The thinner the material, the more difficult it is to evaluate the spring back for open profiles, as well as for closed profiles. At Dallan, we have been developing specific calculation tools and algorithms for thin metal sheets since 1978. This has driven the development of our company and has become the distinctive factor of Dallan machines and equipment.

The image shows the accuracy of Dallan roll forming machines in a comparison between the theoretical design and the final result of a rolling shutter profile with a thickness of 0.20mm plus paint. The rolling shutter profile is one of the most technical made by Dallan systems. Since it is not a static profile, the hook needs to work correctly during winding and unwinding for the entire lifetime of the product.

The Original 1974 Study Of Thin Materials

In 2019, 45 years after its publication, we published the thesis written in Italian. It was written by our founder, Sergio Dallan, for his university degree.

The subject was the cold forming of thin metal sheets. Starting from this study, entitled “The Design Of Rollers For Light Profiles”, published in its original version and complete with all its formulas, our company gradually began to develop, first as a design studio, subsequently as a manufacturer of roll forming machines for the Italian market followed by the international market. 

The formulas were included in the original Dallan roller development software, which we still use today. It has been updated with the experience accumulated in 40 years of work.

Characteristics Of Coatings For Roll Forming And Bending Radii

In addition to developing special techniques for thin materials, from the very beginning we started working in sectors such as metal suspended ceilings and rolling shutters, where many profiles are made of pre-painted material. When forming an aesthetic profile with a pre-finished surface, particular attention is needed in the design to guarantee product quality.

Read more here at page 36

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Roll forming systems used to run at a very slow speed, about 50 ft (15m)/min., making it easy to handle everything manually at the end of the line. These days roll formers can run anywhere from 300 (91m) to 500 ft (152m)/min. Speed can make parts hard to handle, so does part configuration, which has become more complex as machine capabilities have expanded.

Typically, parts were roll-formed and additional features and processes were incorporated manually down the line. Today’s roll forming systems can include some punching, forming, bending, and other processes that have nothing to do with roll forming itself, and are designed for complete, done-in-one part manufacturing. Following these systems are sophisticated material handling automation.

Moving from one process to another, automated material handling eliminates human error, particularly as it relates to part orientation. Automation helps verify that the correct part is being handled and orients it for proper processing. It also helps to reduce the dependency on an operator, which increases roll forming uptime and speed.

A material handling system can process parts much faster than any operator can, especially when the parts on the line are large and heavy. Manually moving and orienting these parts repeatedly throughout the day opens operators up to fatigue and injuries.

Time savings is another benefit of an automated material handling system, especially with packaging and nesting. An operator can sometimes lose count of part runs, and shipments can go out with inaccurate orders.

The ability to count part runs to ensure orders are completed correctly saves time, both on the front end with inventory and in ensuring orders will not need to be reproduced and reshipped. COVID-19 also has demonstrated additional benefits of automated material handling systems.

Fabricators are required to follow strict protocols for limiting the number of people in a workspace and maintaining proper distancing. These systems reduce the number of workers needed to run the roll forming equipment, maintaining safety standards.

What You Need to Know

Most shops have limited space on the shop floor, and incorporating automated material handling equipment can take up more space than what is currently allotted, so a restructuring of equipment might be needed. This takes careful planning, especially if there are secondary processes involved.

Some shops might not see the initial value in adding such a system, especially with the upfront costs. But the machine does not take breaks and will continue at the same processing rate throughout the day. By removing the human element and maintaining consistency of the process, fabricators can expect significant throughput gains, sometimes upwards of 35%.

Read more here at page 32

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Over 118,000 square metres of the Düsseldorf Fairgrounds are occupied. Trade visitors from all over the world are expected. With around two thirds of the exhibitors, wire and Tube are among the trade fairs with the highest internationality in Messe Düsseldorf’s portfolio. They come mainly from the strong European production countries, from the USA, Central and South America, Asia and the African continent.

Daniel Ryfisch, Director wire/Tube & Flow Technologies at Messe Düsseldorf

“The Düsseldorf trade fair venue is the absolute front-place for the wire and Tube sectors when it comes to presenting innovations from the relevant industries to a broad, international audience,” says a delighted Daniel Ryfisch, Director wire/Tube & Flow Technologies at Messe Düsseldorf.

In addition to the classic themes such as machinery and equipment for wire, cable and tube production, processing and end products, wire and Tube place a strong focus on topics such as stainless steel, hydrogen, plastic tubes, cutting and slitting technologies and e-mobility. In addition, the topics of fastening and joining technologies, spring manufacturing technology and glass fibre technologies continue to move to the fore.

The main industries here are the chemical, oil and gas sectors, the automotive industry, the construction sector and the entire telecommunications sector.

wire 2024 occupies exhibition halls 9 to 17: wire, cable, wire products and technologies are scheduled in halls 9 to 12 and hall 15. Meet China`s Expertise can be found in Hall 14.

Hall 16 will become a special hall for fastening and fixing technologies and for spring making technology, including their end products such as screws, grooves, eyelets and technical springs. This creates an exclusive, separate technology area here. The large area for heavy, space-consuming mesh welding machines will be located in the central Hall 17.

Tube 2024 occupies exhibition halls 1 to 7a: tube accessories, tube manufacturing and the tube trade are located in halls 1, 3, 4, 5, 6 and 7a. A new feature is the special area for plastic tubes and pipes in Hall 1, which provides the space for plastic tubes that they currently occupy with increasing tendency in the manufacturing and processing industries.

Forming and bending technology is to be found in Halls 4, 5 and 6, and pipe processing technology in Halls 6 and 7a. Machinery and equipment will follow in Hall 7a. Hall 7 is once again reserved for Chinese pipe producers and pipe processors with Meet China’s expertise.

