CN1054549A - The moulding of sheet metal - Google Patents

Abstract

A kind of shaped device that is used for the light sheet of plastically deformable, but comprise the pivoted frame parts (2,3) of a pair of relative calibration, each pivoted frame parts comprises many moulding rollers (4), the moulding roller is formed by solid roller (30,31) or by separable roller (32,33).Relative moulding roller (30,31 or 32,33) correspondingly have the convex of general complementation and the profile of spill periphery (30a, 31a).The hydraulic push rod (10) of last pivoted frame parts (3) under the control of detector for displacement measuring (18) and/or pressure sensor (11) makes it with respect to pivoted frame parts (2) can displacement down.

This device is subjected to microcomputer (20) control, its data by storing, make roller (30,31 or 32,33) reach the decision of going up the optimum organization of roll extrusion power at push rod (10), reach needed light sheet distortion, and guarantee at roller (30,31 or 32,33) and the length-width ratio of the horizontal contact area between the processed light sheet be not less than 3: 1.

Video camera (28) be used to monitor light sheet and roller (30,31 or 32,33) if check and approve and when any deviation takes place, then handle to correct machining state through microcomputer (20) immediately from the signal of video camera.

Description

The moulding of sheet metal

The present invention relates to the shaping of the flat thin plate of metal, and the shaping that particularly is not only applicable to the flat thin plate of metal of shipbuilding.

One aspect of the invention is a kind of metal sheet profiled device, is a kind of method of forming sheet metal on the other hand.The present invention also relates to by by said method and the metallic plate product that constitute or that include this metallic plate processed of device.

Up to the present, there have been many methods to realize metal plate is processed into the 3D shape with simple or compound curved surface.Wherein typical manufacturing process is: heat extends and shrinks, the extension roll extrusion, and the edge shrinks and is shaped punch die drawing, blast cleaning and sclerosis.

The punch die drawing does not need very special technical ability just can accurately produce the product of shaping with metal plate.Yet because the investment of forcing press and mould is very high, this method is limited to the production of a large amount of products of making repeatedly usually, as the panelling of body of motor vehicle.

Blast cleaning and sclerosis are only limited to the shaping that the soft metal sheet of relative thin such as aluminium and this technology have been used for aircraft wing covering parts.

The operation of other prior art comprises thermal contraction and extension, and extension roll extrusion and edge shrink to be shaped all serious deficiency.Just not saying its labour intensity is high and very slow, these technologies all require quite high skill level, and generally can only produce second-rate product.Along with the management practice of relevant occupation at present and worker skill's training, the quantity of the experienced operator in metal sheet profiled field is reduced rapidly.

Be described though only just be used for the metal sheet profiled of shipbuilding below, should more know clearly for the reader with this area technical ability, method and apparatus of the present invention is applicable to the light sheet moulding needs in field widely, comprises the plastically deformable material.

Because the experienced operator's relevant with shipbuilding industry shortage and labour remuneration height, the shipbuilding designers have adopted the design specification method of replacement, to improve the service efficiency of building cost of the ship in industry with keen competition.Design specification although it is so can utilize the simple coverboard of less ripe refining work masterpiece to be shaped, the boats and ships of Jian Zaoing may not necessarily improve the service efficiency of expense by the expense of its calculating like this, when comparing with the boats and ships that traditional profile is built, they do not have same airworthiness or characteristics firm in structure yet.

For resembling luxurious motor boat, aspect expense, there is not single standard, owing to lack oldhand and accurate measuring instrument, usually cause having on the hull coverboard surface of poor quality, and the filler of filling these defectives may be equivalent to 5 percent of whole shipbuilding expenses.

An object of the present invention is to overcome or reduce the problem that exists in the existing metal sheet profiled technology.

Further aim of the present invention is to propose a kind of accurate and repeatably metal sheet profiled apparatus and method that are used for.

