In many situations our modernized inline post fabricating can include many die operations in what used to be only a flying Cutoff Die operation. Our inline post fabrication dies now can do the entire hole punching and other notching required that in the past was done in the pre-punch operation. This reduces the number of dies required allows closer tolerances on the locations of the notching without the distortion that would occur if fabricated with a pre-punch press and then bent into the U Channel or J Channel. Sophisticated inline Flying Die Accelerators and Die Boosts utilizing close tolerance length measurement systems in the Post-Punching and Pre-Punching Presses are critical for close tolerance, higher speed, inline fabricating. The Die Accelerator can allow as many as 12 different functions to be carried out in the same die and can operate both Pre-Punching & Post-Punching/Cutoff presses at the same time.
U Channels & J Channels can be used for many different applications.
U-Channels & J-Channels are used in almost all industries for any possible applications such as in this brief summary of other Channel terms:
Framing & Frames
Channel Rings & Angle Rings
Clamps & Clamp Bands
Girts. (Many other styles of Roll Formed Profiles have these same descriptions, however.)
U Channel & J Channel - Tooling & Costs
Standard tooling for a U Channel and a J Channel with Legs at 90 Degrees is very common and rarely is there any tooling costs associated providing it meets our minimum order requirements of 2,000ft except on pre-production samples. Lower quantities with lot charges can be negotiated. Our Roll Die & Straightener Tooling is adjustable and can easily be changed or added to without cost. Our In-line Cutoff Tooling has smaller, inexpensive inserts making any tooling that we may have to make, (which is rare), very inexpensive and it's most often donated. Johnson Bros. even has existing Adjustable Roll Dies that can produce Hems on the inside or outside of the legs on these U channels & J channels. J Channels and U Channels with other than 90 Degree bends with legs Tilted In or Tilted Out, may require very little or no extra tooling as most of the tooling used comes from a regular set of 90 Degree bend channel tooling and standard hemming rolls. Hems are generally .250"-.125" and sometimes smaller.
U Channel & J Channel High Speed Roll Forming
Johnson Brothers offers High Speed Roll Forming. Greater Length Tolerances allows faster production; however, our modernized length control system allows normal production speeds at close tolerances as well. Tolerances on legs and web of +/- .032 are common with +/- .005 and sometimes less are possible. Highly Accurate Roll Straighteners and Die Boosts allow for very straight parts without kinks from the cutoff operation.
U Channel & J Channel - Minimum Orders
Minimum orders are generally 2,000 feet total and up as parts are produced to order and not kept as a stock list to choose from on a shelf. Exceptions can be made for sample requirements, Blanket Order Releases or for other unique circumstances.