Numerous specialist forums, congresses and tours such as the international meeting of experts from the sectors, a hydrogen and e-mobility congress, the ecoMetal-trails and the daily after-business-chill enrich the range of events in the exhibition halls and on the open-air site.

Even more information about exhibitors, products, industry news and trends can be found on the internet portals at www.wire.de and www.Tube.de and on linkedIn: https://www.linkedin.com/showcase/wire-and-tube-leading-international-trade-fairs/

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The company exhibited a homogeneous minimum-quantity spray lubrication system using less than 0.5 g of oil per m², and a particularly robust variant of the spray.xact c with a new housing structure, among other products. technotrans provided insights into the development of a system solution for hot-melt applications.

Expanding the product portfolio enlarges the application spectrum of technotrans products and provides users with more flexibility. Potential application areas for these spray lubrication systems include cold rolling processes, the forming of aluminium, and tool lubrication, among other processes.

The Draw Of Energy Efficiency

Energy efficiency is a core benefit of this system. By reducing friction and heat generation, energy-efficient spray lubrication directly contributes to lower power consumption in industrial processes. This translates to substantial savings in energy costs, making it a compelling choice for companies aiming to improve their environmental footprint and reduce operational expenses simultaneously.

“The aspect of sustainability has also become a driving force in punching and forming technologies. The economical use of energy and resources is one of the most important objectives today in metalworking companies,” says Hary Kosciesza, Business Development Manager at technotrans.

“Our spray lubrication systems help users to verifiably reduce their ecological footprint.”

The solutions provided by technotrans work with high-frequency valves and without the use of compressed air to ensure a precise and mist-free application of oil. The use of an extraction system is no longer needed, and no oil that could otherwise enter the production environment is wasted. Machine cleaning and maintenance work are consequently reduced to a minimum.

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Article by BalTec AG / SEA@baltec.com

The roller forming head in turn is driven by the machine at a controlled linear feed rate as well as the optimal rotational speed. While using an appropriate control, quality of every part is monitored during the forming process.

Roller profiles are custom defined to meet individual application requirements. The material will either be rolled inward or outward, depending on the product design specifications. Due to many years of experience and the constantly changing customer needs, we have diversified and perfected the machine and tooling over time. We supply customized roller forming heads with two to five rolls that form the material.

ROLLER FORMING, THE VERY GENTLE FORMING PROCESS

One major advantage of Roller Forming is that only minimal force is necessary in order to displace material. While there are very few limitations, most hollow parts can be roll formed. Diameters between about 2 – 200 mm. Parts with a very thin wall, made out of Aluminium Die Cast, part with Difficult Access or parts with interruptions in the area to be formed. And in some cases, parts that are oval!

Assemblies that are formed under a press have to endure relatively high forces. Forces which can actually cause for the assembly to collapse and result in rejected assemblies or NOK parts. Such unusable parts of course are a loss of money and efficiency.

APPLICATIONS

Following are some common Roller Forming applications that often times present challenges while manufacturing.

3D ROLLER FORMING – REVOLUTIONARY CAPABILITY

3-D roller forming is now possible with the three axis fully programmable system. Hollow bodies / tubes can be formed on one machine, with one setup, per following examples:

The BalTec EA30 https://baltec.com/en/technologies/articulating-roller-forming  is able to form any of above geometries without tool change. Each geometry can be defined within a program. Stored programs can be called up in order to form these geometries on demand.

The following sample has been formed in approximately 20 seconds.

CONSULATION

BalTec core competence lies in the execution and development of intelligent solutions in the field of joining technology – Industry 4.0 ready. To find the optimal solution for your individual requirements, BalTec AG performs feasibility studies, the first one at no cost to you. We determine a suitable process (radial, orbital, tangential, roller forming), machine size and necessary accessories to meet your specific requirements in regard to quality & productivity. Our knowledge results from over 50 years of experience in joining and assembly technology.

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Covering a total exhibition area of over 50,000sqm—25 percent more than the 2017 event—Lamiera 2019, which took place at Fiera Milano Rho from May 15–18, presented a wide overview of automation systems, robotics, welding and technologies linked with the digital world, organised in the New Innovation Areas (Robot Planet, FabbricaFutura and Saldatech), which were added to the usual Innovation Areas, Fastener Industry, Ecocoatech and Blech Italy Service.

Amongst the highlights of this year’s event was the LAMIALAMIERA, developed with the support of the Lombardy Region. Set up in Hall 18, LAMIALAMIERA hosted a comprehensive programme of 40 exhibitor meetings spread throughout the four-day event. Moreover, LAMIERA honoured Leonardo da Vinci, 500 years after his demise, with the special show “Italians like us, excellence becomes identity” set up in the exhibition area, and awarded the medal of the Presidency of the Italian Republic. This special exhibition featured a presentation of some drawing reproductions of metal forming machine tools and automation systems developed by da Vinci, highlighting the close parallelism between his projects and the modern technologies being exhibited in the halls.

“We are very satisfied with the outcome of this edition of LAMIERA that closed with increased figures with regard to square metre of exhibit area, exhibiting companies and visiting operators,” said Massimo Carboniero, president of Ucimu-Sistemi Per Produrre, the event organiser.

“Milan is confirmed as the most suitable location, the only one in Italy capable of hosting such an important event, which we hope will keep growing and improving. For this reason, based on the achieved results, we are already working on the definition of the next edition, which will be held at Fiera Milano Rho from March 17–20, 2021,” Alfredo Mariotti, general manager of Ucimu-Sistemi Per Produrre, said.

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The post Lamiera 2019 Closes On Strong Note appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.