EP3421147B1 - Walzanlage zur herstellung eines rohlings mit variabler dicke und verfahren zur herstellung eines rohlings mit variabler dicke - Google Patents

Walzanlage zur herstellung eines rohlings mit variabler dicke und verfahren zur herstellung eines rohlings mit variabler dicke Download PDF

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Publication number
EP3421147B1
EP3421147B1 EP18174346.9A EP18174346A EP3421147B1 EP 3421147 B1 EP3421147 B1 EP 3421147B1 EP 18174346 A EP18174346 A EP 18174346A EP 3421147 B1 EP3421147 B1 EP 3421147B1
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EP
European Patent Office
Prior art keywords
roller
metal sheet
thickness
translational
sets
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EP18174346.9A
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English (en)
French (fr)
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EP3421147A1 (de
Inventor
Stephan RÖHNER
Ranga Reddy Suhant Prajwal
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Dus Operating Inc
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Dus Operating Inc
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/22—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/08—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling structural sections, i.e. work of special cross-section, e.g. angle steel
    • B21B1/12—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling structural sections, i.e. work of special cross-section, e.g. angle steel in a continuous process, i.e. without reversing stands
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/08—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling structural sections, i.e. work of special cross-section, e.g. angle steel
    • B21B1/0805—Flat bars, i.e. having a substantially rectangular cross-section
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/38—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling sheets of limited length, e.g. folded sheets, superimposed sheets, pack rolling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B27/00—Rolls, roll alloys or roll fabrication; Lubricating, cooling or heating rolls while in use
    • B21B27/02—Shape or construction of rolls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B27/00—Rolls, roll alloys or roll fabrication; Lubricating, cooling or heating rolls while in use
    • B21B27/02—Shape or construction of rolls
    • B21B27/028—Variable-width rolls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B37/00—Control devices or methods specially adapted for metal-rolling mills or the work produced thereby
    • B21B37/16—Control of thickness, width, diameter or other transverse dimensions
    • B21B37/24—Automatic variation of thickness according to a predetermined programme
    • B21B37/26—Automatic variation of thickness according to a predetermined programme for obtaining one strip having successive lengths of different constant thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B39/00—Arrangements for moving, supporting, or positioning work, or controlling its movement, combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills
    • B21B39/02—Feeding or supporting work; Braking or tensioning arrangements, e.g. threading arrangements
    • B21B39/08—Braking or tensioning arrangements
    • B21B39/082—Bridle devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
    • B21H8/00—Rolling metal of indefinite length in repetitive shapes specially designed for the manufacture of particular objects, e.g. checkered sheets

Definitions

  • the present disclosure relates generally to a roll forming system for forming a variable thickness blank according to the preamble of claim 1 and to a method for forming a variable thickness blank according to the preamble of claim 1 3 (see e.g. US 2013/0020835 A1 ).
  • Known roll forming processes provide for altering a thickness of a metal blank in a longitudinal direction parallel to a feed direction of a metal sheet, and for constructing metal blanks from multiple plates of differing thicknesses as desired.
  • Known roll forming processes may not provide for incrementally varying a thickness of a plate across a transverse direction of the plate, and therefore require a second or subsequent manufacturing, welding, or brazing steps to add further material of a differing thickness.
  • Roll forming processes in which metal sheets with a varying thickness of a plate across a transverse direction of the plate are known from documents US 2013/0020835 A1 , US 1,915,084 , US 4,578,979 , DE 10 2006 024 775 A1 and GB 10,850 .
  • variable thickness roll forming system comprising the features of claim 1 is provided.
  • the multiple shaping faces of the second roller include a first shaping face which defines a first spacing distance between the first shaping face and the face of the first roller.
  • the first spacing distance is equal to an initial thickness of the metal sheet.
  • the second roller further includes a second shaping face defining a second spacing distance between the second shaping face and the face of the first roller which is less than the initial thickness of the metal sheet.
  • the second roller further includes a third shaping face defining a third spacing distance between the third shaping face and the face of the first roller which is less than the initial thickness of the metal sheet.
  • the second spacing distance defines a thickness of the second portion of the roll formed blank.
  • the third spacing distance defines a thickness of a third portion of the roll formed blank oppositely positioned about the first portion with respect to the second portion.
  • the thickness of the second portion is reduced by up to approximately 40% of the thickness of the first portion.
