Different types of rolls are used in the roll forming process.

Roll Forming Basics

Roll forming is a metal forming process in which metal in the form of sheets, coil, or strips is converted into an engineered shape. The THORS Roll Forming Basics course is relevant for learners who are new to the industry, as well as experienced learners. Ready to take the next step? Explore the course details and see everything we’ve packed into this program!

Learning Hours: 2.5

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Course Description

Roll forming is a metal forming process in which metal in the form of sheets, coil, or strips is converted into an engineered shape. The THORS Roll Forming Basics course is relevant for learners who are new to the industry, as well as experienced learners that require a deeper knowledge of the roll forming line equipment, the different machine configurations, the procedure involved in the designing the rolls, and a deeper insight into the roll forming process and secondary processes carried out in the roll forming line. In addition, the course explores major defects and troubleshooting techniques that occur on the formed product during the roll forming process.

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Who will benefit from this Roll Forming course?

Sales, Quality, Engineering, Purchasing, and Manufacturing

Course Classification

This manufacturing course by THORS eLearning Solutions covers identification of key terms, understanding of key concepts, and application of the covered topics.

*THORS uses the Bloom’s Taxonomy Methodology for our course development.

Certificate Awarded for Roll Forming Basics

Example of certificate awarded upon successful completion of the course.

*upon successful completion

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Learning Objectives

  1. Recognize the basic equipment used in the roll forming process.
  2. Identify the different configurations of the roll forming machines and tools.
  3. Understand the steps involved in the roll forming process.
  4. Analyze the major secondary processes carried out in the roll forming line.
  5. Identify the various defects and troubleshooting in roll forming.

Roll forming machines are available in various configurations.

Table of Contents

  1. Roll Forming Line
    1. Roll Forming Equipment
      1. Decoiler
      2. Strip Straightener
      3. Roll Forming Machine
    2. Rolls
      1. Types of Rolls
        1. Forming Rolls
        2. Side Rolls
        3. Carrying Rolls
        4. Drive Rolls
        5. Embossing Rolls
        6. Rotary Punching Rolls
      2. Roll Design
    3. Additional Equipment
      1. Strip Shear and End Welder
      2. Press Feed Unit
      3. Pre-Punch Press
      4. Section Straightener
      5. Cut-Off Press
      6. Run-Out Table
    4. Types of Roll Forming Lines
    5. Roll Forming Machine Components and Configurations
      1. Components
        1. Bed
        2. Roll Stands and Shafts
        3. Control System
          1. Motor
          2. Control Panel
        4. Lubrication System
      2. Configurations
        1. Cantilever Mills
        2. Duplex Mills
        3. Standard Mills
        4. Through Shaft Duplex Mills
        5. Double High Mills
        6. Rafted Mills
        7. Side By Side Mills
        8. Spiral Tube Mills
        9. Truck Mounted Mills
  2. Roll Forming Line Processes
    1. Roll Forming Process
    2. Secondary Processes
      1. Cutting Operations
        1. Shearing and Cut-Off
        2. Punching
        3. Perforating
        4. Notching
        5. Mitering
        6. Piercing
      2. Forming and Shaping Operations
        1. Louvering
        2. Embossing
        3. Hole Flanging
        4. Lancing
        5. Bending
        6. Curving
        7. Rotary Coining
      3. Joining Operations
        1. Lock Seam
        2. Riveting
        3. Welding
      4. Other Operations
        1. Painting
        2. Foaming
  3. Roll Forming Defects and Troubleshooting
    1. Camber
    2. Bow
    3. Twist
    4. Flare
    5. Springback
    6. Herringbone
    7. Waviness
    8. Cracks
    9. Coating Peel-Off
    10. Coating Crack

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