![]() Probably the most common problem associated with designing Roll Forming Tooling is predicting how a forming bend will react during the rolling process. Using the proper “K” factor or “Bend Allowance” is the main item the designer must consider when calculating a strip width. ![]() Various factors contribute to the bend allowance, such as material type and yield strength, profile characteristics, such as large radii or 180-degree bends, and roll design techniques. When calculating strip widths and designing rolls, the maximum thickness within the gage range is generally used. This is done to eliminate interference between the male and female rolls when the material is passing through. Unfortunately, many companies purchase their raw materials to the low side of the thickness range, to net more footage per ton, which leads to a lesser quality cross-section (poor dimensional and bend characteristics). The use of restricted tolerance material will greatly improve part consistency but is rarely done, due to increased costs for raw materials.įIG #1: C-CHANNEL CROSS-SECTION WITH MATERIAL AND MILL SPECSįirst, consider the material to be formed. ![]() Using steels with yield strengths of 30-55 KSI with forming angles of around 90-degrees and a 1t – 5t inside bend radius, a “k” factor between 35-40% of the material thickness is most common. Higher yield materials between 60-85 KSI (with a low elongation percentage), a factor between 40-55% may be necessary.
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