  • a first translational roller is positioned between a first roller set of the multiple roller sets and a second roller set of the multiple roller sets.
  • a second translational roller is positioned between the first roller set and the second roller set and positioned oppositely about the metal sheet with respect to the first translational roller, the second translational roller when displaced toward the metal sheet in a direction opposite to the displacement direction of the first translational roller deforming and thereby lengthening a further portion of the metal sheet.
  • a variable thickness roll forming system for forming a variable thickness blank includes multiple sets of cylindrical shaped rollers.
  • Each of the multiple sets of rollers includes: a first roller having a face which is linear where the first roller contacts a metal sheet; and a second roller having multiple shaping faces positioned about a perimeter and directed toward the face of the first roller.
  • Each of the sets of rollers incrementally alters a thickness of the metal sheet in a direction transverse to a feed direction of the metal sheet when the metal sheet is passed between the first roller and the second roller.
  • the metal sheet when passed between the first roller and the second roller forms a roll formed blank having a central portion, a first outer portion and a second outer portion located opposite about the central portion with respect to the first outer portion, the central portion having a thickness greater than a thickness of each of the first outer portion and the second outer portion.
  • the thickness of the central portion after passing through a final one of the sets of rollers is substantially equal to an initial thickness of the metal sheet.
  • the thickness of each of the first outer portion and the second outer portion is substantially equal after passing through the final one of the sets of rollers.
  • the thickness of the first outer portion is greater than the thickness of the second outer portion after passing through the final one of the sets of rollers.
  • the thickness of the first outer portion is less than the thickness of the second outer portion after passing through the final one of the sets of rollers.
  • the thickness of the first outer portion and the thickness of the second outer portion are reduced by up to approximately 40% of the thickness of the central portion after passing through a final one of the sets of rollers
  • a first translational roller is positioned between a first roller set of the sets of cylindrical shaped rollers and a second roller set of the sets of cylindrical shaped rollers, the first translational roller altering a length and a thickness of the metal sheet in a direction parallel to the feed direction of the metal sheet when the first translational roller is pressed into contact with the metal sheet between the first roller set and the second roller set.
  • a second translational roller is positioned between the first roller set of the sets of cylindrical shaped rollers and the second roller set of the sets of cylindrical shaped rollers and oppositely about the metal sheet with respect to the first translational roller.
  • variable thickness blank comprising the features of claim 13 is provided.
  • the method includes: setting a first spacing distance between a first shaping face of the multiple shaping faces of the second roller and the face of the first roller substantially equal to an initial thickness of the metal sheet; setting a second spacing distance between a second shaping face of the multiple shaping faces of the second roller and the face of the first roller less than an initial thickness of the metal sheet; and setting a third spacing distance between a third shaping face of the multiple shaping faces of the second roller and the face of the first roller less than the initial thickness of the metal sheet.
  • the method includes positioning the first, second and third shaping faces wherein the metal sheet when passed between the first roller and the second roller forms a roll formed blank having a central portion, a first outer portion and a second outer portion located opposite about the central portion with respect to the first outer portion, the central portion having a thickness greater than a thickness of the first outer portion and the second outer portion.
  • a variable thickness roll forming system 10 feeds a metal sheet 12 made for example from a steel or aluminum material off of a reel through multiple sets of generally cylindrical shaped rollers, each incrementally altering a thickness of the metal sheet 12 in at least one of a longitudinal and a transverse direction.
  • the metal sheet 12 is fed into a first roller set 14 and at least a second roller set 16 in a feed direction 18.
  • the metal sheet 12 as it comes off from a roll or reel of material provides a planar body 20 having a uniform initial thickness 22, for example a thickness of approximately 2.00 mm.
  • the initial thickness 22 can vary depending on the desired final geometry after completion of the roll forming operations.
  • a roll formed blank 25 of the metal sheet 12 after passing through both the first roller set 14 and the second roller set 16 may include a central portion 26, a first outer portion 28, and a second outer portion 30 located opposite about the central portion 26 with respect to the first outer portion 28.
  • the central portion 26 may have a first finished thickness 32 which may equal the initial thickness 22.
  • the first outer portion 28 may have a second finished thickness 34 less than or equal to the first finished thickness 32.
  • the second outer portion 30 may have a third finished thickness 36 less than or equal to the first finished thickness 32 and equal to or different from the second finished thickness 34.
