EP4180141A1 - Rolling method for producing profiled end products and rolling device - Google Patents

Abstract

Described and illustrated is a rolling process for producing profile end products (11, 11') from a metal flat product (8) by means of roll forming. So that a higher throughput can be achieved without disproportionate effort, it is provided that the flat metal product (8) is transported in a burnishing direction (RR) along a plurality of burnishing rollers (3) arranged one behind the other in such a way that the flat metal product (8) is in contact with the burnishing rollers (3), that the metal product (8) is deformed at least in sections through contact with the burnishing rollers (3), that the metal flat product (8) through contact with the burnishing rollers (3) gradually becomes an intermediate profile product (10, 10 ') is formed and that the intermediate profile product (10, 10') is divided into at least two end profile products (11, 11') in the longitudinal direction of the intermediate profile product (10, 10').

Description

The invention relates to a rolling method for producing profile end products from a metal flat product by means of roll forming. Furthermore, the invention relates to a burnishing device for producing profile end products from a metal flat product by means of roll forming with a plurality of burnishing rollers arranged one behind the other in a burnishing direction for forming the metal flat product into an intermediate profile product.

Roll forming, also known as rolling or roll profiling, is a manufacturing process that is regularly used to manufacture profiles and tubes from a flat metal product. Burnishing devices for carrying out such methods have also been known for a long time. Roll-formed components are used for a wide variety of purposes.

In known rolling processes, the flat metal product is typically provided as a coil and fed to the rolling device in an endless manner. Before the metal sheet is subjected to roll forming, recesses are often punched into the metal sheet. The flat metal product is then formed by roll forming. For this purpose, the flat metal product is gradually bent with the aid of several pairs of rollers arranged one behind the other in a line, through which the flat metal product is guided, until the desired final cross-section is reached. At the end of the line, the profile is cut to the desired length.

However, rolling devices are often relatively complex and expensive, but still only allow a limited throughput if the forces to be used for the roll forming are to be limited.

The present invention is therefore based on the object of designing and developing the burnishing method and the burnishing device of the type mentioned at the outset and previously explained in more detail in such a way that a higher throughput can be achieved without disproportionate effort.

• bei dem das Metallflachprodukt in einer Rollierrichtung entlang einer Mehrzahl von hintereinander angeordneten Rollierrollen transportiert wird,
• bei dem das Metallflachprodukt derart in Kontakt mit den Rollierrollen gelangt, dass das Metallfachprodukt durch den Kontakt mit den Rollierrollen wenigstens abschnittsweise umgeformt wird,
• beim dem das Metallflachprodukt durch den Kontakt mit den Rollierrollen schrittweise zu einem Profilzwischenprodukt umgeformt wird und
• bei dem das Profilzwischenprodukt in Längsrichtung des Profilzwischenprodukts in wenigstens zwei Profilendprodukte geteilt wird.

This object is achieved according to claim 1 by a rolling process for the production of profile end products from a metal flat product by means of roll forming,

• in which the flat metal product is transported in a burnishing direction along a plurality of burnishing rollers arranged one behind the other,
• in which the metal flat product comes into contact with the burnishing rollers in such a way that the metal product is deformed at least in sections through contact with the burnishing rollers,
• in which the metal flat product is gradually formed into an intermediate profile product through contact with the burnishing rollers and
• wherein the intermediate profile product is divided into at least two end profile products in the longitudinal direction of the intermediate profile product.

The stated object is also achieved in a roller burnishing device according to the preamble of claim 13 in that a dividing device for dividing the intermediate profile product into at least two end profile products is arranged in the roller burnishing direction after the burnishing rollers.

The invention has thus recognized that it is expedient first to roll form an intermediate profile product and then to produce individual profile end products from this intermediate profile product. In this way, several work steps for rolling several profile end products can be combined efficiently, so that an increase in throughput can be achieved. If two profile end products are made from the profile intermediate product, the cycle times for the production of the profile end products can be reduced by about half.

In a method according to the invention, a metal flat product, for example in the form of a sheet metal strip or a sheet metal blank or blank, is used to produce an intermediate profile product which has a profile in cross section which corresponds to a profile of two or more profile end products. By dividing the intermediate profile product in its longitudinal direction, two or more end profile products are obtained. In this way, several intermediate profile products can be produced in parallel on one burnishing device.

For the sake of better understanding and to avoid unnecessary repetition, the roller burnishing process and the roller burnishing device for producing profile end products from a metal flat product by means of roll forming are described together below, without distinguishing between the roller burnishing process and the burnishing device in detail. However, based on the context, it is clear to the person skilled in the art which feature is particularly preferred in each case with regard to the burnishing method and in regard to the burnishing device.

