How Metal Channels are Roll Formed

Metal channels are produced by roll forming a sheet or strip of metal. Roll forming is a continuous bending of a metal strip as it passes through a set of consecutive rollers, also known as stands, that incrementally deform a portion of the metal until the desired shape is achieved. Once the shaping and configuring is completed, the formed                                                                                                                                                                                                                                                                                                                                                                     

Roll forming is an inexpensive method for producing large quantities of parts without the need for secondary processing or finishing. There is a limitless number of metal channel profiles that can be produced using roll forming.

How Metal Channels are Roll Formed

CAD Design

All roll formed parts, including metal channels, begin with a computer aided design (CAD) that includes the design elements of geometry, length, and metal. The purpose of the design is to display it as a single structure to streamline production. The flexibility of CAD allows the part to be created by entering its dimensions or drawing the part directly into CAD. From the entered data, the program creates a nested and separated representation of the metal channel. Both representations show the progression of the part from stand to stand in the roll forming process.

Below is a CAD separated progression of a hat channel being roll formed. The data for the roll forming progressions can be taken directly from CAD and changed into G codes to be entered into a computer numerical controlled (CNC) roll forming machine.

Sheet Metal Coil

The process of roll forming begins with a coil of metal that is mounted on an uncoiler, also known as a decoiler. The roll of sheet metal is steadily fed by the decoiler into the roll forming machine. In the image below, the uncoiler or decoiler can be seen to the right of the roll forming machine.

Pre-Processing Treatment

Metal channel roll formed parts often require hole punching of slots, holes, notches, or special custom patterns, which is performed by in-line pre-processing. Hardened tools with sharp cutting edges apply force to the metal sheet using a programmed mechanical, pneumatic, or hydraulic machine.

Roll Forming Dies

In preparation for the roll forming process, the roll forming machine has a set of precision engineered dies placed in each of the stands. These special tools are designed to exactly fit the requirements of the metal channel to be shaped. The dies for roll forming are divided into stations with a roller for each station that progressively shapes the metal sheet.

The image below shows the progressive dies for the shaping of a U shaped metal channel.

Roll Forming

Once the dies are placed in the roll forming machine and the CAD program has been downloaded, the roll forming process begins. As the metal strip leaves the uncoiler, it goes through pre-processing and into an entry guide or table that gives the metal a square straight entry into the first pass. This part of the process is essential for ensuring the quality of the final product. The number of passes a metal channel may require can go from a very few up to thirty or more depending on the complexity of the metal channel.

Final Cut of Metal Channel

There are several different methods that are used for the beginning and ending of roll forming. Some processes have straightening at the beginning of the process while others have it at the end. Regardless of which method is being used, once the channel has been shaped, the necessary length feeds out at the end and is cut to the exact specifications and collected on a table or set of rollers.

The image below is a hydraulic cutting machine that is cutting lengths of U shaped metal channeling.

Uses for Metal Channels

Metal channels are used for a variety of applications. Their most common use is as a means of support for walls, ceilings, and roofs. Each of the different profiles offer rigid support of several thicknesses, sizes, lengths, and types of metal. The fact that metal channels can be adapted and configured for many uses makes them a valuable tool for a variety of applications.

The multiple surfaces of metal channels is one of their many benefits. The different faces provide a means for connecting them. Metal channels with notches, holes, or specialty patterns make connectivity easy.

Uses for Metal Channels

Walls

Metal channels, made of steel or aluminum, are used to build walls for garages, warehouses, workshops, or metal out buildings. They are positioned from the bottom plate of a wall to the top plate to bear the vertical load. Unlike wood studs, metal studs can support a greater amount of weight and are more rigid. The fastening of metal channels for building is more secure since they are attached using bolts or rivets instead of nails.

Roofs

Metal channels made of various materials can be used as rafters that run from the eaves to the ridge and give support to the roof deck. The advantage of metal channels for rafters is their light and smaller size with the same weight bearing capabilities as other materials. Also, unlike wood, metal channels last longer since they are not susceptible to rot, decay, or the effects of moisture. In the construction of roofs, metal channels can be the main support or function as additional support for other materials.

Door Frames

Metal channels can be easily slid into door openings to offer a secure fit for the installation of the door. The inserted channels provide a smooth, flat, even surface for door placement and are tighter and more secure than wood framing. In cases when a fire door is required, metal channeling is the most obvious choice because of its strength and non-flammable materials.

Vehicle Frames

Specially designed and shaped metal channels are produced to perform specific and unique functions for a wide range of vehicles. In most cases, these vehicle framing metal channels are made of heavy duty aluminum or steel to create the frame of a vehicle with lighter metal channels being used as cross framing and extra support. The main benefit of metal channels in vehicles is their strength and rigidity as well as their ability to prevent the vehicle from flexing but allowing a sufficient amount of movement to compensate for the torque of the vehicle‘s engine.

Solar Panel Frame

A requirement for solar panels is that they be lightweight but sturdy enough to withstand harsh conditions. Metal channels are ideal for those conditions since they meet both criteria. The tensile strength of metal channels provides them with the strength necessary to endure the conditions where solar panels are installed. The lightweight of metal channels allows solar panel manufacturers to install their products in a wide variety of conditions and environments.

Industrial Uses for Metal Channels

Construction

What has become a necessity in construction are materials that are lightweight and recyclable but have the strength and endurance to fit the many applications required by the industry. Over the past few years, as the use of wood has become limited, the construction industry has shifted its structural needs to metal channels that meet all of the characteristics of wood but are stronger.

From the manufacturing of scaffolding to the support for walls, metal channels can be found as a sturdy, reliable and dependable material that can have one time use and be recycled or be stored for multiple uses. Since several of the metals used to produce metal channels are weather resistant, they are a practical and long lasting replacement for other methods of construction.

Transportation

In the transportation industry, metal channels can be found in window tracks, bumpers, reinforcement bars, structural components, and vehicular trim. In the basic structural design of modern vehicles, metal channels have become a necessity as a means of reducing the overall weight of vehicles to improve gas mileage.

Design engineers depend on metal channels in the development of new designs and lightweight structural support. The flexibility and adaptability of metal channels are the major reason that designers and engineers rely on them as a major component in the development of new transportation concepts.

Agriculture

A challenge for the agricultural industry is materials that can withstand constant use but be able to endure harsh environmental conditions. The main use for metal channels in the industry is for the construction of enclosures for animals and storage bins. The nature of grains, animal feed, and fertilizers requires that any form of storage unit or enclosure be able to meet the conditions of use and weather but not be contaminated or contaminate what is being stored. The varieties of metals from which metal channels are produced offers several solutions to meet the agriculture industry requirements.

Since metal channels are lightweight but resilient, they can be used to build storage units for one location and later be easily moved to another location with little effort. This reduces storage expenses and provides producers with multifunctional equipment.

Aviation

The main requirement for any product or component for aviation is that it be functional and lightweight. Metal channels are widely used in aviation for those very reasons. Cabin walls, seats, and supports on aircraft use light weight metal channels as a reliable, dependable, and fail safe asset.

In most cases, metal channels used in the aerospace industry are made of lighter metals such as aluminum, which has the added benefit of being resistant to weathering, rust, and corrosion, three factors that can be harmful and dangerous to aircraft.

Other Uses

The uses for metal channels described above are only a few of the many ways that engineers and designers have made creative use of metal channels. Highway signs, bridges, heaters, home appliances, factory equipment, and office furniture depend on metal channels as a means of support and reliable function.

As natural materials, such as wood, become more limited, metal channels, a recyclable and strong part, will find greater use.