  • Other variations in thickness of the central portion 26, the first outer portion 28, and the second outer portion 30 can also be provided, and roll formed blanks 25 may also have only two of the thickness portions, or may have more than three thickness portions.
  • the first roller set 14 includes a first roller 38 and a second roller 40.
  • the first roller 38 includes a face 42 which according to several aspects is generally linear where the first roller 38 contacts the metal sheet 12.
  • the second roller 40 includes multiple shaping faces about a perimeter directed toward the face 42, including a first shaping face 44 which defines a first spacing distance 46 between the first shaping face 44 and the face 42.
  • the first spacing distance 46 is equal to the initial thickness 22 of the metal sheet 12.
  • the second roller 40 further includes a second shaping face 48 defining a second spacing distance 50 which is less than the initial thickness 22.
  • the second roller 40 also includes a third shaping face 52 defining a third spacing distance 54 which is less than the initial thickness 22.
  • the second spacing distance 50 and the third spacing distance 54 may be equal, and in a non-limiting example may be 1.98 mm. These spacing distances create an initial thickness reduction of 0.02 mm where the metal sheet 12 passes between the face 42 of the first roller 38 and each of the second shaping face 48 and the third shaping face 52.
  • the initial thickness 22 may be unchanged or may have a thickness reduction less than 0.02 mm where the metal sheet 12 passes between the face 42 of the first roller 38 and the first shaping face 44 of the second roller 40.
  • each of the roller sets including the second roller set 16 include a first roller and a second roller, for clarifying a distinction between the first roller set 14 and the second roller set 16, the first and second rollers of the second roller set 16 are defined as a third roller 56 and a fourth roller 58.
  • the third roller 56 similar to the first roller 38, includes a face 60 which according to several aspects is generally linear across a width of the third roller 56 where the third roller 56 contacts the metal sheet 12.
  • the fourth roller 58 similar to the second roller 40, provides multiple shaping faces directed toward the face 60, including a fourth shaping face 62 which defines a fourth spacing distance 64 between the fourth shaping face 62 and the face 60 of the third roller 56.
  • the fourth spacing distance 64 is substantially equal to the initial thickness 22.
  • the fourth roller 58 further includes a fifth shaping face 66 defining a fifth spacing distance 68 which for example is reduced by 0.02 mm from and is thereby less than the second spacing distance 50.
  • the fourth roller 58 also includes a sixth shaping face 70 defining a sixth spacing distance 72 which is reduced by 0.02 mm from and is thereby less than the third spacing distance 54.
  • the fifth spacing distance 68 and the sixth spacing distance 72 may be equal, and in a non-limiting example may be 1.96 mm.
  • the spacing distances of the second roller set 16 create an additional thickness reduction of 0.02 mm where the metal sheet 12 passes between the face 60 of the third roller 56 and each of the fifth shaping face 66 and the sixth shaping face 70.
  • the initial thickness 22 may continue to be unchanged where the metal sheet 12 passes between the face 60 of the third roller 56 and the fourth shaping face 62 of the fourth roller 58.
  • each roller set of the present disclosure is used to create an additional, incremental thickness reduction in the metal sheet 12, at predetermined positions and by predetermined spacings between the shaping faces of the roller sets.
  • multiple roller sets are ganged defining a roller set gang 74 having eleven roller sets, including the first roller set 14 and the second roller set 16.
  • An initializing roller set 76 which does not perform thickness reduction may be used as an initial feed roller set, aligning the metal sheet 12 with the remaining roller sets.
  • the central portion 26 of the metal sheet 12 provides the first finished thickness 32 which is equal to the initial thickness 22, the first outer portion 28 has as the second finished thickness 34 a thickness of 1.98 mm, and the second outer portion 30 has as the third finished thickness 36 a thickness of 1.98 mm.
  • each of the successive roller sets of the roller set gang 74 incrementally reduces the second finished thickness 34 and the third finished thickness 36 by an additional 0.02 mm.
  • each of the successive ten thickness reducing roller sets of the roller set gang 74 reduces a thickness in at least one portion of the metal sheet 12 by 0.02 mm, thereby providing a total thickness reduction of 0.2 mm (10 roller sets each creating a reduction of 0.02 mm).
  • the central portion 26 of the metal sheet 12 retains the first finished thickness 32 which is equal to the initial thickness 22, the first outer portion 28 has as the second finished thickness 34 a final thickness of 1.8 mm, and the second outer portion 30 has as the third finished thickness 36 a final thickness of 1.8 mm.