Proposed a kind of building mortion that is used for light sheet by one aspect of the present invention, said device comprises:

A bracing frame supports at least two roller parts, and said at least two roller parts are to rotate around separated, substantially parallel turning cylinder.

Make at least one relative another contiguous control device that is moved in the said roller part.Can under the induction of pressure sensor and/or detector for displacement measuring, select operation.

Preferably the turning cylinder separately of said at least two roller parts with one perpendicular to arranging with the axis of said turning cylinder.

Than suitable be, one or more said at least two roller parts have rotating pivoted frame parts, and these pivoted frame parts comprise many be centered around its outside, isolated shaping rollers.

If necessary, one or more shaping roller can be made up of many roller units.

Said device preferably include one with freely rotate the separated driving shaping of shaping roller roller.Can selectively adjust in the displacement that drives between shaping roller and free forming roller.

Than suitable be, can be with respect to following roller part along axis shift perpendicular to said rotation.

The displacement of preferably said upper roller parts is applied predetermined pressure by being contained in shaping roller on the upper roller parts and that act on metallic plate and controls along with one by said contiguous control device.In addition, the displacement of upper roller parts by said contiguous control device along with a predetermined displacement between the shaping roller that respectively is contained on said upper roller parts and the following roller part is controlled.

This device preferably has bracing or strutting arrangement to be used to support processed sheet of material.

Suitable is that said bracing or strutting arrangement comprises one or more supporting planes, is supported on movably on the processed thin plate.

If necessary, said device can also have adjusting device, to be applicable to that sheet of material is with respect to the calibration of forming rolls in said metal sheet forming process.

Said device preferably has the micro processor controls device.Suitable is, said upper roller parts comprise many shaping rollers, has a curved periphery that is roughly convex on roller transversal.

Equally, said roller part down comprises many shaping rollers, has the curved periphery of a spill roughly on the cross section of roller.

The method of a sheet material forming has been proposed according to a further aspect in the invention.Said method comprises: between relative roller along the light sheet of predetermined groove roll extrusion plastically deformable, by the horizontal contact area between each relative roller and each contact area at said sheet material have one greater than 3: 1 length-width ratio.

Preferably the length-width ratio of said contact area was greater than 4: 1.

The length-width ratio of said contact area is better greater than 5: 1.

In order to make the present invention can be easier to understand, existing in conjunction with the accompanying drawings to one preferably embodiment describe.Wherein Fig. 1 is a front elevational schematic.

Fig. 2 is a side view of device shown in Figure 1.

Fig. 3 is a vertical view of device shown in Figure 1.

Shown in Figure 4 is a forming rolls subassembly.

Shown in Figure 5 is the forming rolls subassembly of a replacement.

In Fig. 1, building mortion comprises a bracing frame 1, supports following pivoted frame parts 2 and last pivoted frame parts 3.Upper and lower pivoted frame parts 2 and 3 all have rotatable pivoted frame, and this pivoted frame has the shaping roller 4 that many rotations around it are installed.

Following shaping roller 4 is driven by hydraulic motor 8,9, and this motor 8,9 is by 12 controls of the control valve parts in the underground 13 that connects hydraulic pump system 15.Roller 4 is driven by retractible driving shaft 8a, 9a, and driving shaft 8a, 9a mesh with roller 4 on demand by attachment plug and socket (not shown).Motor 8 and 9 can coordinatedly drive, or owing to reason described below, they also can be controlled respectively.Calibration motor 5 rotates pivoted frame parts 2 makes selected shaping roller 4 be in desired and last shaping roller positions aligning.Equally, last pivoted frame parts 3 have a calibration motor 7 that is used to adjust shaping roller 4.Last shaping roller 4 does not have power, and in the processing that is shaped can by with contact and " rotating freely " with being formed the sheet metal upper surface portion.

Pivoted frame parts 2,3 have the character that adapts to the sheet metal that is formed, and the shaping roller group that forms the character of profile.In the explanation of this device, last shaping roller 4 has the protruding profiled surface of different curvature, and following shaping roller 4 also has the recessed profiled surface of different curvature.

