JP2000246346A - Manufacture of curved material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily lessen dispersion of warpage size after bend processing without frequently adjusting height of a guide by removing a residual stress of a raw material through a leveler composed of a roll group arranged in zigzag before the raw material, which is wind-released from a raw material coil, is curved and deformed in its width direction by means of a pair of pore mold rolls. SOLUTION: After a raw material metallic plate 1 is heated for baking a coating film in a coating line, a coating film is formed on the surface. Then, the raw material metallic plate 1 is picked up in a given direction while a tension is provided by a tension reel via a supply roll 2. The metallic plate 1 is passed in zigzag between small diameter rolls 6a of a leveler 6, so as to remove winding forms, and to reduce warpage and the size of the residual stress. The metallic plate 1 passes through a pore mold roll group 4a of a molding stand group 4 while height of a passline is adjusted by a guide 3, so as to be sequentially bent in a width direction, and is molded into an arc cross sectional shape.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a curved material obtained by bending a material in the width direction by using a pair of hole-shaped rolls whose diameter changes in the axial direction, and in particular, the magnitude of warpage after bending. The present invention relates to a method for manufacturing a curved material capable of easily reducing the variation in height.

[0002]

2. Description of the Related Art Heretofore, slat materials having an arc-shaped cross section have been used for window blinds and the like. The slat material is formed, for example, by bending an aluminum alloy plate or the like having a coating film formed on the surface into an arc-shaped cross section using a roll. The material is not limited to the aluminum alloy plate, but may be another metal plate or an alloy plate (hereinafter simply referred to as a material metal plate). FIG. 6 is a schematic view showing a conventional bending material manufacturing apparatus. FIG. 7 is a schematic diagram showing a grooved roll. FIG. 8 is a graph showing the relationship between the bending moment in the longitudinal direction and the bending moment applied to the material metal plate in the process of forming the slat material.

As shown in FIGS. 6 and 7, in a conventional bending material manufacturing apparatus, a coating line (not shown) for forming a coating film on the surface of a material metal plate 1 and a coating film are formed. A plurality of supply rolls 2 for winding the material metal plate 1 (to make a coil shape) and a tension reel (not shown) for pulling the material metal plate 1 in a predetermined direction while applying tension thereto are provided. Between the supply roll 2 and the tension reel, a forming stand group 4 including a plurality of grooved roll groups 4a is provided. In the case of a hole-shaped roll, FIG.
As shown in FIG. 5, a pair of concave rolls 7 and convex rolls 8 having a rotation axis arranged horizontally are provided. The concave roll 7 is composed of a roll portion 7a having a small diameter at the center of the shaft and a large diameter at the shaft end, and a roll shaft 7b serving as a rotation shaft. Similarly, the convex roll 8 corresponds to the shape of the roll portion 7a. As shown in the figure, a roll part 8a having a large diameter at the center of the shaft and a small diameter at the end of the shaft is provided with a roll shaft 8b serving as a rotating shaft. By passing the material metal plate 1 between the roll portion 7a and the roll portion 8a of the grooved roll, the material metal plate 1 is curved and deformed in the width direction to be formed into an arc-shaped cross section. .

[0004] A guide 3 for adjusting the height of the pass line of the material metal plate 1 is provided between the supply roll 2 and the forming stunt group 4. This guide 3 adjusts the height of the pass line by adjusting its own position (height).

[0005] Further, a cutting machine 5 (for example, a shear type cutting machine) for cutting the material metal plate 1 formed into an arc-shaped cross section into a predetermined size is provided between the forming stand group 4 and the tension roll. ing.

A process for manufacturing a slat material using the manufacturing apparatus having the above-described configuration will be described below.

First, the raw metal plate 1 is heated to bake a coating film on a coating line, and then a coating film is formed on the surface. Next, the material metal plate 1 is pulled in a predetermined direction while being tensioned by a tension reel via a supply roll 2. Next, the height of the pass line is adjusted by the guide 3 and the material metal plate 1 is sequentially bent in the width direction through the grooved roll group 4a of the forming stand group 4 and formed into an arc-shaped cross section. Next, the slat material 1a is obtained by being cut into a predetermined size by the cutting machine 5.

