The shaping process called form rolling is, as its name implies, a method of giving a desired form to metal parts by rolling them into shape. Form rolling is one of the processing methods in which high pressure is applied in order to transform the shape of the raw material. In form rolling, tools?or dies, as they are called?are applied to the work piece, and as the work piece is rotated, form is created.
The illustration shows the basic principle of form rolling using round dies. As the illustration shows, the dies are applied with due pressure in the chosen direction, the work piece is rotated, and the surface of the work piece rises into the desired form. The shape of the product surface is dependent on the configuration of the dies.
Dies are usually applied in pairs, though some form rolling processes require three dies to the set. Dies must be chosen to match the part shaping requirements. While a cooling period is needed, the shaping process is mostly done at ordinary room temperatures.
Form rolling was originally developed in order to make threaded parts, and threaded parts are still the main application of form rolling platforms. However, other kinds of part forms such as spline, serration, and worm gears are also highly suited to form rolling processing.