COLD ROLL FORMING TOOLING PREPRESS
Cold Roll Forming Tooling Progression & Flower Pattern Vector Guide
Cold roll forming is a continuous high-speed bending process wherein coiled sheet metal strip is progressively formed into complex uniform cross-sections through pairs of contoured mating rolls. Designing a defect-free roll set hinges upon the flower pattern progression.
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1. Longitudinal Edge Strain & Station Pitch
During cold roll forming, while the web center follows a straight line, the outer edges of the strip travel along an extended 3D helical path. The peak longitudinal strain $\varepsilon_{\text{edge}} = (h / L_{\text{pass}}) \tan(\Delta\theta)$ must remain below 1.0% to prevent edge buckling.
2. Engineering Specifications & Tolerances
| Progression Method | Bend Angle Strategy | Best Applications | Tooling Complexity |
|---|---|---|---|
| Constant Bend Method | Equal Δθ per pass (15°/stand) | Simple channels, angles, U-shapes | Standard |
| Constant Radius Method | Bend radius held constant while arc length expands | Deep structural sections & tubes | Medium |
| Down-Hill Method | Neutral forming line lowers progressively | Wide panels & AHSS high strength steel | Advanced |
3. CNC Roll Turning Lathe DXF Prepress Rules
- Clearance Gap Compensation: Roll clearance between top and bottom roll profiles must equal sheet thickness plus 8% (Gap = 1.08 * t) to prevent pinching.
- Driven Roll Pitch Line: Tool turning profiles must align roll pitch diameters at the zero-slip neutral line to eliminate scuffing.
- Overbend Calibration: Final sizing passes must incorporate 1.5° - 3.5° springback overbend based on alloy tensile strength.
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