  • the initial thickness of 2.00 mm and the thickness reduction of 0.02 mm at each passage between a roller set are exemplary values.
  • the thickness reduction that is desired can be varied depending on the number of roller sets, the initial thickness 22, the material of the metal sheet 12, a desired feed rate of the metal sheet 12, the total thickness reduction desired, and other factors.
  • a single translational roller 80 is positioned between an axially fixed first roller set 82 and an axially fixed second roller set 84 defining a single offset roller system 86.
  • the single translational roller 80 can be positioned between the first roller set 14 and the second roller set 16, or between any two successive roller sets of the roller set gang 74.
  • the fixed first roller set 82 includes a first roller 88 and a second roller 90 spaced from the first roller 88 to frictionally grip the metal sheet 12.
  • the fixed second roller set 84 includes a third roller 92 and a fourth roller 94 spaced from the third roller 92 to also frictionally grip the metal sheet 12. As the metal sheet 12 is displaced in a feed direction 96 a center-to-center spacing 98 is retained between the fixed first roller set 82 and the second roller set 84.
  • a rotational speed of the rollers of the fixed second roller set 84 can also be varied (e.g., increased) from a rotational speed of the rollers of the fixed first roller set 82 to permit longitudinal stretching of the length 102 between the fixed first roller set 82 and the fixed second roller set 84.
  • a dual offset roller system 104 may be used in place of the single offset roller system 86.
  • the dual off-set roller system 104 includes a first translational roller 106 and an oppositely displaced second translational roller 108 both positioned between an axially fixed first roller set 110 and an axially fixed second roller set 112.
  • the fixed first roller set 110 includes a first roller 114 and a second roller 116 spaced from the first roller 114 to frictionally grip the metal sheet 12.
  • the fixed second roller set 112 includes a third roller 118 and a fourth roller 120 spaced from the third roller 118 to also frictionally grip the metal sheet 12. As the metal sheet 12 is displaced in a feed direction 122 a center-to-center spacing 124 is retained between the first roller set 110 and the second roller set 112.
  • a rotational speed of the rollers of the second roller set 112 can also be varied (e.g., increased) from a rotational speed of the rollers of the first roller set 110 to permit longitudinal lengthening of the first and second lengths 130, 132 between the first roller set 110 and the second roller set 112.
  • Roller translation can directly be controlled using a feedback control system (not shown) designed for the above applications.
  • a thickness reduction achieved for each of the above systems is mapped directly to a displacement in the roll of the metal sheet 12.
  • a blank length can also be controlled by at least one of increasing the metal sheet feed speed, reducing the center-to-center spacing 98, 124 between the fixed roller sets, or decreasing a roller diameter of the translational rollers.
  • variable thickness roll forming system 10 can be created using the variable thickness roll forming system 10 of the present disclosure.
  • a drawn part 134 can be created.
  • the central portion 26 having a greater thickness than the first outer portion 28 and the second outer portion 30 provides the thickness necessary to use a drawing process to form a drawn portion 136.
  • a flanged part 138 can be also created.
  • the central portion 26 having a greater thickness than the first outer portion 28 and the second outer portion 30 can provide increased stiffness over an entire length of the flanged part 138.
  • the first outer portion 28 and the second outer portion 30 can each define flanges that can be further modified such as to provide for a flange cutout 140 to suit installation requirements.
  • An assembly 142 can be created for exemplary use as a vehicle door frame.
  • the central portion 26 can be used as a rigid web, while the first outer portion 28 can be reformed to support a window assembly, while the second outer portion 30 can be formed as a flange to longitudinally stiffen the assembly 142.
  • a tubular structure 144 can be created using for example two roll formed blanks 25 of the present disclosure.
  • a first central portion 26(1) can be spaced apart from a second central portion 26(2) by joined, for example welded, first outer portions 28(1), 28(2) and joined second outer portions 30(1), 30(2).
  • the metal sheet 12 is shown in an initial state as it is fed for example off a reel, and prior to any forming operations of the present disclosure.
  • the metal sheet 12 with the planar body 20 initially has a uniform width 146 and a uniform thickness 148.
  • a tailor roll formed blank 150 having a rolled width 152 which is greater than the width 146.
  • Opposed edges 154, 156 of the tailor roll formed blank 150 have a "wavy" shape due to the metal flowing laterally during the initial rolling operations.
  • the wavy shape of the opposed edges 154, 156 is also due to the metal sheet 12 being unconstrained during the initial rolling operations.
