--- title: "Roll Forming Design Considerations: Tolerances of Forming Materials" description: In this post, we continue our discussion of roll forming designs with a discussion on the tolerances of forming materials. image: https://blog.formtekgroup.com/hubfs/Imported_Blog_Media/Tolerances-Fig-3-300x127.gif --- [![Formtek](https://blog.formtekgroup.com/hs-fs/hubfs/raw_assets/public/Formtek_January2022/images/FormtekWhite-min.png?width=500&height=334&name=FormtekWhite-min.png "Formtek")](https://www.formtekgroup.com/) - [About Formtek](https://www.formtekgroup.com/about-formtek/) - [Brands](https://www.formtekgroup.com/formtek-brands/) - [Solutions](https://www.formtekgroup.com/solutions/) - [Industries Served](https://www.formtekgroup.com/industries-served/) - [News and Updates](https://blog.formtekgroup.com/news-and-updates) - [Service and Support](https://www.formtekgroup.com/service-and-support/) - [Products](https://www.formtekgroup.com/products/) - [Resources](https://www.formtekgroup.com/resources-formtek/) - 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The manufacturer is often asked to propose equipment to make a given shape from more than one gauge of metal and in the interest of minimum tool cost, to do so in one (1) set of rolls.  Remembering that rolls must be fitted for the maximum metal thickness and also that the only adjustment available to the operator is vertical to bring the rolls closer together or farther apart.  Figure #3 shows the minimum and maximum conditions that exist in a typical case.  Note the change in the angle of the vertical leg, the change in overall height and the change in arc length at the bends.[![Figure 3: Minimum / Maximum Relationship - Multiple Gauge Forming](https://blog.formtekgroup.com/hs-fs/hubfs/Imported_Blog_Media/Tolerances-Fig-3-300x127.gif?width=300&name=Tolerances-Fig-3-300x127.gif "Figure 3: Minimum / Maximum Relationship - Multiple Gauge Forming")](https://blog.formtekgroup.com/hubfs/Imported_Blog_Media/Tolerances-Fig-3.gif) Figure 3: Minimum / Maximum Relationship - Multiple Gauge Forming Strip width variations also affect section tolerance.  In the case of the hat section pictured here, width variation would be reflected as a variation in the length of the legs.  The part designer should be governed accordingly. **b.** The straightness of a formed section varies due to any one of several factors, strip thickness or hardness changes in a given coil, or for that matter, from coil to coil, roll pressure adjustments, lubricant or temperature changes and camber.  The operator must recognize the affect of these conditions and be able to compensate for them.  A straightening attachment on the exit end of every machine provides this facility. **c.** Straightness consists actually of three (3) considerations - camber, or deviation from a straight line in a vertical plane; sweep, deviation from a straight line in a horizontal plane; and twist, the order of magnitude, for camber and sweep being about 1/8” or ¼” in about 10’ and twist about 5° to 15° in 10’. Tags: [Roll Forming](https://blog.formtekgroup.com/tag/roll-forming) [Back to Blog](https://blog.formtekgroup.com) - [Tweet](https://twitter.com/share) ## Related Articles ## [Roll Forming Line Operation and Setup](https://blog.formtekgroup.com/roll-forming-line-operation-and-setup) While there is no catch-all roll forming solution for every business, there are some elements of... [Read More](https://blog.formtekgroup.com/roll-forming-line-operation-and-setup) ## [The Value of a Roll Forming Line](https://blog.formtekgroup.com/the-value-of-a-roll-forming-line) Whether you're considering getting started with roll forming or expanding your capabilities with a... [Read More](https://blog.formtekgroup.com/the-value-of-a-roll-forming-line) ## [Single Point Adjustment in Roll Forming Production](https://blog.formtekgroup.com/single-point-adjustment-in-roll-forming-production) In order to run a more productive roll forming operation, you need to ensure that your machinery... [Read More](https://blog.formtekgroup.com/single-point-adjustment-in-roll-forming-production) ##### WE’RE HERE TO HELP Have questions about our machinery and equipment? Looking for a solution to address a particular application? Looking to improve the overall productivity and profitability of your operation? Please don't hesitate to reach out or schedule a no obligation, 1-on-1 consultation with a Formtek Technical Specialist — we'd love to help. 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