The door frame roll forming machine is used to form door frames. A door frame is made up with four sides which are usually made of wood, plastic or metal. A door frame roll forming machine is made primarily for forming metal door frames. The door frame roll forming machine is also known as the metal forming machine as a result. The process to make a door frame consists of several procedures, such as cutting thin metal sheets, bending and folding the metal sheets, and combining the components into a door frame.
Generally speaking, the door frame roll forming machine fabricates specific configurations out of long strips of metal. The specific configuration refers to the cross section profile of the metal sheet. The metal forming machine is able to bend the metal strip into the designed configuration. After the metal strips are folded into a column like metal component, these components will be assembled later on and turned into a door frame. This process comes in as a continuous working cycle with multiple processing stations.
The door frame roll forming process has the layout of a long production line with stations which can last tens of feet and the door frame roll forming machine lies at the second half of the production line. The very first station of a door frame roll forming process is the feeding of metal sheets. At the start of the line, there is a metal sheet roll. As the machine rolls, the metal sheet is constantly fed into the next station. The width of the metal sheet may vary based on the application. At this stage, it is referred to as the entry section.
The metal sheet is fed from the entry section to the next station, the station rollers. At this stage, the machine works to keep the metal sheet going and drive it into the next station. In this station, the metal sheet will also go under a process that creates holes into the material. The holes come into different styles; it can be a simple round hole or it can sometimes be an indexing arrow or other configurations. The holes indicate the length of each side of the door frame. In the next station, the metal sheet will be dissected according to the hole marks.
Besides making marks, the major goal of the station rollers is to bend and fold the metal sheet into the desired cross section configurations. There will be more station rollers if more folds or corners are required in the cross section of the material. This is where the roll forming process lies and the configuration of the door frames formed. The station rollers also serve as the driving force of the machine.
Typically speaking, the metal sheet goes through two rollers, one on the top and one at the bottom. When the thin metal material goes through these rollers, the shape changes according to how the rollers are configured. This whole process is conducted at room temperature. After the rollers, the component will go to the next station, the cut off press, to be dissected.
The bending process done in the previous station is also called the profiling process. After the metal sheet goes through the station rollers, it is profiled into the designed shape. The material is now ready to enter the cut off press to be cut. The length of the material is predetermined. During this process, a flying die is usually used in the press to cut the material apart. Just like a regular press machine, a ram descends onto the base of the machine where the material lies. When the ram goes down and engages the base, the material is cut by the dies. After the cut off press, there is one more station ahead of the components, the exit station.
The finished and dissected parts eventually exit the door frame roll forming machine at the exit station. These parts will be sent to a conveyor from the exit station and be collected onto a working table. This is where the automated operation ends and the manual operation takes over. Once the finished components are collected, these pieces will be assembled manually into door frames.
Generally speaking, since the configuration is created accurately by the roll forming machine, the assembly of the door frame is relatively simple. The roll forming machine is ideal for producing constant profiled parts with long length and large quantity. The metal roll forming is considered one of the simplest metal forming processes to date. The process is useful when working with the metal materials such as stainless steel or some steel-based alloys.
In the modern roll forming manufacturing industry, the metal roll forming machines are mostly incorporated with the computerized control units to achieve a better quality of mass production with precision. By working with the CAD or CAM systems, the roll forming machines are capable of functioning at the maximum potential. In addition, the computerized control unit enables the machine to detect the errors or imperfection during the production process so that the damage to the equipment and the waste of the material can be minimized.
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