Last pivoted frame 3 is installed in rotation on the retractible carriage 6.Carriage 6 is released or is regained by the hydraulic push rod parts.The action of push rod 10 is by the device and 17 controls of the control valve in the underground of pressure sensor 11.Go up and reach the relative displacement between the shaping roller 4 down by high-precision electronic gauge device 18 measurements.

The hydraulic pressure supporting surface 22,23 that can tilt respectively is provided on each limit of pivoted frame parts 2,3, is used for being supported on the formed metal plate that passes through between the shaping roller 4.For the position sensor (not shown) that the position of determining supporting surface 22,23 provides can be controlled respectively by the valve gear (not shown) in underground.

One has suitable switch, and the control panel 19 of a signal lamp and a VDU screen is installed on the arm 19a, one side it can be from the another side of putting of device.This control panel is to be used for selecting determining operating parameter, makes the more easily operation under the control of microcomputer 20 of this device.

Fig. 2 has shown the front view of a device shown in Figure 1.On each limit of pivoted frame parts 2,3, by the supporting surface 24,25 that hydraulic cylinder 26 drivings can further be tilted, each hydraulic cylinder 26 controllably adopts the device precalculated position nearby at position sensor 27.

Be installed in top and between adjacent shaping roller 4 the shaped region both sides be high-resolution camera 28, it is in the roller 4 residing planes.

Fig. 3 is the vertical view of a Fig. 1,2 shown devices, and it has shown supporting surface 23a, the 23b that can tilt respectively.Supporting surface 22 shown in Figure 1 can tilt respectively equally.

Fig. 4 has shown a pair of solid convex concave roller 30,31, and they can be used for this device.The cross-sectional perimeter 30a of convex-concave bending, 31a are roughly complementary, thereby make them have the identical or roughly the same center of curvature.

Fig. 5 has shown pair of separable convex concave roller 32,33, and it more is applicable to the present invention.Under the situation of using separable upper and lower roller, by bottom two halves roller 33a, the 33b that motor 8,9 drives separately, can be along the control of the non-directional groove realization on sheet metal to forming sheet metal.

In the extension of using rolling forming metallic plate of the prior art is produced, get used to utilizing the combination control roll extrusion direction of convex-concave shape shaping roller, to realize the control transverse curvature.Along the roller that has used the convex-concave combination in the production of roll extrusion direction transverse curvature.Because each edge of concave surface shaping roller plays the flat thin plate of support metal as a fulcrum respectively, when plate passed through roller, under pressure, the convex surface roller was exerted pressure downwards and is made the plank distortion.Groove is often drawn on plank, it as the executor of a replacement to cause the profile of an expectation, accurately against a series of skeleton patterns.In general, such forming board by by same groove repeatedly roll extrusion be shaped gradually, with avoid owing to the direction of required distortion on uncontrollable distortion of producing of perpendicular extension.Because in fact last convex surface roller " floats " on the surface of metallic plate, the edge alternate by the concave surface roller supporting from below, needs very high technical ability and judgment, to judge the adequacy of the transversely deforming that does not produce vertical extension.Further, because convex surface distortion roller " floating " act on, inconsistent on the thickness of flat board and metal quality and the corrugated surface that causes.For avoiding unwanted extension, be necessary by same groove so repeatedly.But the result who does so usually is because excessive calendering has increased the hardness of forming board.

Because the radius of curvature of support metal plate and concave surface roller is complete intersection, avoided uncontrollable " floating " effect of epirelief roller.The control that alleviates vertical fluctuating quantity conflicted mutually with former extension rolling step.By to push rod pressure and/or roller displacement together with a pair of protruding/control of the roller of definite radius recessed complementation, that intersect selection garden week curvature, can realize the degree of desired distortion along the groove of giving, and more clearly not run into unwanted (with uncontrollable) and vertically extend.