In a first particularly preferred embodiment of the roller burnishing process, the flat metal product is formed into an intermediate profile product that is at least essentially mirror-symmetrical and/or at least essentially point-symmetrical in cross section. Burnishing a correspondingly symmetrical intermediate profile product can contribute to a significant reduction in component stresses. In addition, a corresponding intermediate profile product can expediently be divided into two end profile products with a substantially identical cross section. In this way, two similar profile end products can be manufactured. Profile end products manufactured in this way are particularly suitable for use as components in which it is particularly important that two components have the same length. This is the case, for example, with the frame construction of box bodies for commercial vehicles, in which the length of opposite frame elements should be as identical as possible.

In addition to the positive effect on the tolerance dimensions of the profile end products, the burnishing rollers are less heavily loaded when burnishing intermediate profile products with an at least essentially mirror-symmetrical and/or at least essentially point-symmetrical cross section. As a result, the burnishing rollers can be made smaller. This in turn leads to cost advantages for corresponding rolling devices.

The flat metal product can expediently be reshaped into an intermediate profile product that is essentially U-shaped in cross section. A U-shaped profile intermediate product can be divided particularly easily into two L-shaped profile end products with essentially the same cross section, which are widely used in commercial vehicle construction.

With the roller burnishing process, particularly precise profile end products can be produced by guiding the flat metal product through a roller gap formed by a pair of roller burnishing rollers and thus forming it. Through contact with the pairs of rollers, the metal product is formed at least in sections, so that by guiding the metal flat product through the pairs of rollers arranged one behind the other, the metal flat product is gradually formed into an intermediate profile product. By guiding the flat metal product through a gap formed by a pair of burnishing rollers, the flat metal product can be formed particularly precisely, so that profiled end products can be manufactured with close tolerance limits. In addition, by guiding the metal flat product through roller gaps formed by pairs of rollers, profile end products with particularly small bending radii can be realized.

In order to produce profile end products with a high flexural strength, it has proven to be expedient if the metal flat product is at least partially shaped by the burnishing rollers in such a way that an intermediate profile product with an at least partially double-layered trained cross-section is obtained. Due to this double layer, profiles with material thicknesses can be manufactured in a simple manner, which otherwise could not be manufactured or only with considerable effort. The flat metal product is particularly preferably formed by the burnishing rollers in such a way that an intermediate profile product is obtained with a cross-section that is almost entirely double-layered. With an almost continuously double-layered cross-section, high flexural rigidity is ensured over the entire cross-section of the intermediate profile product.

In this context, it is of particular advantage if the intermediate profile product is divided into two profile end products at a section that is not formed in two layers. Sharing can be done very easily, gently and with little effort. By dividing the almost continuously double-layer profile intermediate product in a single-layer area, the profile end products have a satisfactory flexural rigidity almost throughout, without the intermediate profile product being difficult to divide into the profile end products.

Furthermore, it can be desirable if recesses and/or indentations are made in the flat metal product. Recesses are preferably introduced by punching. Advantageously, the recesses and/or indentations are made in the flat metal product before the flat metal product comes into contact with the burnishing rollers. Recesses and/or indentations can be made comparatively easily in a flat metal product, so that it is advantageous to carry out this method step before the roller burnishing.

The advantages of the method according to the invention are particularly evident when the intermediate profile product is separated into at least two end profile products by cutting rollers. The axis of rotation of the cutting roller used for this purpose is arranged transversely to the rolling direction. Using cutting rollers Long intermediate profile products can be continuously cut particularly easily and precisely. Alternatively, other cutting processes such as laser cutting can be used in this context.

To make the process even more efficient, the flat metal product can be pulled off a coil and brought into endless contact with the burnishing rollers. In this way, the cost of warehousing for stocking circuit boards can be saved. In addition, the packaging can take place very late in the process with regard to the component length, which can increase production flexibility. Alternatively, the flat material product can be provided as a circuit board. The use of circuit boards when carrying out the method according to the invention offers advantages in terms of flexibility, but is also associated with losses in productivity.

For certain applications it can be preferred if the metal flat product is brought into contact with the burnishing rollers as a coated metal flat product. For example, a zinc layer can have an advantageous effect on the quality of the profile end products in question here. A layer of zinc is suitable to protect the material of the profile end product from corrosion. Galvanizing of the profile end product is then typically no longer necessary.