At this time, the raw metal plate 1 is slightly deformed due to bending deformation in the longitudinal direction, and warpage remains after molding. As shown in FIG. 8, the relationship between the bending curvature and bending moment in the longitudinal direction and the residual warpage (represented by the residual curvature) differs depending on the height of the guide. A ₁ , A _{2 in the} figure
And A ₃ indicate that the maximum bending curvature changes according to the change in the height of the guide, and B ₁ , B ₂ and B _{3 in} the figure indicate residual curvatures corresponding to A ₁ , A ₂ and A ₃ respectively.

FIG. 9 is a graph showing the relationship between the bending moment and the bending moment in the longitudinal direction when the material metal plate has an initial curvature and when it has no initial curvature. FIG. 10 is a graph showing the relationship between the bending moment in the longitudinal direction and the bending moment when the material metal plate has and has no residual stress.

[0010] The metal sheet for slat material is heated to bake a coating film on a coating line, is given a high tension, is bent by a plurality of deflector rolls, and is wound up by a tension reel. During the process, warpage and residual stress are formed in the material metal plate. In general, when the bending curvature applied to the material metal plate (material) is sufficiently large, the influence of the warpage and residual stress of the material metal plate on the magnitude of the warpage remaining on the metal plate after bending is small. small. However, in the case of forming a slat material, it is considered that the bending deformation in the longitudinal direction caused by adjusting the height of the pass line is extremely small, and occurs near the elastic deformation limit. Therefore, as shown in FIG. 9, the warpage of the material metal plate before molding is reflected on the warpage after molding. The line connecting C ₄ -A ₄ -B ₄ indicates the case where the material before molding is warped, and O (origin) -A ₅ -B ₅
Indicates the case where the material before molding has no warpage.

Further, when there is residual stress in the material metal plate,
Since plastic deformation starts even with a smaller bending curvature,
As shown in FIG. 10, in a region where the bending curvature is small, the relationship between the bending curvature and the bending moment is different from that of a material having no residual stress. The line connecting O (origin) -A ₆ -B ₆ indicates the case of a material having no residual stress.
₇ connecting -B ₇ lines indicate the case of a material with residual stress. As described above, the slat material varies depending on the magnitude of the residual stress of the material.

Further, it has been found that the warpage of the slat material is affected by the thickness of the coating film formed on the surface of the metal plate.

For this reason, when slats are manufactured using the conventional bending material manufacturing apparatus shown in FIG. 6, the amount of warpage of the slat material generated after forming by the group of grooved rolls depends on the material metal plate before forming. Warpage, residual stress and thickness of the coating film. Since it is difficult to make the operating conditions of the coating line the same from the leading end to the trailing end of all the material coils, warpage of the material coils, residual stress and variations in the thickness of the coating film inevitably occur. In order to use slat materials for blinds, it is required that the amount of warpage in the longitudinal direction is within a predetermined standard.In actual operation, the height of the guide is changed by changing the height of the guide. The height is adjusted to reduce the variation in the amount of warpage of the slat material after bending.

[0014]

However, in order to keep the warp of the slat material within the standard, it is necessary to adjust the position (height) of the guide every time the material coil changes, If the warpage, residual stress and coating thickness vary greatly within the same coil, it is necessary to adjust the position of the guide even during the use of the same coil. As described above, there is a problem that the height of the guide needs to be frequently adjusted in order to keep the magnitude of the warp of the slat material after bending within the standard. To adjust the height of the guide, for example, first set the initial height to an appropriate height, perform bending of the material metal plate, and then confirm the amount of warpage of the slat material after bending, and check the size. If is not within the predetermined target value, the operation of correcting the height of the guide again is performed until the magnitude of the warp is within the target value, so the height of the guide is frequently adjusted. It is extremely undesirable. As a result, productivity and yield of the slat material are also reduced.

In order to solve the above-mentioned problems, there has been proposed a method in which a material is formed into a target cross-sectional shape and the warpage of the formed product is corrected by a pair of correction rolls (Japanese Utility Model Publication No. 61-16886). Gazette).

In the method for correcting the warpage of a molded article as described above, for example, a material metal plate having a relatively thick wall and a cross-sectional shape having a large moment of inertia is corrected after forming. Therefore, it is expected that the height adjustment of the guide for compensating for the warpage and the variation of the residual stress of the material is not required.

However, when this method is applied to a slat material, the slat material has a very small thickness, the cross-sectional arc depth is as small as about 1% of the arc radius, and the secondary moment of area is also small. For this reason, it has been found that the material metal plate buckles between the straightening rolls, and it is difficult to impart longitudinal deformation to the slat material while maintaining the original cross-sectional shape. As described above, the above-described method of correcting warpage after molding cannot be applied to a slat material.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and a curvature which can easily reduce the variation in the magnitude of the warpage after the bending without frequently adjusting the height of the guide. An object of the present invention is to provide a method for manufacturing a material.

