THE EFFECTS OF ROLL FORMING PASS DESIGN ON EDGE STRESSES

Roll forming is the process of bending welded pipe, tube, closed or open profiles from sheet metal strips by using rolls and reels. In this study, the roll design processes of the roll form machines and the stages of designing rolls according to a C-type profile with the Ubeco PROFIL (R) software are examined. The manufacture of rolls is the most important parameter that affects the costs in roll forming lines. It is essential to keep the number of stations and the rolls used in these stations at an optimal level according to the product to be rolled. It is possible to calculate the number of passes where the profile can be formed most appropriately, to determine how the rolls should be positioned and to obtain the technical drawings of the rolls that need to be manufactured for each station with the help of roll forming software products. This study examines the edge stresses and optimum amount of rolls at the stations where the product can be rolled without exceeding the strain limits.