  • the first outer portion 28 and the second outer portion 30 have been work hardened by the action of the rollers, resulting in a material that has higher strength and stiffness than a metal sheet of similar reduced thickness that has not been work hardened.
  • the physical properties of the metal sheet 12 in the areas of the first outer portion 28 and the second outer portion 30 are also enhanced. It is noted that work hardening is more effective in steel materials than aluminum materials. The center portion 26 remains not work hardened.
  • a sheet 158 is shown after an edge trimming operation is performed on the tailor roll formed blank 150.
  • the edge trimming operation forms the sheet 158 having a width 160, where the width 160 is less than the rolled width 152, but can be greater than, less than, or the same as the original width 146 of the metal sheet 12.
  • Edge trimming is performed to provide sheet 158 with consistent, parallel and linear opposed outer edges 162, 164. After edge trimming, portions of the sheet 158 are still work hardened.
  • Finished part 166 takes advantage of the differing thicknesses of the sheet 158, for example having the first outer portion 28 and the second outer portion 30 of a reduced thickness compared to the center portion 26, while the work hardening provided by the variable thickness roll forming system 10 provides specific predetermined strength and weight requirements for the finished part 166. While reference has been made herein to an exemplary initial metal sheet thickness of approximately 2.00 mm with reductions made thereafter, the reduced thickness edge portions defining the first outer portion 28 and the second outer portion 30 can be selectively reduced by approximately 30-40% below any initial metal sheet thickness in the finished part.
  • the thickness of the first outer portion 28 and the thickness of the second outer portion 30 may be reduced by up to approximately 40% of the thickness of the central portion 26 after passing through a final one of the sets of rollers. This allows for significant weight savings in the finished part while retaining enough thickness for strength, particularly when the material of the metal sheet 12 is a steel allowing the maximum benefit from work hardening.
  • a graph 168 presents strain amounts in different areas of an exemplary roll formed blank 170 formed using the variable thickness roll forming system 10 of the present disclosure.
  • Predominant portions indicated in a first strain zone 172 exhibit strain amounts below a predetermined "safe" strain.
  • Portions of the roll formed blank 170 indicated in a second strain zone 174 define areas deemed to provide insufficient stretching and therefore elevated strain.
  • Portions of the roll formed blank 170 indicated in a third strain zone 176 define areas trending to exhibit minor plate wrinkling due to the roll forming process.
  • Portions of the roll formed blank 170 indicated in a fourth strain zone 178 define areas having a trend to exhibit strong or significant plate wrinkling due to the roll forming process.
  • a forming limit diagram 180 presents exemplary minor versus major strain data 182 for roll formed blanks such as the roll formed blank 170 depicted in FIG. 16 made using the variable thickness roll forming system 10 of the present disclosure. All of the data 182 is significantly below a curve 184 defining maximum allowable strain values, indicating roll formed blanks made using the variable thickness roll forming system 10 of the present disclosure do not exhibit material cracking or failure due to strain introduced during the rolling process which introduces both material thinning and work hardening.
  • variable thickness roll forming system 10 of the present disclosure offers several advantages. These include the ability to accurately provide incremental thickness reductions in a metal blank while maintaining a cost effective minimum feed speed for all of the roller sets. This is in lieu of imparting all of the desired thickness reduction using only a single roller set, which may reduce an overall feed speed compared to a feed speed achieved by only applying an incremental thickness reduction over multiple roller sets.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)