Find unexpectedly to be,, can suitably increase pressure to realize control, do not lose the extension of transversely deforming again with the convex surface roller even produce a required vertical extension of complex bend.In the forming process of metallic plate, by the combination of conversion roller in a predetermined manner on the length of whole groove, and/or push rod pressure, and/or the roller displacement, can realize extremely complicated and very accurate on the other hand combined shaping.

Apparatus and method of the present invention have obtained advanced lower cost of extension rolling technology technology and producing effects of consumption like this, and precision, the speed of advanced extruding and mould pressing process technology and do not need producing effects of skilled labor.

By to the careful of all deformation parameters and coordination control, can and simply be shaped by device realization complexity of the present invention and combined shaping.Simultaneously, owing to make the metallic plate distortion with the rolling groove of minimum, final forming board reaches level and smooth shaping, and does not have relative stress.

The used groove of shape cutting operation forming board that the CAD-CAM microcomputer software has been used for coverboard in shipbuilding industry preferably is marked at the plate that is decorated with outline line.

In the operation of apparatus of the present invention, the flat board that is decorated with outline line is placed on the supporting surface 22,23,24,25 that is initially in a horizontal level.

Then the data about shaping and face profile are taken out from CAD-CAM software, import microcomputer 20 together with the thickness of relevant plate and the metal type information of formation plate simultaneously.

Then the device starting operation before, the groove aligned with camera 28 that metallic plate is suitable.

Microcomputer 20 according to the thickness and the metal model of flat board, is made moulding roller 4 and the decision that acts on the optimum combination of the rolling pressure on the push rod 10 by the data of storing then, to be implemented in the deformation extent that needs when each passage is passed through a corresponding groove.

The required combination of moulding roller 4 can obtain by the position of conversion pivoted frame parts 2 and 3, makes push rod 10 actions then when CD-ROM drive motor 8,9 is activated.When top shaping roller 4 under pressure during with the metallic plate CONTACT WITH FRICTION, the bottom drives shaping roller 4 and makes dull and stereotyped moving along the initial groove under video camera 28 monitoring.If groove is not aimed at by video camera 28 or groove is a non-rectilinear, the signal that is come by video camera is controlled the relative velocity of the cheek operation of separable shaping roller 4 down selectively by microcomputer 20, to be guided in the groove between the upper and lower forming rolls.The change of direction is to regulate in last shaping roller 4, because it also is a pair of parts in two, these parts can rotate freely independently of one another.

In order to process the complex bend face, when roller during through a groove pressure on push rod 10 can change in a predetermined mode.

In the end of the metallic plate that rolls across each time, next groove is aimed at by video camera 28, and if desired, microcomputer 20 can be changed the position of pivoted frame 2,3.

If desired, the roller pivoted frame parts that device of the present invention is changed by the multiple combination of using different protruding and/or recessed rollers can use the mode identical with roll extrusion machinery with the extension of prior art to operate.

Place at a complex bend, promptly require to have the recessed flexure plane of a traffic direction perpendicular to by the distortion roller time, with a recessed flexure plane that is parallel to traffic direction, this can be by finishing with the recessed/protruding shaping roller of the predetermined groove in a pair of edge with a pair of convex surface roller along same or another groove.When protruding roller tends to the drawn metal plate forming one during perpendicular to groove and to recessed distortion, this is recessed/and protruding roller is to forming concave surface upwards along groove.

Yet, by means of the present invention, with a pair of recessed/distortion of the metallic plate that the shaping roller of protruding complementation is controlled, be by deformation characteristics at the special metal model of the sheet metal of known specific thicknesses, pressure on the push rod 10 is controlled, and realize at the roller diameter that provides.Proofreading and correct varied in thickness can realize by the signal of micrometer 18 outputs.Micrometer can be by measuring the thickness that the upper and lower relative displacement that is listed as between the shape roller 4 comes monitor board.

