INDIVIDUAL EQUIPMENT
55+ YEARS OF INDUSTRY EXPERIENCE
PS PRECISION SERIES ROLL TOOLING STANDS
METFORM OFFERS AN INDUSTRY-UNIQUE AND FULLY MODULAR STAND DESIGN. HIGH ACCURACY AT A LOW PRICE.
Metform has developed an industry-unique and cost-effective rafted tooling system for the roll forming industry. Since inception we have supplied thousands of the PS series stands to the industry. It is designed primarily as a rafted system with the intent to make a more accurate stand at a lower price.
Our PS Series Stand offers robust and cost-efficient solutions for our customers. The Metform modular PS rafted system allows you to effectively add new products to your rollforming line as you expand your business. It offers the flexibility to adapt to older mills with different drive and locating configurations. The PS raft is lighter, stronger and fully CNC machined with fewer components. The result is a Stand System with Reduced Cost and Improved Accuracy.
Flexible Rafted Tooling (Rafted Cassette) Increases Product Changeovers
The flexibility generated from this truly modular rafted tooling system allows for simple nesting of passes and side roll fixtures. This process allows for more creative solutions when trying to solve specific bending challenges. In addition, the mill set-up can be repeated resulting in faster tooling change and higher productivity.
The PS Series Stands are available with shaft diameters from 1.5” to 4.5” with corresponding horizontal centers, vertical center adjustment and roll space.
M SERIES ROLL TOOLING STANDS
The Metform M-series roll form tooling stand was originally designed over 55+ years ago. It is still an industry standard today. Originally a cast steel design it was converted to a fabrication to increase strength and reduce cost. It was the first stand to feature the “removable top cap” allowing for loading and removal of a full “chock and shaft assemblies” onto the stand. The other key feature of this stand is a separate bottom chock versus a “fixed” bottom shaft. This allows for flexibility in shaft alignment and special circumstances where the bottom shaft needs to be raised or lowered.
METFORM’S M SERIES STANDS, AN INDUSTRY STANDARD.
PRESSES - MECHANICAL PRE-PUNCH AND CUT-OFF
Metform has been supplying presses for rollforming lines for many decades. The Metform press is an industry standard and its legacy is durability. It is specifically designed for the roll form process. It is a fast-acting press designed to keep up with higher rollforming strip speeds and the rigors of high-volume production environments.
Features:
- Available in 40 to 250-Ton
- Automatic Central Lube System
- Combination Clutch/Brake Unit
- Optional “Wet” Hydraulic Clutch Available
- Nitrogen Counterbalance System
- Flywheel Brake
- Dual Redundant Press Safety Valve
- Quick Die Change Systems Available
- Hydraulic Die Clamping
Hydraulic Presses:
Metform also supplies hydraulic pre-punch presses up to 300-Ton.
For cut-off applications specifically where longer strokes and horizontal cutting is required Metform supplies flying hydraulic cut-off systems. These include die platens for quick die change. These systems are necessary when there is significant blade engagement time during the cut. They are popular when cutting welded tube sections.
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METFORM STANDARD 150 TON 4 POST PRE-PIERCE PRESS |
METFORM HPL-100 HYDRAULIC PIVOT LIFT SWEPT PART CUTOFF PRESS |
AUTOMATED DIE CHANGE SYSTEMS
Most rollform lines have several products if not many products. The key to increasing capacity on these types of lines is reducing changeover times.
One key piece of equipment specifically with lines with a pre-pierce press is a “quick die change” or “automated” die change system. This system can change dies in less than 10 minutes with a push of a button. A pre-staged rolling die cart with the next die in the production schedule is indexed into the press for automatic loading and subsequent clamping.
If your operation could use some die-loading assistance but can’t afford fully automatic, Metform offers several mechanically assisted die-loading systems. These systems still offer safe die-loading at a lower cost.
AUTOMATIC STACKERS FOR METAL FORMING EQUIPMENT
Often times the bottleneck for roll forming lines is the process of removing product from the end of the line. This should be considered an opportunity to improve overall production efficiency with the use of a stacker.
Stackers also eliminate the ergonomic and safety issues created by manual sheet handling. A properly designed stacker will allow components to be moved from the end of the production line onto a well-organized pack where operators can focus on labelling, packaging and loading trucks.
- Improved Operator Safety
- Higher Productivity
- Lower Employee Costs
- Reduced Scrap
- Reduced Floor Space
- Higher Uptime
- Square And Balanced Packs
- Metform Stackers Increase Production Line Throughput
Metform offers standard panel and deck stackers, as well as, custom-designed units for specific customer applications on both new and existing lines. Metform also produces stackers for coil processing lines, again, for both new and existing lines.