Claims (15)

  1. Walzprofiliersystem (10) variabler Dicke zum Formen eines Rohlings mit variabler Dicke aus einem Metallblech (12), das durch mindestens zwei Sätze von Walzen läuft, wobei das Walzprofiliersystem (10) umfasst:
    - mindestens zwei Sätze zylindrisch geformter Walzen, wobei jeder der mindestens zwei Sätze von Walzen Folgendes umfasst:
    ∘ eine erste Walze (38) mit einer Fläche (42), die dort linear ist, wo die erste Walze (38) das Metallblech (12) berührt; und
    ∘ eine zweite Walze (40) mit mehreren Formflächen, die um einen Umfang herum angeordnet und auf die Fläche (42) der ersten Walze (38) gerichtet sind;
    - wobei jeder der mindestens zwei Sätze von Walzen eingerichtet ist, eine Dicke des Metallblechs (12) in mindestens einer Richtung quer zu einer Vorschubrichtung (18, 122) des Metallblechs (12) schrittweise zu ändern, wenn das Metallblech (12) zwischen der ersten Walze (38) und der zweiten Walze (40) hindurchgeführt wird;
    wobei die erste Walze (38) und die zweite Walze (40) eingerichtet sind, einen walzprofilierten Rohling (25) zu bilden, der einen ersten Abschnitt und mindestens einen zweiten Abschnitt aufweist, der in der Richtung quer zur Vorschubrichtung (18, 122) des Metallblechs (12) in Bezug auf den ersten Abschnitt positioniert ist, wobei der erste Abschnitt eine größere Dicke als eine Dicke des zweiten Abschnitts aufweist,
    dadurch gekennzeichnet, dass
    das Walzprofiliersystem (10) variabler Dicke eine Translationswalze (80, 106, 108) aufweist, die zwischen einem ersten Satz von Walzen (82, 110) der mehreren Sätze von Walzen und einen zweiten Satz von Walzen (84, 112) der mehreren Sätze von Walzen angeordnet ist, wobei die Translationswalze (80, 106, 108) so eingerichtet ist, dass sie in einer Verschiebungsrichtung (100, 126, 128) im Wesentlichen quer zu dem Metallblech (12) und in Richtung des Metallblechs (12) verschoben werden kann, um das Metallblech (12) zwischen dem ersten Satz von Walzen (82, 110) und dem zweiten Satz von Walzen (84, 112) zu verlängern.
  2. Walzprofiliersystem (10) variabler Dicke nach Anspruch 1, wobei die mehreren Formflächen der zweiten Walze (40) eine erste Formfläche (44) umfassen, die einen ersten Distanzabstand (46) zwischen der ersten Formfläche (44) und der Fläche (42) der ersten Walze (38) definiert.
  3. Walzprofiliersystem (10) variabler Dicke nach Anspruch 2, wobei die zweite Walze (40) ferner eine zweite Formfläche (48) aufweist, die einen zweiten Distanzabstand (50) zwischen der zweiten Formfläche (48) und der Fläche (42) der ersten Walze (38) definiert, der geringer ist als der erste Distanzabstand (46).
  4. Walzprofiliersystem (10) variabler Dicke nach Anspruch 3, wobei die zweite Walze (40) ferner eine dritte Formfläche (52) aufweist, die einen dritten Distanzabstand (54) zwischen der dritten Formfläche (52) und der Fläche (42) der ersten Walze (38) definiert, der kleiner als der zweite Distanzabstand ist.
  5. Walzprofiliersystem (10) variabler Dicke nach Anspruch 4, wobei:
    - der zweite Distanzabstand (50) eine Dicke des zweiten Abschnitts des walzprofilierten Rohlings (25) definiert; und
    - der dritte Distanzabstand (54) eine Dicke eines dritten Abschnitts des walzprofilierten Rohlings (25) definiert, der in Bezug auf den zweiten Abschnitt gegenüber dem ersten Abschnitt (26) positioniert ist.
  6. Walzprofiliersystem (10) variabler Dicke nach einem der vorhergehenden Ansprüche, wobei die Dicke des zweiten Abschnitts um bis zu etwa 40 % der Dicke des ersten Abschnitts (26) reduziert ist.
  7. Walzprofiliersystem (10) variabler Dicke nach einem der vorhergehenden Ansprüche, wobei die Translationswalze eine einzelne Translationswalze (80) ist, die ein einzelnes versetztes Walzensystem (86) definiert, das zwischen dem ersten Satz von Walzen (82) der mehreren Sätze von Walzen und dem zweiten Satz von Walzen (84) der mehreren Sätze von Walzen angeordnet ist, wobei die Translationswalze (80) so eingerichtet ist, dass sie in Richtung des Metallblechs (12) in einer Verschiebungsrichtung (100) im Wesentlichen quer zu dem Metallblech (12) verschoben wird und dass sie eine Länge des Metallblechs (12) zwischen dem ersten Satz von Walzen (82) und dem zweiten Satz von Walzen (84) verformt und dadurch seitlich verlängert.
