Engineering Book from C.H.I.P.S.

Roll Forming Handbook
edited by George T. Halmos

Roll Forming Handbook presents the first comprehensive, dedicated treatment to all facets of roll forming, supplying references to more in-depth information to fill in the gaps.


  • Includes real-world case studies, recommendations for efficient plant layout and material handling as well as hundreds of illustrations and references
  • Explains the principles and methods of manual and computer-aided roll design and tool setup
  • Supplies equations to calculate number of passes, shaft diameters, and bending factors, published here for the first time
  • Presents guidelines for training personnel as well as for performing troubleshooting and maintenance


Roll Forming Mill

  • Mill Types
  • Mill Components

Presses and Die Accelerators

  • Mechanical Presses
  • Pneumatic Presses
  • Hydraulic Presses
  • Information and Dimensions for Press/Die Purchasing and Installation
  • Rotary and Other Cutting, Punching Equipment
  • Flying Die Accelerators

Secondary Operations in the Roll Forming Line

  • Secondary Operations
  • Straightening
  • Tight or Loose Line: Cutting Before, In-Between, or After Roll Forming
  • Location of the Secondary Operations
  • Stationary and Flying Dies
  • Punching, Perforating, Notching, and Mitering
  • Piercing and Partial Punching
  • Flanging, Louvering, and Lancing
  • Embossing and Drawing
  • Bending
  • Curving (Sweeping)
  • Marking
  • Swedging (Off Setting)
  • Rotary Dies
  • Mechanical Joining of Different Strips or Parts
  • Adhesive Bonding
  • Soldering and Brazing
  • Resistance Welding
  • Painting
  • Foaming
  • Packaging

Roll Design

  • Roll Design Process
  • Cross-Section
  • Product Orientation and Other Operations in the Line
  • Materials
  • Roll Forming Mill
  • Other Tool Design Considerations
  • Spacers and Shims
  • Calculating Strip Width
  • Bend Lines
  • Number of Passes
  • Flower Diagram
  • Roll Design
  • Calculating Roll Dimensions Manually
  • Computer-Aided Roll Design
  • Roll Marking System
  • Roll Orientation
  • Setup Charts


  • Design Considerations
  • Mechanical Properties
  • Crystalline Structure of Metals
  • Forming Metals
  • Increasing the Strength of Metals by Cold Working
  • Hot Rolling
  • H.R. and H.R.P.O. Steels
  • Cold Rolled Steel
  • Carbon Steel
  • Alloyed Steel
  • Stainless Steel
  • Metallic Coatings
  • Nonmetallic Coating and Laminating
  • Joining Different Materials in the Roll Forming Process
  • Aluminum
  • Other Metals and Materials
  • Influence of Primary Metal Processes on Roll Forming
  • Guideline to Steel Prices


  • Tribology of Lubrication
  • Selection of Lubricants
  • Surface Properties of Formed Material
  • Lubricants for the Secondary Operations
  • Application Techniques
  • Preparation and Maintenance of Lubricants
  • Operating Problems during Production

Coil Processing, Material Handling, and Plant Layout

  • Flow of Material
  • Coil Handling and Storage
  • Sheet Handling and Storage
  • In-Line Coil Handling
  • Coil End Welding
  • Strip (Coil) Accumulators
  • Flattening and Leveling
  • In-Line Sheet Handling
  • Finished Product Handling
  • Finished Product Storage
  • Material Handling Equipment
  • Material Handling Accessories
  • Crane Controls
  • Plant Layout

Designing Products for Roll Forming

  • Developing Light Gage Products
  • Design Considerations
  • Secondary Operations
  • Profiles Manufactured in Different Sizes
  • Design of Specific Products
  • Dimensioning and Tolerancing

Equipment Installation, Roll Setup, Maintenance, and Troubleshooting

  • Installation of Roll Forming Lines
  • Roll Installation and Setup
  • Maintenance and Spare Parts
  • Troubleshooting and Trouble Prevention

Behavior of Metal Strip During Roll Forming

  • Various Types of Deformations
  • Causes of Redundant Deformations
  • Effects of Redundant Deformations on Product Defects
  • Mathematical Simulation of the Deformation of a Metal Strip
  • Computerized Design System for Roll Profiles
  • CAE for Roll Forming

Acquiring Roll Forming Lines, Education, and Training

  • Why Roll Form Products?
  • Different Paths to Start Roll Forming
  • Evaluating the Product
  • Selecting Line Components
  • Procuring Roll Forming Tooling
  • Equipment and Tool Specifications
  • Acceptance Test
  • Education and Training
  • Motivation


  • Safety
  • Common Safety-Related Definitions
  • Safety Design Procedure
  • Determining Limits of the Machinery or System
  • Determining Hazards/Risk Estimation
  • Risk Reduction by Design
  • Safeguarding
  • Selection of Guards and Protective Devices
  • Required Characteristics of Guards and Protection Devices
  • Signals and Warning Devices
  • Personal Protective Equipment
  • Training

Increasing Efficiency of Roll Forming Lines and Case Studies

  • Output, Productivity, and Efficiency
  • Line Utilization
  • Improving Productivity
  • Case Studies
  • Preliminary Tool and Equipment Cost Analysis
  • Preliminary Cost Analysis

Unusual, New, and Future Roll Forming Technologies

  • The Last 100 Years
  • The Future of Roll Forming
  • Pull-Through Mills: Nondriven Rolls
  • Tension Roll Forming
  • Combining Roll Forming and Cold Drawing
  • Developing New Roll Forming Methods
  • Roll Forming Tools
  • Reducing the Thickness of the Starting Material
  • Forming at Elevated Temperature
  • Hot Roll Forming Variable Cross-Sections
  • Hot Thickness Reduction along the Length of the Strip
  • Welding Hot Roll Formed Sections
  • Other "Hot" Processes
  • In-Line Soldering, Brazing, and Heat Treating
  • Equipment and Tooling Requirements for Hot Roll Forming
  • Press Tooling for Conventional Roll Forming Lines
  • Computer-Controlled Roll Forming Lines


click here to see books of related interest


Roll Forming Handbook
edited by George T. Halmos
584 pages • $204.95 + shipping
Texas residents please add 6.75 % sales tax

Go to Top of Page

copyright © 1997-2012 Culinary and Hospitality Industry Publications Services