Side Roll Height Shim in Roll Forming Machines — Vertical Calibration & Precision Setup Guide

Side Roll Height Shim in Roll Forming Machines — Complete Engineering Guide

Introduction

The side roll height shim is a precision spacer component used to adjust and calibrate the vertical position of side rolls in a roll forming machine.

While the adjustment screw controls lateral movement, the height shim controls vertical alignment, ensuring that:

• The side roll contacts the strip at the correct elevation

• Edge forming pressure is evenly distributed

• Flange height remains consistent

• Profile twist is minimized

• Tool geometry remains aligned with pass design

Even small variations in vertical alignment can impact edge quality, particularly in tight-tolerance or high-strength steel applications.

1. What Is a Side Roll Height Shim?

A side roll height shim is a thin, precision-manufactured metal plate installed between:

• The side roll mount block and bracket

• The mount block and slide plate

• The bracket and machine frame

It alters the vertical position of the side roll assembly by a controlled thickness increment.

2. Primary Functions

2.1 Vertical Alignment

Adjusts the side roll centerline relative to the strip.

2.2 Flange Calibration

Controls final flange height consistency.

2.3 Pass Matching

Ensures correct alignment with preceding and following forming passes.

2.4 Fine Correction

Corrects minor setup deviations without full mechanical repositioning.

3. Where It Is Installed

Side roll height shims are typically placed:

• Under the mount block

• Between mounting bracket and support plate

• Between adjustment assembly components

• On cassette-style side roll systems

They are stacked or replaced to achieve exact height.

4. Thickness & Precision

Common shim thicknesses:

• 0.01 mm

• 0.02 mm

• 0.05 mm

• 0.10 mm

• 0.25 mm

• 0.50 mm

• 1.00 mm

Precision ground shims allow micron-level adjustment.

5. Material Construction

Side roll height shims are typically made from:

• Hardened spring steel

• Stainless steel

• Precision ground alloy steel

• Brass (less common for structural loads)

Material selection ensures:

• Flatness

• Load stability

• Corrosion resistance

6. Load Characteristics

Although thin, shims must withstand:

• Compression load

• Lateral forming pressure transfer

• Vibration

• Clamp torque force

High-quality shims prevent deformation under load.

7. Flatness & Surface Finish

Proper shims have:

• Ground parallel faces

• Burr-free edges

• Consistent thickness

• Smooth surface finish

Irregular surfaces can introduce misalignment.

8. Importance in Roll Forming Geometry

Incorrect vertical alignment may cause:

• Uneven flange formation

• Edge roll marking

• Profile asymmetry

• Twist or camber

Shims allow correction without redesigning tooling.

9. Use During Setup & Changeover

Height shims are often adjusted:

• During initial machine installation

• After tooling change

• When switching material thickness

• During tolerance correction

They provide repeatable setup accuracy.

10. Stackable Adjustment Method

Shims may be:

• Used individually

• Stacked in combination

• Replaced with custom thickness plates

Stacking must maintain flat contact surfaces.

11. Interaction with Side Roll Mount Block

The shim directly affects:

• Side roll vertical centerline

• Bearing alignment

• Contact angle with strip edge

Precision here protects tool life.

12. High-Tensile Steel Considerations

When forming high-strength materials:

• Lateral forces increase

• Compression on shim increases

• Material hardness must resist creep

Hardened steel shims are recommended.

13. Compression & Creep Resistance

Low-quality shims may:

• Compress over time

• Develop indentation

• Lose height consistency

Precision-ground shims resist long-term deformation.

14. Corrosion Protection

Shims may be:

• Stainless steel

• Zinc plated

• Oiled for protection

Corrosion changes thickness tolerance.

15. Installation Best Practices

Proper installation requires:

• Clean contact surfaces

• Even bolt torque

• No burrs or debris

• Proper stacking alignment

Uneven stacking creates tilt.

16. Vertical Adjustment vs Screw Adjustment

Height Shim	Adjustment Screw
Controls vertical position	Controls lateral position
Static once installed	Adjustable during setup
Precision thickness-based	Thread pitch based

Both systems work together for full roll positioning.

17. Impact on Profile Tolerance

Correct shim selection ensures:

• Uniform flange height

• Consistent web geometry

• Reduced scrap

• Stable production repeatability

Precision vertical control supports high-spec profiles.

18. Maintenance & Inspection

Routine checks should verify:

• No shim deformation

• No corrosion buildup

• No stacking misalignment

• No surface galling

Shims must remain flat and intact.

19. Advantages of Shim-Based Adjustment

Height shims offer:

• Simple mechanical solution

• No moving parts

• Long service life

• Micron-level correction

• Reliable repeatability

They are one of the most stable adjustment methods.

20. Summary

The side roll height shim is a precision spacer used to control the vertical alignment of side rolls in a roll forming machine.

It:

• Adjusts roll centerline height

• Maintains flange accuracy

• Supports pass alignment

• Resists compression and vibration

• Ensures repeatable setup precision

Though thin and simple, it is critical for dimensional accuracy in high-performance roll forming systems.

FAQ

What is a side roll height shim?

A precision spacer used to adjust the vertical position of a side roll assembly.

Why is it important?

It ensures correct flange height and profile alignment.

What material is it made from?

Typically hardened steel or stainless steel.

Can shims be stacked?

Yes, but surfaces must remain flat and aligned.

Does it affect profile quality?

Yes, vertical misalignment directly impacts flange geometry.