Fig. 10. Resistance spot welded brace to Manufacture and Test Considering the complexity of the machine, the actual manufacture of the detail parts and assembly of the beam builder, as well as its preacceptance debugging and testing, went very well. There were, however, several areas in which problems did occur, as discussed in the following paragraphs. Beam Cap Roll Forming Machinery The lower right rolling mill (when looking at the machine from the material feed end) produced beam caps with pronounced flange waviness. Although structural compressive load tests demonstrated that this waviness was not detrimental to the strength of the part, it was still considered unacceptable since the other two machines were producing beam caps without waviness. No amount of adjustment of the roll tooling or subsequent weld block shunt bars which guide the beam caps through the brace fastening section of the beam builder eliminated the problem. Finally, all the roll form tooling from the three rolling mills were removed and shipped back to the manufacturer for comparative measurements on a forming station by forming station basis. It was found that the roll tooling from the lower right rolling mill was slightly different from that of the other two rolling mills, although it was still within
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