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.
Structural shapes that can be rolled include: I-beams, H-beams, T-beams, Z-beams, angle iron, channels, pipes and tubing, bar stock, and railroad rails. The most commonly rolled material is structural steel, however other metals, plastic, paper, and glass can be rolled.[citation needed]
Common applications include: railroads, bridges, roller coasters, art, and various building applications where a curved wall, roof, or entrance is desired.
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. When the distance between the rollers is adjusted, various curvatures can be made (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 also
References
Notes
Bibliography
- Manufacturing Processes & Materials By George F. Schrader, Ahmad K. Elshennawy