A vehicle reinforcement beam is roll formed from a metal sheet to provide a multi-tubular reinforcement beam that includes two adjacent tubular sections that share a common center wall. The outer sections the metal sheet extend from opposing ends of the common center wall and are formed to enclose the adjacent tubular sections. An edge portion of the metal sheet that is bent to have a bend radius of about 3-9 mm, where the edge portions attach in abutting and continuous contact with the common center wall to form crevices between the adjacent tubular sections along the first and second faces. A weld is formed in each of the crevices to define crevice ribs in general alignment with and at each of the opposing first and second ends of the common center wall that are configured to improve bending strength and torsional strength of the reinforcement beam.

A single piece roll-formed frame comprising a first channel having a base section and one or more legs, each leg comprising an upper side extending from the base section at a first angle and a lower side extending from the upper side at a second angle, a second channel having a base section and one or more legs, each leg comprising an upper side extending from the base section at the first angle and a lower side extending from the upper side at the second angle and wherein the base section of the first channel and the base section of the second channel are formed from a single piece and intersect to form a third angle, and the upper side of each leg of the first channel overlaps the upper side of each leg of the second channel.

A single piece roll-formed frame comprising a first channel having a base section and one or more legs, each leg comprising an upper side extending from the base section at a first angle and a lower side extending from the upper side at a second angle, a second channel having a base section and one or more legs, each leg comprising an upper side extending from the base section at the first angle and a lower side extending from the upper side at the second angle and wherein the base section of the first channel and the base section of the second channel are formed from a single piece and intersect to form a third angle, and the upper side of each leg of the first channel overlaps the upper side of each leg of the second channel.

Forming roll units included in an apparatus for manufacturing a roll-formed component each include a roll pair. The roll pair includes a receiving roll part and a first bending roll part that face each other. A plate member passing area is formed below the first bending roll part, the plate member passing area allowing a roll formed member excluding its side edge portions to pass through. The roll pair is configured to make, during bending, sliding movement in a width direction of the roll formed member and rotational movement about a normal direction to the roll formed member as a rotational center.

Forming roll units included in an apparatus for manufacturing a roll-formed component each include a roll pair. The roll pair includes a receiving roll part and a first bending roll part that face each other. A plate member passing area is formed below the first bending roll part, the plate member passing area allowing a roll formed member excluding its side edge portions to pass through. The roll pair is configured to make, during bending, sliding movement in a width direction of the roll formed member and rotational movement about a normal direction to the roll formed member as a rotational center.

A roll-forming manufacturing method of a roller bearing seal case includes (a) roll-forming, from a cylindrical ring, a profiled ring including a first section extending at least along a cylinder axis of the cylindrical ring and a second section extending from the first section inward toward the cylinder axis, and (b) trimming the second section to expand the first aperture to achieve location and geometry according to design parameters. A roll-forming manufacturing method of a roller bearing seal case includes (a) roll-forming, from a cylindrical ring, a first profiled ring having a first section extending along cylinder axis of the cylindrical ring and a second section extending from the first section inward toward the cylinder axis, (b) applying outward pressure to the first section, in direction away from the cylinder axis, to round the first section, and (c) roll-forming a second profiled ring from the first profiled ring.

A thermal-assisted method deforms a sheet metal assembly having constrained ends. A focus bending area located between the constrained ends is heated. The focus bending area is bent while the sheet metal assembly is within an elevated bending temperature range. A sheet metal assembly may be formed by this method, which includes an outer metal sheet and an inner metal sheet fixed together to form constrained ends. The sheet metal assembly has a bend formed therein between the first and second constrained ends, wherein each metal sheet is bent at the bend with a maximum gap between the inner and outer metal sheets at the bend. The maximum gap is no greater than five times the thickness of one of the inner and outer metal sheets, and the bend has a radius less than three times the thickness of one of the inner and outer sheets.

A thermal-assisted method deforms a sheet metal assembly having constrained ends. A focus bending area located between the constrained ends is heated. The focus bending area is bent while the sheet metal assembly is within an elevated bending temperature range. A sheet metal assembly may be formed by this method, which includes an outer metal sheet and an inner metal sheet fixed together to form constrained ends. The sheet metal assembly has a bend formed therein between the first and second constrained ends, wherein each metal sheet is bent at the bend with a maximum gap between the inner and outer metal sheets at the bend. The maximum gap is no greater than five times the thickness of one of the inner and outer metal sheets, and the bend has a radius less than three times the thickness of one of the inner and outer sheets.

A method of aligning a flat or profiled metal sheet with preformed notches on the two sides of the metal sheet when the sheet enters into a bender or folding machine directly from a roll forming machine linked or joined to the folder. The metal sheet has to be effectively aligned on the folder before folding to avoid potential damages to the metal sheet of not being properly squared or angled on bending while reducing the times to produce the folded products. Moreover, this method according to the invention allows the metal sheet to feed directly into the folder from the rollformer without having to pass through an intermediary transfer table or aligning device/machine before entering the folder for folding or manual alignment in the folder.

An apparatus (10) includes internal mechanisms (18, 20, 24) for advancing, guiding and roll forming fascia molding (30, 30a) from sheet material (14) fed from coil stock (16) or in precut sheets (72). The fascia molding (30, 30a) includes a roll formed curved profile (32) in between angled top and bottom portions.