I. Equipment Overview
The Outer Window Frame Roll Forming Machine is a specialized cold-roll forming production line designed for manufacturing closed-profile steel door and window frame sections. Closed profiles offer significant advantages—such as high structural strength, excellent torsional rigidity, and an aesthetically pleasing appearance—making them the preferred choice for high-quality steel doors and windows. Compared to open-section cold-formed steel, closed-section profiles feature complex and often asymmetrical shapes; consequently, they require distinct approaches regarding welding quality control, dimensional accuracy, and forming equipment specifications.
Utilizing a continuous cold-roll forming process, this equipment integrates the entire production workflow—uncoiling and leveling, servo feeding and hydraulic punching, guided entry, roll forming (41 stations), flying saw cutting, and discharge—into a single pass, directly yielding finished closed-profile door and window frames.
The entire line features fully automated PLC control and a touchscreen HMI, ensuring continuous, automated operation from uncoiling to finished product discharge. The equipment employs a robust "arch-style" chain drive structure, offering high rigidity, precision, and durability. It is compatible with various metal sheets, such as galvanized steel and low-carbon steel (e.g., Q235), with a material thickness of 0.8 mm. The forming line speed ranges from 0 to 15 m/min (excluding punching and cutting times), and the process involves approximately 41 forming stations. Requiring only one operator, this system is core equipment for door and window manufacturers aiming to achieve large-scale, standardized, and intelligent production.
The closed-profile door and window frames produced by this equipment strictly comply with the industry standard JG/T 152-2003, "Steel Profiles for Multifunctional Residential Door Frames," covering profiles manufactured from cold-rolled steel sheets or strips via the cold-roll forming process.
II. Core Advantages and Selling Points
(1) Closed-section design offering structural strength far superior to open-profile sections
This is the core advantage distinguishing this equipment from conventional production lines for open-profile door and window frames.
Compared to open-section cold-formed steel, closed-section cold-formed steel offers significant advantages, including higher structural strength, superior torsional resistance, and enhanced aesthetic appeal. The closed profile forms a tubular structure that distributes external forces more evenly, making it resistant to twisting and deformation. These profiles feature an optimized cross-sectional shape, uniform hardness distribution, high dimensional accuracy, and a lightweight design. With their superior cross-sectional geometry and precision, these steel profiles are the preferred choice for high-quality architectural doors and windows.
Closed-profile door and window frames are particularly well-suited for high-end residential, commercial, and public infrastructure projects that demand superior quality. By optimizing the cross-sectional shape, cold-formed steel allows for greater load-bearing capacity with relatively less material, making it a highly efficient and economical structural steel solution.
(2) Ultra-precise 41-stage roll forming for single-pass closed-section shaping
The process utilizes a progressive cold-forming method involving approximately 41 stages. Forming closed profiles requires a greater number of forming stages and auxiliary deformation tools. The 41-stage layout is scientifically designed; precision algorithms optimize the tooling and forming parameters to gradually bend 0.8mm sheet metal into the standard closed cross-section of the door or window frame. This multi-stage progressive forming effectively minimizes material stress concentration, ensuring dimensional stability, precise angles, and tight, seamless joints for the closed profile. Forming Machine Structure: Arch-style frame with chain drive; offers high rigidity and excellent resistance to deformation.
Shaft Material: 40Cr steel with quenched and tempered treatment (HB 220–260); provides excellent comprehensive mechanical properties.
Shaft Diameter: Large-diameter (Φ60 mm) forming shafts ensure high load-bearing capacity.
Shaft Machining: CNC turning followed by precision cylindrical grinding to ensure dimensional accuracy and superior surface finish.
Roll Tooling: 1 set.
Roll Material: GCr15 steel with quenching treatment (HRC 58–60); offers high hardness and excellent wear resistance.
Roll Machining: CNC turning to ensure precise control over circular and radial runout.
Spacers: Machined from thick-walled tubing to minimize shaft runout and ensure strict form and position tolerances; designed to maximize contact area with the rolls, with a clearance fit between the inner bore and the shaft.
(3) Arch-style frame with chain drive: High rigidity, high precision, and long service life.
The machine utilizes an arch-style frame structure with a chain drive. The arch-style frame provides superior rigidity and deformation resistance, while the chain drive ensures smooth, reliable operation. Powered by dual 5.5kW motors, the system delivers ample driving force, ensuring stable and efficient processing of 0.8mm sheet metal across 41 forming stations.
(4) Turkish-style straightening head: Ensures straightness of the finished product.
Equipped with a Turkish-style straightening head, the machine performs in-line straightening on the formed closed-profile door and window frames, effectively eliminating longitudinal bending and torsional deformation. This ensures the profiles meet straightness standards, guaranteeing effective sealing and smooth operation during the subsequent installation of door and window sashes.
