what affects the number of roller stations?

In the cold roll forming industry, customers often ask  the number of roller stations. In fact, there is no absolute answer to this question. Each roller designer has his own solutions. Below we briefly describe what  affects the number of roller stations?

First, the thickness of the material affects the number of roller stations. Many people believe that the thicker the material, the more roller stations needed. However, from the perspective of cold roll forming technology . If the design of the cold roll forming machine is designed to be high, such as wall plates, shafts, roll materials, motors, etc., the thicker the material is, the less the required number of tracks will be. If the configuration of the equipment is not high, more passes should be used to reduce the force each group bears. In the case of thin material, if you increase the number of roller stations, you can reduce the chance of waves. Or if the surface is demanding and there are no scars, the number of roller stations can be increased and the problem can be better resolved.

Second, the material affects the number of roller stations. The higher the hardness of the material, the more roller stations required. If a thick stainless steel section is cold-formed, more roller stations are required.

Third, the machine cost will affect the number of roller stations. For the manufacturer of cold roll forming machines, in order to control the production cost, the number of roller stations will be reduced as much as possible. Therefore, in many cases, if the contracted unit price is low, the manufacturer will suggest fewer trips.