Similarly, the distortion of control metallic plate can realize by the displacement that monitors and control between the upper and lower shaping roller.The varied in thickness of metallic plate can be proofreaied and correct by the fluid pressure that monitors and control on the push rod 10 then.

In the process that is shaped gradually, supporting surface 22,23,24,25 controls at microcomputer 20 have a down dip, when metallic plate process stayed surface, corresponding to each adjacent part of formed metal plate, supporting deformation metallic plate correctly, and support by this way helps forming rolls to lead along groove.

The deformation data of the metallic plate of, complexity simple for producing and combined shaping can be by encoding to the calculating of the calculating of known parameters and/or method and calibration by experiment.Yet, find that in practice theoretic data may need to make modification a little according to the data that reach optimum efficiency that experiment is determined.

In addition, because the quality difference of some metal wishes that by simple standard deformation test method test metal sample one group of group ground is proofreaied and correct localized metallic and changed.By this way, the program of the shaping control parameter of insertion can be worked out and calculate to microprocessor, adjusts different metal model and thickness, and the height repeatability that allows metal to change in forming metal.

Although the reader for capable territory technical ability is clear, many variablees are arranged as at the forming rolls diameter, be considered in the selection of the parameter relevant with metallic character with the different-thickness of metallic plate in roller edge radius of curvature, roll pressure and the uses such as roller position parameter and shaping roll speed, these variablees may be by calculating and/or being determined by experiment.Subsequently, the data that obtain like this can be specialized in the Microcomputer Calculation of this device of control.

About the various combination of physical parameter, can in the work of this device, be optimized.Draw, the contact-making surface on each forming rolls surface with the flow of metal zone, should have one on traffic direction greater than 3: 1 length-width ratio, so that fully control deformation process.When length-width ratio during, owing to, cause uncontrollable distortion along the excessive spread of groove direction less than 3: 1.Though this ratio is can obtain good result at 4: 1, best ratio is 5: 1 or bigger.Compare with prior art extension rolling step, these are notable attribute, do not have to monitor or control easily the parts of contact area size in the prior art.

The distance that the shaping roller moves on metallic plate can come to determine in many ways.Also can provide vertical groove in addition, x wire at interval is so that microcomputer can be determined the deformed region of corresponding dull and stereotyped yardstick by video camera 28 with vision.On the other hand, many proximity senses can be connected in supporting surface 22,23,24,25, on.

Yet best sensor (not being shown) is connected on the driving shaft of motor 8,9, to detect the distance that roller 4 moves through on the metal surface.By this way, determine by the diameter parameters and the degree of rotation of shaping roller 4 along the displacement of groove.

The reader who is familiar with this area technical ability is with clear, and many changes and variation all can not run off the spirit and scope of the present invention.

For example, this device can be intervened by an operator, and it is possible operating with a kind of automanual mode.Preferably provide a remote control that " joystick " arranged, so that can substitute device by Artificial Control.

In addition, the manually operated device that substitutes can be used to control pressure or the mutual relative displacement of shaping roller on the push rod 10.When controlling actual shape according to shape required on the VDU screen, an operator can handle this device in manual or semi-automatic mode, uses or replace the automatic control of this device.This device is for the shaping of the metallic plate of off-standard size or metallicity, perhaps for being useful in the data referencing with new standard shaping operation.

This device also can comprise the standard set-up that is used for the continuous score lines of standard on formed metal plate.

For the reader who is familiar with this area technical ability, will be considerably clear, can be applied to broad multiple field by apparatus and method of the present invention.The shaping of the light sheet of metallic plate or other plastically deformable that needs is wherein arranged.For example this device can be used to boiler industry, and the garden tube of tonnage bend of vessel side in shipbuilding industry, is used for the shaping and the similar use of structural member, or is used for plate forming in aircraft and auto industry.Equally, though the above-mentioned metallic plate that only limits to, the sheet member of other synthetic material plastically deformable also can be shaped with device of the present invention as plastics.Such plastics comprise as partly solidified heat cured or thermoplastic synthetic.When successively solidifying with commonsense method in a stable mecystasis, they can be shaped.The present invention also can be applied to the thin plate that the plastically deformable material is made, and as a kind of pressure laminate of plastic-metal, and with the pressure laminate of some plastics, the metal level of shaping provides support for plastic layer in solidification process or as its model.

