Transformation of Stamping Part Profiles to Roller Profiles

An important extension to the process of roll forming is the production of embossments by a secondary stamping operation. In this paper, a system is described for transforming stamping profiles to roller profiles, thus eliminating the need for the secondary stamping operation. Included in the system are techniques for identifying and avoiding interference between the rollers, and for calculating torque and power requirements. The system is illustrated by describing how the process was used to design a pair of rollers for embossing a profile generated by the LaBarge method [1].