[0019]

A method of manufacturing a curved material according to the present invention comprises the steps of unwinding a material from a material coil and passing the material through a leveler comprising a group of rolls arranged in a zigzag pattern. And a step of obtaining a curved material by curving the material in the width direction with a pair of hole-shaped rolls whose diameter changes in the axial direction.

In this case, the hole type roll pair is composed of a first roll having a large diameter at the center of the shaft and a small diameter at the shaft end, and a second roll having a small diameter at the center of the shaft and a large diameter at the shaft end. It can be opposite to the direction.

Further, the curved material may be a slat material curved in an arc shape in the width direction.

Further, after the material has passed through the leveler,
Before entering the grooved roll, it passes through a guide, and the guide is configured so that the material pass line is displaced in one direction from a reference path line determined by the leveler and the grooved roll. be able to.

In this case, the direction of displacement of the pass line by the guide may be on the outer surface side of the material curved by the hole type roll.

The displacement of the pass line by the guide is -20 to + 20 ° with respect to the reference pass line.
It is preferred that

Further, the leveler has a plurality of rolls arranged so that the rolling contact lines with the material are staggered in the longitudinal direction of the material. It is preferable that the size of the intermesh when the intermesh is defined as a distance staggered from the pass line is 3 mm or more.

In the present invention, a step of removing the residual stress by passing the raw material through a leveler composed of a group of rolls arranged in a zigzag pattern is included. The variation in the magnitude of the warp of the curved material can be easily reduced without frequently displacing the pass line by the guide. Thereby, the dimensional accuracy of the curved material can be improved, and the productivity and yield can be improved.

[0027]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for manufacturing a curved member according to an embodiment of the present invention will be specifically described below with reference to the accompanying drawings. FIG. 1 is a schematic diagram showing a manufacturing apparatus used in a method for manufacturing a curved material according to an embodiment of the present invention. 2A and 2B are diagrams showing a leveler, FIG. 2A is a schematic diagram showing the entire leveler, and FIG. 2B is a schematic diagram showing an intermesh δ of the leveler.

As shown in FIG. 1, in the manufacturing apparatus used in the method of manufacturing a curved material according to the present embodiment,
A coating line (not shown) for forming a coating film on the surface of the substrate, a plurality of supply rolls 2 for winding (forming a coil) the material metal plate 1 on which the coating film is formed, and tension on the material metal plate 1 And a tension reel (not shown) that pulls in a predetermined direction while applying the tension. Between the supply roll 2 and the tension reel, a forming stand group 4 including a plurality of grooved roll groups 4a is provided. In the grooved roll, a pair of concave rolls (second rolls) 7 and convex rolls (first rolls) 8 whose rotation axes are arranged horizontally are provided (see FIG. 7). The concave roll 7 is composed of a roll part 7a having a small diameter at the center of the shaft and a large diameter at the end of the shaft, and a roll shaft 7b serving as a rotating shaft.
In order to correspond to the shape of the roll portion 7a, a roll portion 8a having a large diameter at the center of the shaft and a small diameter at the shaft end and a roll shaft 8 serving as a rotating shaft.
b. The roll part 7 of this grooved roll
By passing the material metal plate 1 between a and the roll portion 8a, the material metal plate 1 is curved and deformed in the width direction and is formed into an arc-shaped cross section.

A guide 3 for adjusting the height of the pass line of the metal plate 1 is provided between the supply roll 2 and the forming stunt group 4. This guide 3 adjusts the height of the pass line by adjusting its own position (height). The guide 3 causes the material pass line to be displaced in a direction more constant than the reference pass line determined by the leveler 6 and the hole type roll group 4a. This displacement is an angle formed by the material (pass line) with respect to the reference pass line, and is preferably within ± 20 ° vertically.

Further, a leveler 6 having a plurality of small-diameter rolls 6a is provided between the supply roll 2 and the guide 3. As shown in FIG. 2A, in the leveler 6, a plurality of small-diameter rolls 6 a are arranged in a zigzag shape in a side view, and the raw metal plate 1 is passed between the small-diameter rolls 6 a to form the raw metal plate 1. By taking the curl, it is possible to reduce the amount of warpage and residual stress. As shown in FIG. 2 (b), when the height difference between the lower end of the small-diameter roll disposed above and the upper end of the small-diameter roll arranged below is defined as an intermesh (δ), By increasing or decreasing the size of the mesh, the effect of reducing the magnitude of warpage and residual stress increases or decreases.