Coated flat metal products are usually provided with the coating on their upper and lower surfaces. The edges usually have no coating, so that these edges are particularly exposed to environmental influences. These environmental influences lead to corrosion, for example. In order to better protect the edges of the profile end products from corrosion, it has proven to be expedient to separate profile intermediate products, which can have an almost continuously double-layered cross-section, at a non-double-layered section in a special way. This is because the severing can take place in such a way that the edge formed during the severing is at least partially bent around a previously existing edge. The pre-existing edge is the edge of the coil or board. In other words the formed edge is bent in the direction of the other edge by dividing, whereby the edge is covered in sections. This reduces the environmental influences on the uncoated edge. The area potentially affected by corrosion is thus reduced.

After being divided into at least two end profile products, the intermediate profile product can be cut to length transversely to the burnishing direction and/or the longitudinal extent of the intermediate profile product. This process step ensures that the profile end products have the desired length, and in particular the same length in pairs. The profile end products resulting from an intermediate profile product are therefore particularly preferably cut to length together.

In a first particularly preferred embodiment of the device for producing profile end products from a metal flat product by means of roll forming, the dividing device comprises at least one cutting roller, the axis of rotation of which is arranged transversely to the rolling direction. With a cutting roller arranged in this way, the profile end product can be divided particularly easily and precisely into at least two profile end products in the longitudinal direction of the intermediate profile product.

The forming of the flat metal product to form the intermediate profile product can be carried out particularly advantageously by a burnishing device whose burnishing rollers are arranged one behind the other as burnishing roller pairs, each with a roller gap between the burnishing rollers forming a pair. By guiding the flat metal product through the gap formed by a pair of rollers, the flat metal product can be bent particularly precisely. In this way, an intermediate profile product can be manufactured within narrow tolerance limits and with small bending radii.

Recesses and/or indentations can be introduced into the flat metal product in a particularly simple manner by means of a separating device arranged in front of the burnishing rollers in the burnishing direction. In front of the rolling rollers, that shows Flat metal product still has a flat shape, so that recesses and/or indentations can be introduced comparatively easily. The separating device is particularly preferably designed as a punch, which can efficiently introduce recesses into the flat metal product.

In addition, a cutting device for cutting the profile end product to length can be arranged after the dividing device in the rolling direction. With the cutting-to-length device, the profiled end products can be cut to the desired length transversely to the rolling direction and/or the longitudinal extension of the profiled end product, in particular in pairs.

Fig. 1

eine erfindungsgemäße Rolliervorrichtung in einer schematischen Darstellung in Seitenansicht,

Fig. 2A-E

jeweils ein Querschnitt eines Metallflachprodukts bei einem erfindungsgemäßen Verfahren, das schrittweise zu einem Profilzwischenprodukt bzw. einem Profilendprodukt umgeformt wird,

Fig. 3A-B

das Profilzwischenprodukt und das Profilendprodukt aus Fig. 2D-E in perspektivischer Ansicht und

Fig. 4

ein alternatives Profilzwischenprodukt in perspektivischer Ansicht.

The invention is explained in more detail below with reference to a drawing that merely shows exemplary embodiments. In the drawing shows

1

a rolling device according to the invention in a schematic representation in side view,

Figures 2A-E

in each case a cross section of a metal flat product in a method according to the invention, which is gradually formed into an intermediate profile product or a profile end product,

Figures 3A-B

the profile intermediate product and the profile end product Fig. 2D-E in perspective view and

4

an alternative profile intermediate product in perspective view.

In the 1 a roller-curling device 1 according to the invention is shown schematically in a side view. The roller burnishing device 1 comprises, each arranged one behind the other, a separating device in the form of a punch 2, a plurality of pairs of rollers 4 each formed from two roller burnishing rollers 3, a dividing device in the form of a cutting roller 5 and a cutting device 6.

A flat metal product 8 provided as a coil 7 is transported through the rolling device 1 in the rolling direction RR. The rolling direction RR corresponds to the longitudinal direction of the metal flat product 8. First, the metal flat product 8 is pulled off the coil 7 and guided through the punch 2, in which recesses 9, for example in the form of holes, are made in the metal flat product 8. The flat metal product 8 is then conveyed through the pairs of rollers 4 arranged one behind the other. The device for transporting the flat metal product 8 is not shown for the sake of clarity. The pairs of rollers 4 are arranged in such a way that the flat metal product 8 is gradually formed into an intermediate profile product 10 by contact with the pairs of rollers 4 . In a next step, the intermediate profile product 10 is separated in the longitudinal direction of the intermediate profile product 10 by the cutting roller 5 into two profile end products 11. The cutting roller 5 rotates in the roller burnishing direction RR about an axis of rotation 12 aligned transversely to the roller burnishing direction RR. At the end of the rolling device 1, the profile end products 11 are cut to the desired length by the cutting device 6. In this exemplary embodiment, the cutting-to-length device 6 comprises a cutting edge 13 which can be moved vertically up and down in the direction of the arrow, which is not identified in any more detail.

