Foil Rolling

Foil rolling is a continuous deformation process compressing metal between a pair of rollers called work rolls.  Another term for this process is called plate roll bending. This is defined as a cold forming process where plate and steel metal is formed into cylindrical shapes by a combination of three rolls arranged in a pyramid formation. Two of the rolls are power driven, in a fixed position, and the third is adjustable to suit the desired bend radius and workpiece thickness.

Foil is produced for several applications:

• Thermal insulation for the construction industry
• Fin stock for air conditioners
• Electrical coils for transformers
• Capacitors for radios and televisions
• Insulation for storage tanks
• Decorative products
• Containers and packaging

Foil stock is reduced in thickness by a rolling mill, where the material is passed several times through metal work rolls. As the sheets of metal pass through the rolls, they are squeezed thinner and extruded through the gap between the rolls. The work rolls are paired with heavier rolls called backup rolls, which apply pressure to help maintain the stability of the work rolls. The work and backup rolls rotate in opposite directions. As the foil sheets come through the rollers, they are trimmed and slitted with circular or razor-like knives installed on the rolling mill. Trimming refers to the edges of the foil, while slitting involves cutting it into several sheets.

Aluminium alloys are most commonly produced in the foil rolling process because the raw materials necessary for its manufacture are abundant. Aluminium foil is inexpensive, durable, non-toxic, and greaseproof. Iron, silicon, and manganese are all major alloying elements. Sheet metals with a thickness below 200 micrometers are considered foils (Some foils may be as thin as 6.3 micrometers).

Plate Roll Bending

"Plate Roll Bending is a cold forming process. Plate or steel metal is formed into cylindrical shapes by a combination of three rolls arranged in a pyramid formation. Two of the rolls are power driven, in a fixed position, and the third is adjustable to suit the desired bend radius and workpiece thickness."

"Shapes produced range from simple cylindrically shaped parts to more complex parts, such as conical and flattened from 1/16in to 6in, and lengths of up to 20in, or more, can be formed by this method."

Progressive Roll Forming

Roll forming, also spelled rollforming, is a continuous bending operation in which a long strip of metal (typically coiled steel) is passed through consecutive sets of rolls, or stands, each performing only an incremental part of the bend, until the desired cross-section profile is obtained. Roll forming is ideal for producing parts with long lengths or in large quantities.

The geometric possibilities can be very broad and even include enclosed shapes so long as it is the same cross-section throughout. Typical sheeting thicknesses range from 0.025in. to 0.25in., but they can exceed that. Length is almost unaffected by the rolling process. The part widths typically aren't smaller than 1in. however they can exceed 20in.

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