(5) Dual hydraulic punching system: Completes multi-hole punching in a single pass.
Features a servo-feeding and hydraulic punching system; after uncoiling and leveling, the servo system ensures precise positioning, while the hydraulic unit accurately punches various hole types—such as mounting holes, lock holes, and hinge holes. The punching system utilizes a four-post frame design, offering high rigidity and precise guiding accuracy. Punching and forming occur simultaneously, ensuring precise hole positioning and uniform hole shapes, which effectively guarantees ease of installation and accuracy for door and window frames on-site.
(6) Integrated Uncoiling and Leveling: Precise and Reliable Material Pre-treatment
An integrated uncoiling and leveling design compactly combines these two processes. The leveling unit effectively eliminates internal stresses in 0.8mm sheet material, ensuring the steel strip enters the subsequent punching and forming stages in a flat and precise condition.
(7) Flying Saw Cutting: Continuous Production Without Stopping
Equipped with a flying saw cutting system, the machine automatically tracks and synchronously cuts profiles to length while they move at high speed. There is no need to slow down or stop the machine, completely eliminating downtime and significantly boosting equipment utilization.
High cutting precision: The servo system ensures accurate positioning and precise cut lengths.
Clean cuts: Sawing produces no burrs and leaves smooth edges, eliminating the need for post-processing.
Maximized efficiency: The forming process runs at a constant speed, enabling continuous, uninterrupted production.
(8) Drive-Side Safety Guard: Safe and Reliable
A safety guard is installed on the drive side, fully enclosing moving parts such as chains and transmission components. This effectively prevents accidental contact by operators, ensuring safe production. Additionally, the guard is dust- and oil-resistant, protecting transmission components from external contaminants and extending the equipment's service life.
(9) Fully automated PLC control for intelligent production
Fully automated PLC control with a touchscreen HMI enables comprehensive digital process management.
Operators can configure parameters—such as production speed, cut length, and output quantity—via the interface with a single touch.
Supports the pre-programming of multiple production tasks for automated operation.
Equipped with real-time monitoring and fault warning systems, the machine automatically alerts operators to anomalies and displays the specific cause of the fault.
Novices can work independently after just 1–2 days of training, significantly reducing operator skill requirements.
(10) Robust, durable, stable, and reliable
The forming frame features a rigid arch-style structure with excellent resistance to deformation.
Rollers are made of GCr15 steel (quenched to HRC 58–60), offering high hardness, superior wear resistance, and a long service life.
Shafts are made of 40Cr steel (quenched and tempered to HB 220–260), providing excellent comprehensive mechanical properties.
Precision manufacturing via CNC turning and cylindrical super-finishing ensures high accuracy regarding circular and radial runout.
Key electrical components are sourced from internationally renowned brands, ensuring low failure rates and long service life.
III. Technical Parameters
Item Parameter
Applicable materials: Galvanized sheet, low-carbon steel (e.g., Q235), etc.
Material thickness: 0.8 mm
Forming machine structure: Arch-frame type with chain drive
Number of forming stations: Approx. 41 stations
Shaft material: 40Cr steel, quenched and tempered (HB 220–260)
Shaft diameter: Φ60 mm
Shaft machining method: CNC turning followed by precision cylindrical grinding
Forming machine motor power: 5.5 kW × 2 units
Forming line speed: 0–15 m/min (excluding punching and cutting)
Roll tooling: 1 set
Roller material: GCr15 steel, quenched (HRC 58–60)
Roller machining method: CNC turning; ensures precision in circular and radial runout
Spacer sleeves: Machined from thick-walled tubing; ensures geometric and positional tolerances
Straightening mechanism: Turkish-style straightening head
Safety guards: Protective cover installed on the drive side
Control system: Fully automatic PLC control
Operators 1 person
IV. Production Process
Uncoiling & Leveling → Servo Feeding & Hydraulic Punching → Guided Infeed → Roll Forming (41 Stations) → Flying Sawing → Discharge
Process Step Description
Uncoiling & Leveling: The uncoiler holds the metal coil; the leveler performs precision leveling to eliminate internal stress and improve flatness.
Servo Feeding & Hydraulic Punching: The servo system ensures precise positioning; hydraulic punching accurately creates mounting holes, lock holes, hinge holes, etc.
Guided Infeed: Lateral roller guides ensure the material enters the main forming unit in the correct position.
Roll Forming: 41-station progressive cold-roll forming using GCr15 quenched rollers to gradually shape the standard closed-profile door or window frame.
Flying Sawing: Online flying saw cuts to length; continuous production without stopping the line; high precision and clean cuts.