In the Figures 2A-E is shown schematically the forming of the metal flat product 8 in the rolling device 1 in a profile end product 11 .. In the Figures 2A-E each shows a cross section of the metal flat product 8 in different stages of the forming process. The forming takes place with a plurality of pairs of rollers 4, through which the flat metal product 8 is guided. The burnishing rollers 3 are not shown for the sake of clarity. In addition, several forming steps are combined.

The metal flat product 8 is first fed with a flat, horizontal cross-section and, as it passes through a plurality of roller nips formed by the pairs 4 of roller burnishing rollers 3, stepwise into a U-shaped profile reshaped cross section. This is particularly in the Figure 2A For this purpose, two outer sections 14 of the flat metal product 8 are bent upwards in the direction of the arrow, which is not identified in any more detail. The metal flat product 8 after this forming step is indicated by a dashed line in Figure 2A shown.

According to Figure 2B then two sections 15 of the U-shaped profile arranged at the upper edge are bent downwards in the direction of the arrow, not further identified, so that an H-shaped profile is formed. The H-shaped profile is double-layered in sections. Subsequently, two single-layer sections 16 of the profile arranged at the lower edge are bent upwards into the horizontal, so that an almost completely double-layered U-profile is produced, which corresponds to the intermediate profile product 10 .

The cross sections in the Figures 2A-C The profiles shown are essentially mirror-symmetrical at any point in time before the intermediate profile product 10 is divided into two end profile products 11 . The plane of symmetry 17 of the profiles is in the Figures 2A-C each shown as a dotted line.

Like this in the Fig. 2D-E shown, the U-shaped intermediate profile product 10 is then divided into two L-shaped end profile products 11 . For this purpose, the intermediate profile product 10 is severed in the middle in the longitudinal direction of the intermediate profile product 10 with the cutting roller 5 and is thus divided, so that two end profile products 11 with the same cross section are produced. The profile intermediate product 10 is divided along the area that is not double-layered.

The outer edges 18 of the flat metal product 8 that is shown and is preferred in this respect are uncoated. However, the top and bottom of the flat metal product 8 are coated, in particular galvanized. The coating of the metal flat product 8 is in the Figures 1-4 the better Not shown for the sake of clarity. At the in 2D In the intermediate profile product 10 shown, the edges 18 are arranged opposite one another on the lower side of the intermediate profile product 10 . When the intermediate profile product 10 is divided into two end profile products 11, a further cut edge 19 is produced on the end profile products 11, running in the longitudinal extension of the end profile product 11. When the intermediate profile product 10 is divided, the cut edge 19 is in the direction of the edge 18 already present on the edge of the metal flat product 8 bent. This is done in such a way that this edge 18 is placed at least in sections in contact with the edge formed during dividing. In the area of the installation, ie the covering, the original edge 18 is shielded from environmental influences by the edge adjoining the subsequently formed cut edge 19 . For example, moisture can come into contact with the edge 18 in this way, so that the risk of corrosion can be reduced.

In the Figures 3A-B are the profile intermediate product 10 and the profile end products 11 from the Fig. 2D-E shown in perspective view. In Figure 3A a dashed dividing line 20 is drawn in, which lies in the plane of symmetry of the intermediate profile product 10 . The intermediate profile product 10 is separated into two end profile products 11 along this dividing line 20, so that two mirror-image end profile products 11 with the same cross section are produced.

In 4 An alternative method of making an intermediate profile product 10' is shown. The cross section of this intermediate profile product 10' is essentially point-symmetrical with a center of symmetry 21. The intermediate profile product 10' is thus designed to be axially symmetrical. It can therefore be divided along a separating cut 20', in which the axis of symmetry of the intermediate profile product 10' is arranged. This results in two L-shaped profile end products 11', which essentially have the same cross section.