  8. Walzprofiliersystem (10) variabler Dicke nach einem der vorhergehenden Ansprüche 1 bis 6, wobei die Translationswalze (106) die erste Translationswalze (106) eines doppelten versetzten Walzensystems (104) ist, das zwischen dem ersten Satz von Walzen (110) und dem zweiten Satz von Walzen (112) angeordnet ist, wobei das doppelte versetzte Walzensystem ferner eine zweite Translationswalze (108) umfasst, die in Bezug auf die erste Translationswalze (106) gegenüberliegend um das Metallblech (12) angeordnet ist, wobei die erste Translationswalze (106) so eingerichtet ist, dass sie in Richtung des Metallblechs (12) in einer Verschiebungsrichtung (126) im Wesentlichen quer zu dem Metallblech (12) verschoben wird, um eine Länge des Metallblechs (12) zwischen dem ersten Satz von Walzen (110) und dem zweiten Satz von Walzen (112) zu verformen und dadurch seitlich zu verlängern und wobei die zweite Translationswalze (108) so eingerichtet ist, dass sie in Richtung des Metallblechs (12) in einer Richtung entgegengesetzt zur Verschiebungsrichtung (126) der ersten Translationswalze (106) verschoben wird, um einen weiteren Abschnitt des Metallblechs (12) zu verformen und dadurch zu verlängern.
  9. Walzprofiliersystem (10) variabler Dicke nach einem der vorhergehenden Ansprüche, wobei das System so eingerichtet ist, dass es den walzprofilierten Rohling so formt, dass, wenn das Metallblech (12) zwischen der ersten Walze (38) und der zweiten Walze (40) hindurchläuft, der walzprofilierte Rohling (25) einen zentralen Abschnitt (26), der der erste Abschnitt ist, einen ersten äußeren Abschnitt (28), der der zweite Abschnitt ist, und einen zweiten äußeren Abschnitt (30), der in Bezug auf den ersten äußeren Abschnitt (28) gegenüberliegend um den zentralen Abschnitt (26) angeordnet ist, wobei der zentrale Abschnitt (26) eine Dicke aufweist, die größer ist als eine Dicke sowohl des ersten äußeren Abschnitts (28) als auch des zweiten äußeren Abschnitts (30).
  10. Walzprofiliersystem (10) variabler Dicke nach Anspruch 9, wobei das System so eingerichtet ist, dass es den walzprofilierten Rohling so formt, dass, nachdem das Metallblech (12) durch einen letzten der Sätze von Walzen hindurchgeführt ist, die Dicke des mittleren Abschnitts (26) im Wesentlichen gleich einer Anfangsdicke (22) des Metallblechs (12) ist.
  11. Walzprofiliersystem (10) variabler Dicke nach Anspruch 9 oder 10, wobei das System so eingerichtet ist, dass es den walzprofilierten Rohling so formt, dass, nachdem das Metallblech (12) durch einen der letzten Sätze von Walzen hindurchgeführt ist, die Dicke des ersten äußeren Abschnitts (28) und des zweiten äußeren Abschnitts (30) des Metallblechs (12) im Wesentlichen gleich ist oder die Dicke des ersten äußeren Abschnitts (28) oder des zweiten äußeren Abschnitts (30) größer ist als die Dicke des anderen ersten äußeren Abschnitts (28) oder des zweiten äußeren Abschnitts (30).
  12. Walzprofiliersystem (10) variabler Dicke nach Anspruch 9 oder 10, wobei das System so ausgelegt ist, dass es den walzprofilierten Rohling so formt, dass die Dicke des ersten äußeren Abschnitts (28) und die Dicke des zweiten äußeren Abschnitts (30) des Blechs (12) um bis zu etwa 40 % der Dicke des mittleren Abschnitts (26) reduziert ist, nachdem das Blech (12) durch einen der letzten Sätze von Walzen gelaufen ist.
  13. Verfahren zur Herstellung eines Rohlings mit variabler Dicke, umfassend:
    - Ausrichten mehrerer Sätze zylindrisch geformter Walzen, wobei jeder der mehreren Sätze von Walzen Folgendes umfasst:
    ∘ eine erste Walze (38) mit einer Fläche (42), die dort linear ist, wo die erste Walze (38) das Metallblech (12) berührt; und
    ∘ eine zweite Walze (40) mit mehreren Formflächen, die um einen Umfang herum angeordnet und auf die Fläche (42) der ersten Walze (38) gerichtet sind; und
    - Hindurchführen eines Metallblechs (12) durch jeden der Sätze von Walzen, um schrittweise mehrere Dickenänderungen des Metallblechs (12) in einer Richtung quer zu einer Vorschubrichtung (18) des Metallblechs (12) zu bewirken, wenn das Metallblech (12) zwischen der ersten Walze (38) und der zweiten Walze (40) jedes der Sätze von Walzen hindurchgeführt wird,
    gekennzeichnet durch den zusätzlichen Verfahrensschritt des Verschiebens einer Translationswalze (80, 106, 108), die zwischen einem ersten Satz von Walzen (82, 110) der mehreren Sätze von Walzen und einem zweiten Satz von Walzen (84, 112) der mehreren Sätze von Walzen angeordnet ist, in einer Verschiebungsrichtung (100, 126, 128) im Wesentlichen quer zu dem Metallblech (12) und in Richtung des Metallblechs (12), um das Metallblech (12) zwischen dem ersten Satz von Walzen (82, 110) und dem zweiten Satz von Walzen (84, 112) zu verlängern.