STACKERS ARE AVAILABLE WITH THE FOLLOWING FEATURES:
- Push Button Width and Length Adjustment
- Push Button Scrap Discharge
- Quiet Operation
- Side or End Pack Discharge
- Air Float “Cushion” For Non-Marking of Surface Critical Sheets
- High Speed
- Non-Marking Rollers for Surface Critical Materials
- Push Button Pallet Feeder
- “Flying End Stop” Adjustment
SPECIALIZED STACKERS:
TRUCK STACKER
As the name implies this stacker was specifically designed to move sheets from the line and stack them directly on the truck. There has never been a better example of “one-piece flow” for lean manufacturing. The scrap is removed in-line without production disruption. The stacker has a shuttling head which automatically builds up two packs per truck in an alternating progression so as not to cause the truck to lean from “one-sided” stacking. The labor savings and throughput improvements are significant making the return on investment for this equipment elementary.
FLATTENERS
Metform offers a variety of flatteners sized to suit the specific needs of the roll forming or coil processing line.
These can be used specifically for removing coil sets to prepare tips and tails before entering the coil end joiner. They can also be used in a “pull-through” mode to process the entire coil.
Features:
- Entry Guide
- Central Lube Block
- Pinch Roll Drive Pull Through or Driven Mode
- Optional Polished Rolls When Flattening Sensitive Materials
- Optional “Quick Open” Feature
METFORM 0.5” “PULL THROUGH” FLATTENER WITH “QUICK OPEN” AND FEED UP DRIVE.
UNCOILER MACHINES
Metform offers one of the most robust uncoiler units in the market today to decoil safely up to 500 fpm.
Our machines offer exceptional acceleration rates and quick-stop features. Metform builds uncoilers from light gauge single mandrel units to 60,000lb gearbox style units for service centers.
- Capacity From 6,000lb to 60,000lb
- Single Or Double Mandrel
- 1” To 72” Wide Strip
- 3 and 4 Leaf Design
- Hydraulic Side Shift with Auto Edge Guide Option
- Line Speeds Up to 500 fpm
RECOILER MACHINES
Metform offers recoilers for coil-to-coil processing lines up to 55,000 lb coils with a clamshell gripper to use with or without cardboard spools and speeds up to 150 mpm.
RECOILER WITH PUSH-OFF PLATE AND OVERARM SEPARATOR
- Mandrel Diameter → 508mm (20")
- Mandrel Face → 1473mm (58") Face
- Mandrel Type → Clamshell, Gripper Included
- Push-off Plate Actuation → Hydraulic Cylinder
- Separator Shaft → 88.9mm (3 1/2") Diameter
- Separator Tooling → 6 Disc – Packed Arbor, Quick Change
- Recoiler Drive → 125 HP @ 850/2500 RPM AC VFD Motor
- Traverse Actuation → +152mm (+ 6") Hydraulic Cylinder
- Gearbox Service Factor → 1.25
- Holding Brake → Pneumatic Disc
OUTBOARD BEARING SUPPORT FOR UNCOILERS AND RECOILERS
DIFFERENT MODELS ARE AVAILABLE UP TO AND INCLUDING SERVICE CENTER DUTY.
Metform offers several models of uncoilers and recoilers for roll forming lines and coil processing lines.
When the capacity of the uncoiler/recoiler exceeds 50,000 lbs Metform designers recommend the use of an outboard bearing support to minimize deflection to ensure smooth payoff of the strip specifically at higher speeds. This unit is compact and eliminates the need for increasing the shaft, bearing and gearbox components to minimize the cost of these larger capacity units.
TURNSTILES
IMPROVING YOUR COIL HANDLING EFFICIENCY
Coil handling efficiency is dependent on the terminal equipment at the feed end of the line and the features of this equipment.
Do you have “short run” orders which result in significant “return to stock” in your facility? If the answer is yes, you should consider a turnstile.
The turnstile allows the coil handling operator to safely pre-stage up to 4 coils on “arms” and then rotate this unit presenting the coil to the coil car for removal. This unit helps reduce the coil changeover time significantly.
In a lean manufacturing environment where the goal is to increase inventory turns a turnstile will help make this a reality.
COIL CARS AND COIL CAPSTANS
A VARIETY OF MODELS AVAILABLE FOR SELECTION
Coil cars are a key piece of equipment in any roll forming or coil processing line. They allow for safe and efficient transfer of coils onto the un-coiler.
They allow for pre-staging of coils which reduces coil change downtime. Pendant or console control allows for a safe distance for the operator.
The coil car is also designed to protect your un-coiler from C-hook or coil damage.
Scissor Lift Coil Cars
Metform also offers scissor lift cars to accommodate different coil loading configurations when loading turnstiles or un-coilers at different or changing elevations.
- Capacities from 10,000- 80,000 lbs
- Lubrication Points
- Self Contained Power
- Coil Arms
COIL TIPPERS & COIL UP-ENDERS
ALLOWING FOR SAFE AND EFFICIENT HANDLING OF COILS.
There are several key pieces of equipment specifically designed for safe and efficient handling of coils.
The coil tipper or up-ender allows the operator to rotate coils shipped “eye to the sky” to “eyes horizontal” which is how they are processed in the line. The operator is always at a safe distance from the coil utilizing pendant or console controls.
