Roll Forming Flower Pattern & Pass Progression Calculator
Calculate pass bend angle progression (Δθ), longitudinal edge strain (ε_edge), total forming stations (N), and flat strip width unfolding for custom roll formed profiles.
1. Input Parameters
2. Calculation Results
3. Geometric Visualizer
Tooling & Vector Prepress Engineering Notes
1. Maximum Allowable Edge Strain: To prevent permanent longitudinal edge wrinkling (edge wave) and oil canning, edge elongation strain should satisfy $\varepsilon_{\text{edge}} = \frac{h}{L_{\text{pass}}} \cdot \tan(\Delta\theta) \le 0.8\% - 1.2\%$ for mild steel.
2. Roll Pitch Diameter Matching: To avoid profile scuffing and accelerated roll wear, the drive pitch line of upper and lower forming rolls must match profile linear speed at the neutral forming bend line.
3. Superimposed Flower DXF: A complete roll forming tool design requires exporting each sequential pass profile on dedicated CAD layers (PASS_01, PASS_02, etc.) for CNC roll turning lathe toolpath generation.