Measures towards roll forming at the physical limit of energy consumption

  • Tilman Traub
  • Burcu Güngör
  • Peter GrocheEmail author


The optimization of energy efficiency of industrial processes is a desirable objective. Roll forming is a continuous sheet metal forming process gradually producing profile-shaped parts. Although cold forming processes are usually comparatively energy-efficient, in roll forming, an efficiency of deformation of 25% and less has been observed in previous studies. At the same time, a significant energy-saving potential has been identified by means of the evaluation of drive torques and the readjustment of tool velocities. However, the efficiency of deformation is still small in comparison to other cold forming processes. In this study, a new decision rule for optimizing the tool velocity in roll forming is proposed and tested experimentally and numerically. The objective of this decision rule is, firstly, to avoid decelerating drive torques that counteract the forming process and need to be compensated by additional drive torques in other process steps. Secondly, the accelerating drive torques should not exceed a certain limit in order to ensure an effective process with respect to wear and surface quality of the products. The results show that a reduction of the energy demand of 66% in comparison with a conventionally operated roll forming process is possible resulting in an efficiency of deformation of 89%. Furthermore, the mechanism of the optimization is validated experimentally using a novel sensor concept, a sensorial parallel key.


Metal forming Roll forming Energy efficiency Decision-making 


Compliance with ethical standards

Conflict of interest

The authors declare that they have no conflict of interest.


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© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  1. 1.Technische Universität DarmstadtInstitut für Produktionstechnik und Umformmaschinen (PtU)DarmstadtGermany

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