Structural shape rolling
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Structural shape rolling is a metalworking forming process in which structural shapes are passed through rollers to bend or deform the workpiece to a desired shape, while maintaining a constant cross-section.
It is a cost effective way of bending this kind of material because the process requires less set-up time and uses pre-made dies that are changed out according to the shape and dimension of the workpiece.[1] This process can produce 360 degree bends in structural shapes, therefore allowing the building of such things as spiral staircases and thrill rides.
Process
Structural shape rolling uses profile rolling techniques where the workpiece is passed through a series of rollers (of larger magnitude than that of common rolling devices) that match the beams geometry, the most common method being the use of 3 rollers (refer to Rolling (metalworking) for a more in depth description of the rolling process). Structural shapes can be rolled in different ways such as the “easy-way”, the “hard-way”, heel in/out, ball in/out, leg in/out, stem in/out, and off axis.[2] The hard-way would be bending the workpiece in the orientation where its moment of inertia is the greatest. The easy-way is the opposite; bending along the axis where the moment of inertia is the smallest. For example, a piece of angle iron rolled the easy-way would be rolling it along one of its flanges, while the hard-way would be along the angle itself. (see image for more details).
Structural Shapes That Can Be Rolled
I-beams – H-beams – T-beams – Z-beams – Angle Iron – Channel Iron – Pipe – Tubing – Bar Stock – Railroad Rail
Materials That Can Be Rolled
Materials such as metal (ferrous and non ferrous), plastic, paper, and glass can be rolled, but Structural steel is what is commonly used in structural shapes.
Common Applications
Applications include: railroads, bridges, roller coasters or other thrill rides, and various building applications where a curved wall, roof, entrance, etc. is desired. It is also often used in many forms of art such as sculptures and architecture.
See Also
References
Notes
Bibliography
- Manufacturing Processes & Materials By George F. Schrader, Ahmad K. Elshennawy