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FAQ

1. What type of equipment do I need for special roll-forming?
2. Can my part be roll-formed?
3. What type of information does Rol-Flo require for quotation purposes?
4. What size roller do I need?
5. How many parts will one set of forming dies produce?
6. Can the worn dies be re-ground?
7. What types of materials can be rolled?
8. Is there a cost to receive a quotation?
9. How long does it take to receive a set of special forming tools?
10. How can we be sure the dies will work?
11. Do you make any standard thread die tooling?
12. Do you provide the replacement production tooling?
13. How much do the tools cost?

Questions Frequently Asked by Our Customers

What type of equipment do I need for special roll-forming?
  Flat-die Form Rolling can be accomplished with any type of “Thread Rolling” equipment that you currently have in-house. There are also numerous Flat Die Machine manufacturers from which to choose. Rol-Flo custom designs and manufactures tooling for all types, sizes & models of Flat-Die Rollers.
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Can my part be roll-formed?
  This is where Rol-Flo Engineering’s expertise first comes into play. With 25 years of focused study in the area of Form Rolling Technology, our engineers can quickly and efficiently determine a part’s feasibility for the form-rolling process. Typically our clients will mail, fax or email us a drawing of the part to be formed and we do the rest.
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What type of information does Rol-Flo require for quotation purposes?
  Typically our clients will mail, fax or e-mail us a drawing of the part to be formed. On this drawing or on a separate note the following information should be provided:

a. Prints that are completely legible.
b. All notes translated into English.
c. The detail you are interested in roll-forming.
d. Tolerances on dimensions.
e. Material of part being formed.
f. Types & Sizes of rollers available.
g. A part or inquiry number for referencing.
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What size roller do I need?
  The engineering department at Rol-Flo will determine and advise the optimum size roller for your particular part requirements. There are many variables that determine how many revolutions a part will require to accomplish the required formation.
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How many parts will one set of forming dies produce?
  This will be directly related to the type of material being rolled, the form being produced, the condition of the roller, the set-up expertise, type of coolant being utilized, how often the roller is stopped and started, etc. For increased and optimum tool life, materials having a tensile range from 60,000 to 85,000 PSI (420 / 595 N/mm) are ideal and should be used wherever the part design allows it. Under optimum conditions mild carbon steel will yield on average anywhere from 250,000 to 500,000 pieces per set of point forming or groove forming dies.
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Can the worn dies be re-ground?
  This is highly dependant on the type of form being rolled and the severity of the wear. Often sever fatigue cracks (hairline fractures) run deeply into the grain structure and cannot be detected by the naked eye. The minimal savings obtained by re-surfacing is often lost in the decreased tool life. For a proper determination to be made for your particular case, a set of worn dies can be sent back to Rol-Flo for analysis.
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What types of materials can be rolled?
Today every type of material considered to be “cold-heading quality” is being rolled, from aluminum to titanium. For optimum results, materials having a tensile range from 60,000 to 85,000 PSI (420 / 595 N/MM) are ideal and should be used wherever the part design allows it. If the product application dictates a higher tensile strength, an annealing cycle prior to the form rolling operation may be necessary.
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Is there a cost to receive a quotation?
All quotations are free of charge and are typically offered within 48 hours of receiving a properly detailed part drawing.
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How long does it take to receive a set of special forming tools?
  Generally all special forming tools are custom made and the delivery time is stated on the quotations. Upon the receipt of a customers purchase order, the process is immediately started and the Ship Date is stated when the order is Confirmed. For repetitive orders, a pre-fixed schedule can be arranged so that the required sets of dies can be shipped on a monthly basis.
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How can we be sure the dies will work?
  With 25 years of focused study and thousands of successfully designed tooling, Rol-Flo Engineering has an extensive historical database of proven die designs. These proven designs allow us to provide you tooling with the best possible chance for success. In instances where a design has not been proven we have in-house rolling equipment and technicians that allow us to prove and fine-tune a die design. Cold-headed blanks are sent to us for testing and upon completion, we provide a Development Report along with rolled samples, assuring the customer’s set-up personnel what can be obtained
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Do you make any standard thread die tooling?
  Although our specialty lies in the area of designing and manufacturing special form rolling tools we also can offer standard thread dies and are very competitive with all types of knurl rolling. We custom design knurl TPI for optimum number of teeth and tracking.
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Do you provide the replacement production tooling?
  We have a full production tool shop and provide all your replacement tools as well as offering you competitive pricing on all your current tooling use.
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How much do the tools cost?
  Tooling cost will vary depending on the complexity of the part being formed, the size of roller, the tooling material required and the quantity of tool order. Often a 25% or more savings can be realized when purchasing (6) or more pair of tooling. Our freely offered quotations provide all the specific tooling costs and price break quantities. There are no “hidden” fees to worry about.
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Form Rolling Flat Die Specialists

Rol-Flo Engineering
85A Tom Harvey Rd
Westerly, RI 02891 USA
T=401.596.0060
F=401.596.0216