Page 36 - MetalForming July 2015

Rollforming
secondary operations inline. Rollforming also is well-suited for parts requiring edge conditioning as well as long parts—the process accommo- dates part lengths beyond 50 ft.
Evaluating how a part’s design can be simplified and opti- mized for rollforming will reduce costs down the line, and improve efficiency and product quality.
Material selection
for a new part or
product comprises a
crucial element of
cost control and
design integrity. For rollforming to be most effective, opt for light-gauge high- strength low-alloy or structural steel— material whose physical condition can
ner gauges, translate to less material content in a part while maintaining physical properties and strength. This allows fabricators to heat, cool, melt, mold, bend, punch and stamp the material into the desired profile.
Creativity Combats Tooling Costs
For custom shapes, rollform tool- ing can be engineered to form quality, cost-effective profiles. But escalating tooling costs have deterred manufac- turers from the rollforming process.
Some manufacturers have turned to partial tooling investment, which ties up capital on the shop floor. This arrangement often requires additional payment or fees if the manufacturer wishes to use another supplier or bring production inhouse.
Minimize the tooling’s business impact by amortizing costs, which sta- bilizes cash flow while gaining the bene- fit of a high-volume, long-term produc- tion solution. Choose a fabricator that allows you to spread out the investment over time, without accruing interest.
Invest in Prototyping and Testing
Although finite-element analysis can identify problem areas with a pro- posed part and tooling, a prototype provides true proof of concept. If investing in upfront tooling, also invest in prototyping and real-load testing.
Prototyping helps justify a tooling investment by verifying the design’s integrity. It also can be tested in the context of its assembly or interaction with other components that compose the final product.
Consider Forecasting and Inventory
Rollforming is well-suited for higher volumes because setup and labor costs decrease as production levels rise. As a result of high yield, consider the following:
Sourcing—Choosing to rollform may require reevaluating your current sourcing relationship, ultimately alter- ing sourcing contracts or finding a new sourcing partner to accommodate
34 MetalForming/July 2015
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Tooling costs often deter fabricators from traveling the roll- forming road, but options exist to reign in this expense.
be manipulated during the rollforming process without losing strength.
More and more, steel is fabricated via rollforming. Stronger steels, at thin-