensive picture on the state of the art of these fabrication methods as related to titanium and its alloys. (Author).

Following the long tradition of the Schuler Company, the Metal For ming Handbook presents the scientific fundamentals of metal forming technology in a way which is both compact and easily understood. Thus, this book makes the theory and practice of this field accessible to teaching and practical implementation. The first Schuler "Metal Forming Handbook" was published in 1930. The last edition of 1966, already revised four times, was translated into a number of languages, and met with resounding approval around the globe. Over the last 30 years, the field of forming technology has been rad ically changed by a number of innovations. New forming techniques and extended product design possibilities have been developed and introduced. This Metal Forming Handbook has been fundamentally revised to take account of these technological changes. It is both a text book and a reference work whose initial chapters are concerned to pro vide a survey of the fundamental processes of forming technology and press design. The book then goes on to provide an in-depth study of the major fields of sheet metal forming, cutting, hydroforming and solid forming. A large number of relevant calculations offers state of the art solutions in the field of metal forming technology. In presenting tech nical explanations, particular emphasis was placed on easily under standable graphic visualization. All illustrations and diagrams were compiled using a standardized system of functionally oriented color codes with a view to aiding the reader's understanding.

These proceedings present papers on Additive Manufacturing, Composites Forming Processes, Extrusion and Drawing, Forging and Rolling, Formability of Metallic Materials, Friction and Wear in Metal Forming, Incremental and Sheet Metal Forming, Innovative Joining by Forming Technologies, Lionel Fourment MS on Optimization and Inverse Analysis in Forming, Machining and Cutting, Material Behavior Modelling, New and Advanced Numerical Strategies for Material Forming, Non-Conventional Processes, Polymer Processing and Thermomechanical Properties, Sustainability on Material Forming, and Property-Controlled Forming.

Sheet forming is the most common process used in metal forming and is therefore constantly being adapted or modified to suit the needs of forming composite sheets. Due to the increasing availability of various types of fibre reinforced polymeric sheets, especially with thermoplastic matrices, the scope of use of such materials is rapidly expanding in the automobile, building, sports and other manufacturing industries beyond the traditional areas of aerospace and aircraft applications. This book contains twelve chapters and attempts to cover different aspects of sheet forming including both thermoplastic and thermosetting materials. In view of the expanded role of fibre reinforced composite sheets in the industry, the book also describes some non-traditional applications, processes and analytical techniques involving such materials. The first chapter is a brief introduction to the principles of sheet metal forming. The next two chapters introduce the various forms of materials, manufacturing techniques and the fundamentals of computer simulation. Chapter 4 describes the different aspects of thermoforming of continuous fibre reinforced thermoplastics and the following chapter studies the shear and frictional behaviour of composite sheets during forming. Chapter 6 explores the possibility of applying the grid strain analysis method in continuous fibre reinforced polymeric sheets. The next two chapters address fundamental concepts and recent developments in finite element modelling and rheology. Chapter 9 introduces the theory of bending of thermoplastic composite sheets and shows a novel way of determining both longitudinal and transverse viscosities through vee-bend tests. A significant expansion in the usage of composite materials is taking place in biomedical areas. Chapter 10 discusses the thermoforming of knitted fabric reinforced thermoplastics for load bearing and anisotropic bio-implants. The final chapter introduces roll forming, a commonly used rapid manufacturing process for sheet metals, and discusses the possibility of applying it economically for continuous reinforced thermoplastic sheets.