When a roll forming manufacturer is trying to make an important decision on what roll forming products they are going t make next, another important consideration they have to keep in mind is the ideal mill configuration that will ensure that they are getting the best end result. A roll forming manufacturer will also have to make decisions regarding the right timing for the cut-off as well as what type of materials to be used for roll forming – pre-cut and post-cut. In the case of pre-cut materials, before they are fed into the roll forming machine they must be cut into strips first while post-cut, on the other hand, the material is fed into the roll forming machine first to achieve its shape before it is cut into the desired size. Whatever choice the roll forming manufacturer chooses, there are both pros and cons to each of them. Here are the pros and cons on both pre-cut and post-cut to help one decide.
Pros of post-cut roll form:
- The production is higher while the downtime is reduced because the material is sent to the machine in a continuous manner.
- The most typical situation is that there will be no self-threading required for the material thus less forming stations are needed.
- Once the new coil has been threaded then there is no chance that the edge of the material will be warped.
- Tools do not easily wear because of reconditioning which results to a more uniform footage.
Cons of post-cut roll form:
- The material leaving the cut-off die sometimes have slight burr or deformation in the material’s cross section.
- There is more number of die inserts necessary for the cut-off especially if a certain product requires many different combinations and sizes.
- If the component contains complex notched feature then pre-cut form is recommended.
- In cases where pre-notching is required, the mill system needs added capital in order to aid the system.
Pros of pre-cut roll form:
- In general, this process is less when it comes to cost because the same electronic feed system will still be used during the pre-shear process compared to requiring another post-cut press at the mill’s end.
- The strip when fed into the machine by hand is an economical approach especially in production that requires only low volume.
- Product requiring notch configuration is more convenient to handle.
Cons of pre-cut roll form:
- Strips must undergo self-threading and to make sure that there are no deformations in the edges, another forming station is normally added.
- Because the lead as well the trail ends of the strips have no support then there are issues when it comes to the straightening of the material.
- Auxiliary guides are necessary to guide the material as it moves from one pass to another.
- Tools are subjected to higher abuse and can easily wear die to the lead-in edge of the material.