Discharge: Output of finished products; orderly discharge.
V. Application Areas
The closed-profile door and window frame products manufactured by this cold-roll forming equipment are widely used in the following sectors:
High-end residential and villas: Door and window frame systems for luxury homes and villas—closed profiles offer high structural strength and aesthetic appeal, enhancing the building's quality.
Commercial and public buildings: Door and window frame systems for shopping malls, hotels, office buildings, hospitals, schools, etc.—closed profiles meet high architectural standards.
Security and fire-rated doors: Fully automated production of high-quality security and fire-rated door frames—closed cross-sections provide superior impact resistance.
uPVC door and window components: Production of steel reinforcements for uPVC windows—essential equipment for manufacturing high-quality uPVC doors and windows.
Industrial buildings: Door and window frame profiles for industrial plants, warehouses, and similar structures.
Export-oriented projects: Production of closed-profile door and window frames suitable for international markets, such as Europe.
Customized projects: Production of closed-profile window frames with special dimensions and complex cross-sections based on client-provided drawings.
VI. Market Outlook
Driven by the continuous growth of the global construction industry and rising quality standards for doors and windows, the market for cold-roll forming equipment for closed-profile door and window frames is showing a positive growth trend.
Continued growth in the cold-roll forming equipment market: By 2025, the market size for cold-roll forming equipment in China had surpassed 10 billion RMB, with a compound annual growth rate (CAGR) approaching 8%; equipment for forming closed-profile door frames has emerged as one of the fastest-growing product segments. High-speed, high-precision, and fully automated cold-roll forming lines have become the preferred choice for buyers.
Upgrading of steel door and window profiles: Traditional steel profiles for doors and windows are predominantly of the closed-profile type—formed into tubular structures via cold-roll forming and subsequently welded at the seam. As construction quality standards rise, closed-profile steel frames are seeing expanded application in high-end residential, commercial, and public infrastructure projects, thanks to their high structural strength, aesthetic appeal, and dimensional precision. Cold-rolled steel profiles for door and window frames offer advantages such as optimized cross-sectional shapes, high dimensional accuracy, and lightweight characteristics.
Significant advantages of the cold-roll forming process: Cold-roll forming is characterized by high material utilization, excellent forming precision, high production efficiency, and low costs. The equipment is capable of processing a wide range of metal sheets while maintaining high dimensional accuracy for the profiles.
Demand for customization and flexible production: As the door and window market demands a greater variety of product types and specifications, there is growing demand for flexible forming equipment capable of rapid profile changeovers and multi-purpose operation. Customized cold-roll forming solutions are becoming a key industry trend.
VII. Service and Support
Solution Design: We provide personalized equipment selection and production line layout based on customer product drawings, capacity requirements, and target markets.
Custom Manufacturing: We support non-standard customization; orders can be placed using cross-sectional drawings or samples, with full oversight from roll design to complete machine manufacturing.
Installation and Commissioning: Engineers provide on-site installation, commissioning, and operator training to ensure rapid production startup.
After-Sales Support: We offer long-term technical consultation and spare parts supply; our engineers hold all necessary visas and are available for on-site service worldwide at any time.
Continuous Optimization: We provide equipment modification and capacity upgrade services to adapt to changing production needs.
VIII. Why Choose Us
Nearly 20 Years of Manufacturing Experience: Mature technology, refined processes, and reliable quality
Specialized Expertise in Closed Profiles: Deep understanding of cold-roll forming techniques for closed-section profiles; mature 41-stage ultra-precision forming technology
Arch-style Chain Drive: Smooth and reliable operation, high rigidity, and long service life
41-Stage Ultra-Precision Forming: GCr15 quenched rollers (HRC 58-60), 40Cr heat-treated shafts (Φ60mm), CNC machining combined with ultra-precision grinding
Servo Feeding & Hydraulic Punching: Precise positioning, multi-hole punching in a single pass, and accurate, consistent hole placement
Flying Saw Cutting: Online cutting without stopping the line; ensures both efficiency and precision
Turkish-style Straightening Head: Precise straightening to guarantee the straightness of closed profiles
Drive-side Protective Cover: Safe and reliable; dust-proof and oil-proof; extends equipment lifespan
High-Precision Manufacturing: Consistent product dimensions and stable quality
High-Efficiency Production: Line speed of 0–15 m/min; the entire line can be operated by a single person
Intelligent Control: Fully automatic PLC system with touchscreen interface; one-touch setup and automatic counting
Industry Standard Compliance: Products strictly meet the JG/T 152-2003 standard ("Steel Multi-functional Residential Door Frame Profiles")
Direct Manufacturer: No middlemen; excellent cost-performance ratio
Global Service Network: Engineers hold valid visas and provide rapid response