A roll forming die (roll set) is a precision-engineered pair of contoured rollers installed at each station of a roll forming machine. As the flat strip passes through successive stations, the rollers incrementally bend and shape the material into the required continuous profile such as channels, Z-sections, or custom sections .
A roller forming die (roller head) is a revolving tool with a profiled contour that presses against plastic clay on a rotating plaster mold to form the green body by rolling action.
| Parameter | Specification / Typical Value |
| Tooling Type | Forming Rolls / Sizing Rolls / Turks Head / Straightening Rolls (per profile requirement) |
| Material Options | Cr12MoV (China) = D2 / SKD11 (AISI JIS DIN 1.2379); GCr15 (bearing steel, 100Cr6); 42CrMo (for shaft/holder); Optional: ASP23 / M2 powder metallurgy for special cases |
| Hardness (After Heat Treat) | HRC 58 – 62 (D2 / Cr12MoV); HRC 60 – 64 (GCr15) |
| Heat Treatment Process | Vacuum quenching / Gas quenching + Tempering + Deep cryogenic treatment (optional) |
| Surface Finish | Hard chrome plated (0.01–0.03 mm) or polished to Ra ≤ 0.4 μm (mirror finish on groove) |
| Roller Diameter (OD) | 60 mm – 350 mm (custom per machine stand / profile height) |
| Roller Body Width | 100 mm – 600 mm (according to strip width & pass design) |
| Shaft / Arbor Diameter | 40 mm – 120 mm (typically 45#, 40Cr, or 42CrMo, ground & key-wayed) |
| Inner Bore Tolerance | IT7 (H7), coaxiality ≤ 0.02 mm |
| Run-out Tolerance | Radial run-out ≤ 0.03 mm; Face run-out ≤ 0.05 mm |
| Number of Stations | 8 – 30 stands (depending on profile complexity) |
| Pass Design Method | Incremental bending / Flower diagram, optimized via COPRA® FEA simulation |
| Machining Process | CNC rough turning → Semi-finish → Heat treat → Finish grind → Wire EDM (groove) → Final inspect |
| Inspection Equipment | CMM, Hardness Tester, Profile Projector, Roundness Tester |
| Service Life | ≥ 500,000 – 1,000,000 linear meters per set (depends on formed material & maintenance) |
| Packaging | Anti-rust oil + VCI film + Plywood case / Steel frame |
| Certifications | ISO 9001:2015; Material & Heat Treatment Reports provided |
Roller forming dies (or roll forming tools) are all about turning flat metal into perfectly shaped profiles through continuous, high‑pressure rolling — no heat, just cold mechanical magic.
Shaped by rotation: The die isn’t a single stamp; it’s a series of grooved rollers that gradually bend the metal strip step by step.
Cold work only: Everything happens at room temp — the metal gets harder and stronger as it’s rolled (strain hardening).
Super consistent: Once set up, every piece comes out identical — ideal for long runs like roof panels, door frames, or car parts.
Smooth surface finish: No scratches or tool marks because the metal flows continuously instead of being punched.
Material saver: Uses coils directly, so very little waste compared to blanking + welding.
We are looking forward to working with you. Please feel free to contact us if you have any inquiry.