Reference List

1

rolling device

2

punch

3

roller

4

pair of rollers

5

cutting roller

6

cutting device

7

coil

8th

metal flat product

9

recesses

10, 10'

profile intermediate

11, 11'

profile end product

12

Axis of rotation of the cutting roller 5

13

cutting edge

14

section of the profile

15

section of the profile

16

section of the profile

17

plane of symmetry

18

edge

19

cutting edge

20

parting line

20'

parting cut

21

center of symmetry

RR

burnishing direction

Claims (15)

Rolling method for producing profile end products (11, 11') from a metal flat product (8) by means of roll forming, - in which the flat metal product (8) is transported in a burnishing direction (RR) along a plurality of burnishing rollers (3) arranged one behind the other, - in which the metal flat product (8) comes into contact with the burnishing rollers (3) in such a way that the metal product (8) is deformed at least in sections by contact with the burnishing rollers (3), - in which the metal flat product (8) is gradually formed into an intermediate profile product (10, 10') by contact with the burnishing rollers (3) and - in which the intermediate profile product (10, 10') is divided into at least two end profile products (11, 11') in the longitudinal direction of the intermediate profile product (10, 10'). Burnishing method according to claim 1,
in which the metal flat product (8) is formed into an intermediate profile product (10, 10') that is at least essentially mirror-symmetrical and/or at least essentially point-symmetrical in cross section and, preferably, into two end profile products (11, 11') with an essentially identical cross section is shared. Burnishing method according to claim 1 or 2,
in which the flat metal product (8) is formed into an intermediate profile product (10, 10') with a substantially U-shaped cross section. Burnishing method according to one of claims 1 to 3, in which the flat metal product (8) comes into contact with a roller nip formed by a pair (4) of burnishing rollers (3) for guiding the flat metal product (8) through in such a way that the flat metal product (8) through contact with the pairs (4) of Burnishing rollers (3) are reshaped at least in sections and in which the flat metal product (8) is gradually formed into an intermediate profile product (10, 10') by contact with the pairs (4) of burnishing rollers (3). Burnishing method according to one of claims 1 to 4,
in which the flat metal product (8) is shaped by the burnishing rollers (3) in such a way that an intermediate profile product (10, 10') is obtained with a cross-section that is at least partially, preferably almost continuously, double-layered. Burnishing method according to claim 5,
in which the intermediate profile product (10, 10') is divided into two end profile products (11, 11') at a non-double-layer section. Burnishing method according to one of claims 1 to 6,
in which, preferably before the metal flat product (8) comes into contact with the burnishing rollers (3), recesses (9) and/or indentations are introduced into the metal flat product (8), preferably stamped. Burnishing method according to one of claims 1 to 7,
in which the intermediate profile product (10, 10') is divided into at least two end profile products (11, 11') by cutting rollers. Burnishing method according to one of claims 1 to 8,
in which the metal flat product (8) is drawn off a coil (7) and endlessly in is brought into contact with the burnishing rollers (3). Burnishing method according to one of claims 1 to 9,
in which the metal flat product (8) as a coated metal flat product (8) is brought into contact with the burnishing rollers (3). Burnishing method according to claims 6 and 10,
in which the flat metal product (8) is bent at least in sections around an edge (18) present on the edge of the coated flat metal product (8) when the intermediate profile product (10, 10') is divided into two end profile products (11, 11'). Burnishing method according to one of claims 1 to 11,
in which the intermediate profile product (10, 10') is cut to length transversely to the rolling direction (RR) and/or the longitudinal extent of the intermediate profile product (10, 10') after it has been divided into at least two end profile products (11, 11'). Burnishing device for producing profile end products (11, 11') from a flat metal product (8) by means of roll forming, preferably using a burnishing method according to one of claims 1 to 12, with a plurality of burnishing rollers (3) arranged one behind the other in a burnishing direction (RR) for forming the metal flat product (8) to form an intermediate profile product (10, 10'),
characterized in that
a dividing device for dividing the intermediate profile product (10, 10') into at least two end profile products (11, 11') in the longitudinal direction of the intermediate profile product (10, 10') is arranged downstream of the rollers (RR) in the roller burnishing direction. Burnishing device according to claim 13,
characterized in that
the dividing device comprises at least one cutting roller (5) whose axis of rotation (12) is arranged transversely to the roller burnishing direction (RR), and/or that the roller burnishing rollers (3) are roller burnishing pairs (4) each with a roller gap between the rollers forming a pair (4). Burnishing rollers (3) are arranged one behind the other. Burnishing device according to one of claims 13 or 14,
characterized in that
A separating device, preferably a punch (2), for making recesses (9) and/or indentations in the metal flat product (8) is arranged in the rolling direction (RR) before the rolling rollers (3) and/or in the rolling direction (RR) after the A cutting-to-length device (6) for cutting the profile end product (11, 11') to length is arranged in the dividing device.

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