Further, between the forming stand group 4 and the tension roll, a raw metal plate 1 formed in an arc-shaped cross section is provided.
There is provided a cutting machine 5 (for example, a shear type cutting machine) that cuts into a predetermined size. The guide 3 may be provided after the group of molding stands.

A method of manufacturing a slat material using the manufacturing apparatus configured as described above will be described below.

First, the raw metal plate 1 is heated to bake a coating film on a coating line, and then a coating film is formed on the surface. Next, the material metal plate 1 is pulled in a predetermined direction while being tensioned by a tension reel via a supply roll 2. Next, the material metal plate 1 is meandered between the small-diameter rolls 6a of the leveler 6, thereby removing the curl and reducing the amount of warpage and residual stress. Next, the height of the pass line of the material metal plate 1 is adjusted by the guide 3, and
a, and is sequentially bent in the width direction to be formed into an arc-shaped cross section. After that, the slat material is cut by the cutting machine 5 into a predetermined size.

In the present embodiment, the level of the warp and the residual stress of the raw metal plate 1 are reduced by the leveler 6 before bending in the forming stand group 4. Can be reduced. In addition,
If the size δ of the intermesh of the leveler 6 is less than 3 mm, the effect of reducing the magnitude of the warp and the residual stress of the material metal plate 1 before bending is not sufficient, so that the size δ of the intermesh is 3 mm or more. It is preferable that
This makes it possible to easily reduce the variation in the magnitude of the warpage after bending without frequently adjusting the height of the guide. Thereby, the dimensional accuracy of the slat material is improved, and the productivity and the yield can be improved.

Although the method of this embodiment is applied to the formation of a slat material having a circular arc cross section, the present invention is not limited to this, and can be applied to a curved material having a cross section other than a circular arc. . In the present embodiment, the leveler 6
Is provided between the supply roll 2 and the guide 3,
The present invention is not limited to this, and may be provided in front of the molding stand group.

[0036]

EXAMPLES In order to confirm the effects of the present invention, the following Table 1 was used.
A test was performed under the conditions shown below.

[0037]

[Table 1]

As shown in Table 1 above, CASE1
Does not correct the warpage of the material before molding (the leveler is not used). On the other hand, CASE2 and C
In ASE3, warpage of the material is corrected before molding using a leveler. CASE2
In, the leveler intermesh is 1.5 mm, and in CASE3, the leveler intermesh is 3.0 mm. FIG. 3 is a graph showing the relationship between the level δ of the intermesh of the leveler and the degree of warpage of the material after leveler correction.

As shown in FIG. 3, as the size δ of the intermesh increases, the magnitude of the warpage after leveler passing (correction) decreases, and therefore, the magnitude of the warpage varies before passing. However, the variation is reduced after the leveler is passed. Note that in FIG.
The test was performed using two types of coils, and ○ and Δ are data on these two types of coils. Similarly, it is considered that the variation in the magnitude of the residual stress formed in the material is reduced by increasing the size of the intermesh.

FIG. 4 is a graph showing the relationship between the guide height and the degree of warpage of the slat material. Further, FIG. 5 is a graph showing the relationship between the molding conditions and the optimum guide heights H ₀ of the slat material.

As shown in FIG. 4, the relationship between the height of the guide and the amount of warpage of the slat material is substantially linear, and by adjusting the height of the guide, the warpage of the target size can be reduced. It can be seen that it can be given to

Next, in the case where a leveler is installed in front of the hole-shaped roll group and the slat material after the leveler is passed is bent, guides necessary for setting the magnitude of warpage of the slat material to a target value are set. The height was investigated. As shown in FIG.
In CASE1, optimum guide heights H ₀ in order to obtain a warp of magnitude of the target value varies to reflect the variation in the warping and residual stress with the material. On the other hand, CASE2
In the above, the leveler is passed through before forming, but the intermesh δ is small, the variation in the warpage and residual stress of the material is not sufficiently reduced, and the optimal guide height H is the same as in CASE1. The value of ₀ fluctuates. Also,
In CASE3, intermesh δ is large,
Since the variation in the warpage and residual stress of the material is sufficiently reduced and the optimal guide height H ₀ is almost constant, the height of the guide can be maintained even if there is variation in the warpage and residual stress of the material. It can be seen that a slat material having a small variation in the amount of warpage can be obtained without adjustment.

