In today's manufacturing landscape, the variety of presses and measuring systems available for roll forming is more extensive than ever before. There are three major types of presses that roll forming professionals should know about: mechanical, air, and hydraulic presses.
By understanding the differences between them, you can make more informed equipment decisions that enhance your roll forming system's operations and design. Each type of press has unique advantages and disadvantages, and selecting the right one requires careful consideration of your application's specific needs and constraints.
In this series on our blog, we'll go through each press type one by one and discuss their features, advantages, and disadvantages and how all those elements make them the right choice for certain applications.
Mechanical Presses - Part 1
Introduction to Mechanical Presses for Roll Forming
A mechanical press is a type of press machine that uses mechanical components, such as a flywheel, crankshaft, and connecting rods, to generate and transfer force for various manufacturing processes. Mechanical presses are valued for their high-speed operation, precision, and durability, making them a cornerstone in many manufacturing processes, particularly in metal stamping and forming applications in various manufacturing industries including automotive, aerospace, and metalworking.
When choosing a mechanical press, consider factors such as the required force, speed, and precision. Mechanical presses are known for their high-speed operation and consistent power delivery, making them ideal for high-volume production. However, they also have limitations, including less flexibility in controlling the press cycle and higher maintenance needs.
Why to Use Mechanical Presses in Roll Forming
Mechanical presses in roll forming systems are often used in either a pre-punch setup before the material enters the forming rolls or a post-punch/cutoff setup after the shape is formed. Their high-speed, consistent stroke makes them ideal for high-volume production where accuracy and timing are critical. The die tooling within the press determines the shape, location, and function of the punched or cut feature, and it must be aligned carefully with the moving material to ensure consistent results.
How Do Mechanical Presses for Roll Forming Work?
In roll forming, mechanical presses are used to perform secondary operations such as punching, notching, embossing, or cutting the formed material. These presses work by converting the rotational motion of a motor-driven flywheel into vertical linear motion using a crankshaft or eccentric mechanism. When synchronized with the roll forming line, the mechanical press cycles at high speeds to deliver precise, repeatable force at a specific point in the production process.
It's important to note that these are general rules to use as rough guidelines regarding mechanical presses. However, it's important to remember that there are always exceptions, particularly if you're already using a specific type of press due to budget constraints. Even so, be cautious of this justification, as it might end up costing more in the long run.