Engineers use computers to design rollforming rolls and to simulate their performance before the tools are manufactured, replacing art with science. Rollforming companies expect their operators to possess the special skills needed to take advantage of better roll designs and to reduce machine downtime while improving the quality of the formed products. At the same time, manufacturing engineers must understand the capabilities of the rollforming process. However, neither the operators nor manufacturing engineers typically receive formal training in the rollforming process. Most rollforming operators learn their craft through their own experiences, so it follows that the best operators are those who have worked longest at their jobs. The trial-and-error learning process can work well as long as the machines and tooling do not change. But, it also can result in the development of some bad habits. This article presents principles of rollforming for anyone connected with a rollforming operation, allowing them to understand the process capabilities and limitations.
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