Metal Rings, Rims, Clamps & Flanges
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NEW!! Rings with Side-Ways Bent Cross Section
Clamp Ring and Clamp bands
Overview of Channel, Angle, Profile and Wire: Rings, Rims, Ring Clamps, Flanges and Hoops.
Our channel rings and angle rings are manufactured in a very unique process that is also highly economical. The parts are produced as normal Metal Channel rings, Angle rings, Profiles, Mouldings & Trim, etc., in straight length form, from continuous coiled flat strip or wire. This roll forming is done with a series of stations, containing top & bottom roll dies, that gradually bends it into a Shape, more each station. Instead of going through the flying cutoff press to cut a straight part to length, the Shape goes through a ring bending station made of bending rolls and/or shoes. The channel rings come out as vertical spirals or coiled rings instead of straight lengths. From there the spiraled ring Shapes go through an inline cut-to-length pneumatic or hydraulic press, or can be brought to our secondary fabricating department to be cut to the appropriate circumferal length.Our metal rings make great spacer rings, backing rings, dome rings, filter rings, reinforcement rings, tank rings, steering wheel rings, retaining rings, retaining rings, ring rolling, and decorative rings.
Bending and spiraling on rare occasions is done horizontally or diagonally when the shape forming requires that direction of bending. This process reduces costs of making channel or angle rings if the quantities are from 500 up to millions of pieces. (Fewer parts than that may be done if it is the only forming method that can be used). The expensive process of secondary bending on three roll bending units, then recutting the straight ends of separately produced shapes is avoided. Extruded, Drawn, Pressed or Hot Rolled Profiles that may have cost less in the straight form but need to be bent separately into rings, are much less expensive when designed as Roll Formed parts. Flat Wire, Round and Shaped Wire is made into rings with this same process on roll formers when they come from a continuous coiled supply. A good general rule to follow is that small diameters can be made with thinner and smaller shapes and the larger the shape and/or thicker the part is, the better it is for larger diameters. It's always a good idea to check with Johnson Bros. when unsure on these points. Tooling is Existing for almost all Channel Rings and Angle Rings. Other parts, not shown in our print example pages, will require tooling unless volume is high. Contact us today for more information about our bezels, angles rings, retainer rings, ring rolling,metal rings, aluminum rings, ring spinning, rolled rings, lighting clamps, display rims, angle flanges, glass rims, metal rims, bezel rings, stainless steel rims, and much more.
Joining the Ends of Roll Formed Rings
Joining the ends of the angle or channel rings after forming is a separate operation, which is done by several methods at Johnson Bros, should the customer not wish to do so. Many customers prefer to do this in house for expense purposes. Many customers do not have this capability. The joints can be welded in a variety of ways based on need and expense, and with extra finishing, can have the joints become unseen. Styles of welding the joints can be for less expensive spot welding with overlaps, or tack and intermittent joint weld locations. For full joint welding it's important to specify if the outside or inside joint needs to be welded and if flash or buildup must be removed. Removal of joint buildup does add extra expense as well. Another method of joining is when rings are made into Clamps, Clamp Bands & Boots or require the joint affixing in place after assembly. For this method there is a wide variety of fabricating that is done in the prenotch presses prior to bending, or the inline and secondary cutoff presses. Slots and other fabrications can also be done around the circumferal length in the secondary fabricating presses and prenotch presses. Separate special fittings and clasps can also be produced and provided or assembled by Johnson Bros. onto the ends to provide finished Clamp Rings.
Metal Finishes Available on Roll Formed Rings
Both Prefinishing and Post Finishing can be supplied by Johnson Bros. When welded joint or end assemblies are not required, Prefinishing is common. Prefinished materials include: Preplated, Preanodized, Galvanized, Prepolished, Prepainted, Vinyl Laminated, Strippable PVC Coating, Aluminized, Galvanneal & Galvalume further reducing secondary expense. Post Finishing includes: Plating, Anodizing, Polishing, Painting, and more. Metals used are the same as with all roll formed parts however, very high strength materials are much less desirable in ring forming. Heat-treating Rings after forming will cause diameter distortion. Materials used: Steel, Stainless, Aluminum, Brass, Copper, Bronze, Alloys, Galvanized, Clad, Wire: Flat, Round & Shaped, Perforated, Embossed, Wire Cloth. Request a quote today for steel rings, retaining rings, anodized rings, stainless rings, glass rings, brass rings, aluminum rings, stainless steel rings, and many other types of metal rings.
Limitations to Metal Roll Formed Rings
There are limitations to this roll formed shape ring forming process, however. Angle or Channel Rings made with Roll Formed Parts cannot be made by taking shapes already produced in a different manufacturing operation in straight lengths, such as Extruding, Drawing, Pressing or Hot Rolling, and putting them through a roll forming machine to be bent into a ring. This is a completely different, separate manufacturing method called Rolling and is usually only beneficial on small volumes, thick parts over .125" thick, or parts too thick to be bent into smaller diameters on a roll forming machine. It is also very difficult to bend very wide parts into rings. This is because roll formed shape rings come off the machine vertically, side-by-side, in a spiral coil or slinky form. This causes twist to be put into the shape. Very wide shapes can be made into roll formed rings when the diameter is large enough or a small diameter ring's volume is high enough to use specialized equipment that will cut the part to length before it can be spiraled side by side. This usually requires a stop/start capability on the roll former for each ring, which can be problematic for part or diameter distortion. Rings are very rarely produced from Precut lengths or blanks as end distortion and straight ends become a problem. Bending units on roll forming machines are usually not meant to be used with materials over .125" thick, or when they have long vertical dimensions, as they are lighter duty than the three roll secondary fabricating "Rolling" machines and do not roll the shape back and forth gradually into the ring form. Though roll formed shapes can be bent inline into rings, in more than one bending station, it still is not a substitute for a separate three roll bending machine when "Rolling" is necessary. Very long vertical dimensions can be a problem even more so on thinner parts as waviness can occur in that dimension when multiple bend units or unpowered bend units are not used. Flat Wire is usually not bent into rings with the sides inside or outside of the diameter for this reason. Shapes that have a lot of corners on one side and a long, flat horizontal dimension on the other side can also be difficult to form without the horizontal portion becoming conical after bending into ring form. Roll Formed Channel or Angle Rings are almost always never bent with the part facing sideways. Roll Formed shape rings are not a substitute for small stamped bezels. Stamped bezel rings are made when it is not possible to make the ring any other way and expensive scrap from the inside of the ring is offset by the separate end joining and end finishing afterward on very small diameters. Tubing is not bent into rings unless it has an Open Seam and the general rule on the size of the tube to the size of the ring diameter is followed, although Lock Seam & Open Seam Tubing can be stretch formed or sweep bent sideways or vertically. Learn more about channel and angle ring capabilities including decorative rings, tank rings, steering wheel rings, dome rings, backing rings, filter rings, retainer rings, reinforcement rings, retaining rings, ring rolling, and many more.
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Parts are produced to order and stock reserve only kept for large blanket order shipping releases. Existing samples may or may not be available. Prototypes for large orders are feasible.