[0043]

As described in detail above, according to the present invention,
Since the method includes a step of removing the residual stress by passing the material through a leveler composed of a group of rolls arranged in a staggered manner, the pass line is frequently displaced by a guide as in a conventional method of manufacturing a curved material. Without this, it is possible to easily reduce the variation in the amount of warpage of the curved material. Thereby, the dimensional accuracy of the curved material can be improved, and the productivity and yield can be improved.

[Brief description of the drawings]

FIG. 1 is a schematic view showing a manufacturing apparatus used in a method for manufacturing a curved material according to an embodiment of the present invention.

2A and 2B are diagrams illustrating a leveler, in which FIG. 2A is a schematic diagram illustrating the entire leveler, and FIG. 2B is a schematic diagram illustrating an intermesh δ of the leveler.

FIG. 3 is a graph showing a relationship between a leveler intermesh size δ and a level of warpage of a material after leveler correction.

FIG. 4 is a graph showing a relationship between a guide height and a degree of warpage of a slat material.

FIG. 5: Slat material forming conditions and optimal guide height H ₀
FIG. 6 is a graph showing the relationship between

FIG. 6 is a schematic view showing a conventional bending material manufacturing apparatus.

FIG. 7 is a schematic view showing a grooved roll.

FIG. 8 is a graph showing a relationship between a bending curvature in a longitudinal direction and a bending moment applied to a material metal plate in a process of forming a slat material.

FIG. 9 is a graph showing a relationship between a bending moment and a bending moment in a longitudinal direction when a material metal plate has an initial curvature and when it has no initial curvature.

FIG. 10 is a graph showing a relationship between a bending moment in a longitudinal direction and a bending moment when a material metal plate has residual stress and when there is no residual stress.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1; Material metal plate 1a; Slat material 2; Supply roll 3; Guide 4; Forming stand group 4a; Die roll group 5; 8; convex roll

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Shohei Murakami 15 Kinuigaoka, Moka City, Tochigi Prefecture Inside Kobe Steel Moka Works (72) Inventor Shusuke Yanagi 1-5-5 Takatsukadai, Nishi-ku, Kobe City, Hyogo Prefecture 5 Kobe Steel, Ltd.Kobe Research Institute (72) Inventor Naoto Ota 4024 Nakatsu Sakuradai, Aikawa-cho, Aiko-gun, Kanagawa Prefecture Inside Nichibei (72) Inventor Nobuyuki Kikuchi 4024 Nakatsu-Sakuradai, Aikawa-cho, Aiko-gun, Kanagawa Prefecture F-term in Nichibei (reference) 4E003 AA02 BA11 4E063 AA01 BB05 MA10

Claims (7)

[Claims] A step of unwinding a material from a material coil;
A step of removing the residual stress by passing the material through a leveler comprising a group of rolls arranged in a staggered manner, and bending and deforming the material in the width direction by a pair of hole-type rolls whose diameter changes in the axial direction. And a step of obtaining a material. 2. The roll-shaped roll pair includes a first roll having a large diameter at the center of the shaft and a small diameter at the end of the shaft, and a second roll having a small diameter at the center of the shaft and a large diameter at the end of the shaft. The method for manufacturing a curved material according to claim 1, wherein the method is provided opposite to the above. 3. The method for manufacturing a curved material according to claim 1, wherein the curved material is a slat material curved in an arc shape in a width direction. 4. The material passes through a guide after passing through the leveler and before entering the roll-shaped roll, whereby the guide path of the material is determined by a reference path determined by the leveler and the roll-shaped roll. The method for manufacturing a curved material according to claim 1, wherein the bending material is displaced in one direction than the line. 5. The method for manufacturing a curved material according to claim 4, wherein the direction of displacement of the pass line by the guide is on the outer surface side of the material curved by the hole type roll. 6. The displacement of the pass line due to the guide,
The method according to claim 5, wherein the angle with respect to the reference pass line is -20 to +20 degrees. 7. The leveler according to claim 1, wherein a plurality of rolls are arranged such that a rolling contact line with the material is staggered in a longitudinal direction of the material. 2. The size of the intermesh when the intermesh is defined as a distance staggered from the pass line is 3 mm or more.
7. The method for producing a curved material according to any one of claims 6 to 6.