- Capacities from 10,000- 60,000 lbs
- Lubrication points
- Self contained power unit
- Coil Arms
SWEEP UNITS FOR ROLLFORMED SECTIONS
Metform has provided tooling and equipment for automotive bumper suppliers for many years. Developing the tooling and sweep unit for UHSS (Ultra High Strength Steel) bumpers is very challenging specifically when forming Martensite (M130 to M220) which has elongation properties of less than 3%.
Metform’s tooling engineers utilize their design experience along with FEA (finite element analysis) to optimize both the straight tooling in combination with the sweep unit to meet the stringent part tolerances of the automotive industry.
EMBOSSER UNITS
STRONG AND SIMPLE UNITS THAT REQUIRE MINIMAL MAINTENANCE AND SETUP
Metform supplies embosser units for products requiring an embossed feature. A common product is composite steel deck where the embossment provides “shear” resistance as load is applied to the slab. Other applications include “anti-slip” floor deck patterns.
These units are of robust design to absorb the forming vibration. They are also designed with anti-backlash gearing when using “meshed” tooling.
- Shaft Backup Supports (To Minimize Shaft Deflection)
- Interconnected Jackscrew Adjustment
- Anti-Backlash Gearing
- Feed-Up Drive
- Up To 16 Gauge (80ksi) Material
WELD BOXES
PRECISE ADJUSTMENTS WITH DIGITAL READOUTS FOR REPEATABLE SETUPS.
Metform offers standard and custom sizes of weld boxes for new welded section lines or existing equipment.
Weld boxes are generally used with HFI (high-frequency induction) welding but are also available for TIG, ERW, SAW and laser welding applications.
Features Include:
- 4, 5 Or 6 Roll Design Configurations
- Robust Design with Anti-Friction Ampco Slides
- Precise Adjustments for Accurate Control of The Forging Zone.
- Easy And Repeatable Setup Utilizing Digital Readouts
- Compact Footprint
SCRAP CHOPPERS
HELICAL BLADE DESIGN FOR SMOOTH CUTTING.
Scrap choppers are used in slitting lines to “chop” the edge trim scrap into small pieces for easy collection and disposal.
When the gauge thickness increases there is a point where it is not feasible to “wind” or “ball” the slit edge of the material. The scrap chopper is ideal for heavier gauges as it can cut at speeds up to 100 fpm on .500” thick 80ksi material.
Metform offers a helical cut machine for smooth cutting and lower HP for a given tonnage of cut. Blade clearance can be adjusted through appropriate material thickness ranges and sharpening blades is simple.
SMOOTH CURVE UNIT
CURVE PANEL OR DECK WITHOUT “WRINKLES” BOTH CONCAVE AND CONVEX DIRECTIONS.
Metform has developed a smooth curve unit designed to curve long decking sheets for metal building roof applications. The smooth curve tooling is designed to curve specific profiles such as N-deck or B-deck in both arc directions without wrinkles or crimping!
This is good for architecturally demanding designs where roof curves are both concave and convex.
All of this can be accomplished and the machine is portable making it easy to move directly to the project site.
CROP SHEARS
Metform has standard and custom designs for crop shears depending on the application. These are furnished with safe controls, access for scrap removal and required machine guarding.
These can be used wherever an operator needs to cut the strip for feed-up, tail out, changeover or scrap removal. Also used where square edges are required for welding.
- Hydraulic Cylinder Actuation
- Blade Designed for Easy Change and Re-Sharpening.
- All Material Ranges and Widths
MECHANICAL HIGH SPEED SHEARS
DESIGNED FOR A COMBINATION OF “STOP TO CUT” AND “CONTINUOUS CUTTING” MODES
High-speed shears are used primarily in cut-to-length lines. They are generally used with a precision servo roll feed system which quickly and accurately feeds the sheet in a start-stop mode to the shear.
The shear is coupled to a stacker with an air float system to prevent scratching of the material. Single-point blade adjustment allows for quick changeover to different material gauges
The shear works in either a “start-stop” or continuous mode depending on the cuts required per minute. The result is a high-speed operation running up to 40 cuts per minute.
SERVO ROLL FEED
ACCURATE STRIP FEEDING FOR TIGHT TOLERANCE PRE-PIERCE ROLL FORMING APPLICATIONS OR CUT-TO-LENGTH LINES
Our advanced servo technology yields the highest accuracy and repeatability while minimizing waste. The system includes length measuring and batch counting systems. Our systems provide high speed and accurate control of the strip into the press where tight tolerances of features and length are required.
A User-friendly HMI interface allows for part number selection and parameter settings for closed-loop length corrections.
Features Include:
- Crodon Finished Rolls for Anti-Slip and Long-Term Wear
- High-Speed Smooth Strip Movement
- Robust Anti-Backlash Mechanical Components
- Accurate and High-Speed Electronic Control