Claims (24)

1, a kind of building mortion that is used for thin plate, said device comprises:

A bracing frame supports at least two roller parts, and said at least two roller parts are to rotate around isolated substantially parallel rotating shaft;

The driver part of a shaping roller of rotating driving links with one of said roller part at least;

Make the control assembly of at least one vicinity that moves with respect to another said roller part in the said roller part, said contiguous control assembly is selectively operation under the induction of pressure sensor and/or detector for displacement measuring.

2, by the described device of claim 1, wherein the turning cylinder separately of said at least two roller parts is arranged on the axis vertical with said turning cylinder.

3, by the described device of claim 2, wherein at least two said roller parts one or more comprise rotating pivoted frame parts, and the pivoted frame parts have many and the isolated shaping roller of its outer matrix section.

4, by the described device of claim 1, wherein said shaping roller is made up of many its roller elements.

5, by the described device of claim 3, comprise drivable shaping roller, it is spaced apart with a shaping roller free to rotate, and the displacement between said drive roller and said free rotary rollers can be adjusted selectively.

6, by the described device of claim 5, one of them upper roller parts, being equivalent to a following roller part is to move along said axis perpendicular to said turning cylinder.

7, by the described device of claim 6, the displacement of wherein said upper roller parts is controlled by said contiguous control assembly, and this control assembly is along with applying predetermined pressure by the shaping roller that is connected on the said upper roller parts to the light sheet that is formed.

8, by the said device of claim 6, the displacement of wherein said upper roller parts, controlled by said contiguous control assembly, this control assembly along be connected separately on the said upper roller parts and said roller part down on the shaping roller between predetermined displacement control.

9, by the described device of claim 7, wherein said upper roller parts, to have cross section be that the shaping roller of the convex periphery of basic convex is formed by many.

10, by the described device of claim 7, to have cross section be that the shaping roller of the spill periphery of basic spill is formed to wherein said down roller part by many.

11, by the described device of claim 10, wherein be connected upper roller parts and the corresponding periphery that is connected down the shaping roller on the roller part, have the shape of cross section of basic complementation.

12, by the described device of claim 11, wherein be connected the cross section of basic complementation of the correspondence of the shaping roller on upper roller parts and the following roller part, periphery has basic similar curvature center.

13, by the described device of claim 12, wherein one or more shaping rollers that are connected on the upper and lower roller part of upper roller parts are made up of many its roller elements.

14,, comprise being used to support the support component of light sheet material of being formed by the described device of claim 13.

15, by the described device of claim 14, wherein said support component is made up of one or more movably supporting surfaces, so that support movably forming board thereon.

16, by the described device of claim 15, comprise the micro processor controls device.

17, a kind of method of the light sheet that is used to be shaped: said method comprises:

Between relative roller along the light sheet of a plastically deformable of previously selected groove roll extrusion, thereby the area of the lateral surfaces contact between a corresponding contact area on the relative roller of correspondence and the said light sheet has one greater than 3: 1 length and wide ratio.

18, by the described method of claim 17, wherein said length-width ratio was greater than 4: 1.

19, by the described method of claim 18, wherein said length-width ratio was greater than 5: 1.

No matter 20, substantially according to the method for using a kind of light sheet that is shaped in any device where among the claim 1-16.

21, according to a kind of shaping thin plate of making whenever in the device any among the claim 1-16.

22, a kind of shaping thin plate that processes according to method any among the claim 17-20.

23, be included in converted products according to a kind of thin plate that is shaped of making in the device any among the claim 1-16.

24, comprise converted products according to a kind of thin plate that is shaped of method manufacturing any among the claim 17-20.

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