Roll Form Tool Design

The product shape in the fourth pass is illustrated in Fig. 4.25, together with the bend allowance distribution from the chart in Fig. 4.8:
In Fig. 4.26 the product shape of the fourth pass is shown with the incoming product shape of the third pass in phantom lines.
It again appears that the shoulder detail should be put on the upper roll, as in Fig. 4.27, for the best combination of lead-in and positive stop action to keep the shape centralized within the limits of the strip width tolerance.
Fig 4.28 is the detail drawing for the rolls of the fourth pass. The drive diameters of the fourth pass are increased by .030 from the 6.930 in the third pass to 6.960 in the fourth pass. As before, all the roll dimensions are based on a material gap of .081, and the material gap and the shoulder gap are equal.