Precision in Design, Fabrication, and Repair

Roll form tooling is at the heart of any roll forming operation, determining the quality, accuracy, and efficiency of the final product. The process of designing, fabricating, and maintaining these tools requires a blend of experience, advanced technology, and high-quality materials. Here’s an in-depth look at how roll form tooling is developed and why it plays such a crucial role in manufacturing.

Engineered Tooling: Combining Experience with Advanced Technology

With over 80 years of experience in roll form tooling design, the expertise in this field is unparalleled. This extensive knowledge is combined with cutting-edge software like dataM COPRA, a state-of-the-art tool for roll tooling design. This integration ensures that every tooling set produced meets the highest standards of quality and precision.

The tooling is engineered to create shapes exactly to your specifications, using robust materials like 4140 tool steel or D2 steel upon request. 4140 is an oil-hardened tool steel, known for its versatility and durability. It is heat-treated to 56 – 58 Rc on the Rockwell Hardness Scale, making it a long-lasting choice for roll form tooling.

Precision Manufacturing and Detailed Documentation

Every piece of roll form tooling is manufactured with extreme precision, adhering to a tolerance of +/- .001”. This level of accuracy is critical for ensuring the consistency and reliability of the final roll-formed products. The rolls are designed using a CAD/CAM system, which allows for detailed and accurate design plans.

To maintain a high level of quality control, detailed drawings of all tooling are provided to clients. Additionally, specifications for each roll form die are archived, making it easy to remake a roll if necessary. This archival process ensures that any future production runs can maintain the same exacting standards as the original.

Customization and Retrofitting

In addition to designing and fabricating new roll form tooling, there is also the capability to design roll sets and provide all necessary engineering for tooling that can be outsourced. This flexibility allows manufacturers to meet a wide range of production needs, whether they require in-house tooling or prefer to outsource the manufacturing process.

For those looking to update or retrofit existing equipment, customized roller dies can be supplied. This is particularly useful when transitioning to a new part or updating the production process. By retrofitting existing equipment with new tooling, manufacturers can extend the life of their machinery and adapt to changing production requirements.

Service and Support

Beyond the initial design and fabrication, ongoing support is crucial for maintaining the efficiency and longevity of roll form tooling. Services include roll form machine service and replacement roll dies, ensuring that your production line continues to operate smoothly. Whether you’re starting a new production line or updating an existing one, having access to expert service and high-quality replacement parts is essential.

Conclusion

Roll form tooling is a critical component in the roll forming process, with precision and durability being key factors in its design and manufacture. By leveraging decades of experience and advanced design software, manufacturers can ensure that their roll form tooling meets the highest standards of quality. Whether you’re looking for new tooling, retrofitting existing equipment, or need ongoing support, investing in expertly engineered roll form tooling is essential for achieving consistent, high-quality results in metal forming operations.