  14. Verfahren zur Herstellung eines Rohlings mit variabler Dicke nach Anspruch 13, das den Verfahrensschritt umfasst, entweder
    - - Verschieben der Translationswalze (80) als eine einzelne Translationswalze (80), die ein einzelnes versetztes Walzensystem (86) definiert, in einer Verschiebungsrichtung (100) im Wesentlichen quer zu dem Metallblech (12) und in Richtung des Metallblechs (12), um das Metallblech (12) zwischen dem ersten Satz von Walzen (82) und dem zweiten Satz von Walzen (84) zu verlängern,
    oder von
    - - Verschieben der Translationswalze (80) als eine erste Translationswalze (106) eines doppelten versetzten Walzensystems (104) in einer Verschieberichtung (126) in Richtung des Metallblechs (12) und im Wesentlichen quer zum Metallblech (12), um das Metallblech (12) zwischen dem ersten Satz von Walzen (110) und dem zweiten Satz von Walzen (112) zu verlängern, und Verschieben einer zweiten Translationswalze (108) des doppelten versetzten Walzensystems (104), die gegenüber der ersten Translationswalze (106) um das Metallblech (12) herum in einer Verschiebungsrichtung (128) entgegengesetzt zur Verschiebungsrichtung (126) der ersten Translationswalze (106) in Richtung des Metallblechs (12) und im Wesentlichen quer zum Metallblech (12) angeordnet ist, um einen weiteren Abschnitt des Metallblechs (12) zwischen dem ersten Satz von Walzen (110) und dem zweiten Satz von Walzen (112) zu verlängern.
  15. Verfahren zur Herstellung eines Rohlings mit variabler Dicke nach Anspruch 14, das ferner Folgendes umfasst:
    - Einstellen eines ersten Distanzabstands (46) zwischen einer ersten Formfläche (44) der mehreren Formflächen der zweiten Walze (40) und der Fläche (42) der ersten Walze (38), der im Wesentlichen gleich einer Anfangsdicke (22) des Metallblechs (12) ist;
    - Einstellen eines zweiten Distanzabstands (50) zwischen einer zweiten Formfläche (48) der mehreren Formflächen der zweiten Walze (40) und der Fläche (42) der ersten Walze (38), der geringer ist als eine anfängliche Dicke (22) des Metallblechs (12);
    - Einstellen eines dritten Distanzabstands (54) zwischen einer dritten Formfläche (52) der mehreren Formflächen der zweiten Walze (40) und der Fläche (42) der ersten Walze (38), der geringer ist als die anfängliche Dicke (22) des Metallblechs (12), und vorzugsweise weiter umfassend
    - Positionieren der ersten, zweiten und dritten Formfläche (44, 48, 52), wobei das Metallblech (12), wenn es zwischen der ersten Walze (38) und der zweiten Walze (40) hindurchgeführt wird, einen walzprofilierten Rohling (25) bildet, der einen zentralen Abschnitt (26), einen ersten äußeren Abschnitt (28) und einen zweiten äußeren Abschnitt (30) aufweist, die in Bezug auf den ersten äußeren Abschnitt (28) um den zentralen Abschnitt (26) herum gegenüberliegend angeordnet sind, wobei der zentrale Abschnitt (26) eine Dicke aufweist, die größer ist als eine Dicke des ersten äußeren Abschnitts (28) und des zweiten äußeren Abschnitts (30).
EP18174346.9A 2017-06-30 2018-05-25 Walzanlage zur herstellung eines rohlings mit variabler dicke und verfahren zur herstellung eines rohlings mit variabler dicke Active EP3421147B1 (de)

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