JP2009056487A - Method and apparatus for manufacturing material having profile cross section - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To manufacture a material having a profile cross section with flanges at both the end portions of the same with good dimensional precision, in stable condition and at low cost by employing a simple means. <P>SOLUTION: A flat raw plate is subjected to: a first preliminary forming for providing a C-shape warp such that the edge portions face in a direction erecting the flanges by the right and left side rolls having substantially V-shape grooves; a second preliminary forming for curving upward the center of the plate provided with the C-shape warp by the upper roll provided with the convex portions at both the ends of the same and the lower roll provided with a convex portion having an upper flat portion with the width narrower than the distance between the convex portions in the center of the same; and thereafter passing through a four-directional roll forming machine with a profile according to the predetermined cross sectional shape and in which a pair of up and down horizontal rolls and a pair of right and left smooth vertical rolls are adjacently arranged. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method of manufacturing a deformed cross-sectional material having flanges at both ends with high dimensional accuracy and low cost, and an apparatus therefor.

The cross-sectional material having one or a plurality of the same cross-sectional shape in the width direction of the plate and the center-side thick part and the end thick part and the thin part located at both ends are continuously connected via stepped parts, for example, Widely used in bearing retainers and lead frames.
And as a method for producing such a modified cross-section material, various methods have been proposed for roll forming using a grooved roll or a ridged roll having grooves and ridges of a desired shape on the surface.
When manufacturing an irregular cross-section strip by a conventional roll forming method, a stepped portion having a significantly different inclination angle is easily formed between the thick portion and the thin portion. Each thick part did not correspond to the recess depth of the grooved roll or the ridged roll, and the thickness was different.

In order to solve the above-mentioned problems, the applicant also uses a roll with a ridge that has a profile designed so that the metal flow in each thick part is uniform, so that each thick part has insufficient thickness. Patent Documents 1, 2 and the like have proposed a method for obtaining a deformed cross-section having a good shape accuracy with a constant inclination angle of the stepped portion without causing any problems.
And after obtaining a deformed cross-section plate material formed into a cross-sectional shape corresponding to the roll profile by roll-forming a metal plate material using a roll of a profile in which grooves and projections of a predetermined shape are formed, the predetermined width strip It is slit and used for various applications such as bearing retainers and lead frames.
JP-A-6-328153 JP-A-8-155576

A deformed cross-section material as shown in FIG. 1, which is formed with high accuracy by the above method and then slit and provided with predetermined corners R at both end edge portions, is preferably used for a bearing retainer or the like.
However, due to the recent demand for weight reduction by increasing the strength of each member, it is desired to increase the strength of the deformed cross-section material for the bearing retainer. Since the increase in strength of the material itself rebounds greatly in cost, the strength is increased by changing the shape of the irregular cross-section material.
For example, as shown in FIG. 2, there has been proposed an apparatus having flanges at both ends and having recesses and protrusions formed on both surfaces in the plate thickness direction so that the cross section is formed into an M shape. Higher strength is achieved by flanges at both ends.

As a method for producing such an M-shaped modified cross-section material, it is assumed that multistage forming is performed by upper and lower horizontal rolls. However, when the flange is low, it is difficult to form by multistage forming. In addition, when the flange is high, it can be formed into a desired shape by multi-stage forming. However, the number of processing steps is increased, and the roll recombination work load corresponding to the shape is increased, resulting in poor productivity.
Therefore, it was decided to perform four-direction roll rolling. However, if the four-direction roll rolling is performed directly from a flat metal plate, the material is extended in the longitudinal direction, so that it is difficult for the material to enter the flange portions at both ends. Therefore, the flange cannot be formed sufficiently.

  The present invention has been devised to solve such a problem, and an odd-shaped cross-section material having flanges at both ends is simply and stably manufactured at low cost with dimensional accuracy by adopting means. For the purpose.

In order to achieve the object, the method for producing a modified cross-section material according to the present invention imparts a C-warp to the flat material plate so that the edge portion faces the direction in which the flange is raised by the left and right side rolls having substantially V-shaped grooves. The C-warp is given by the first preform to be formed, and the upper roll provided with convex portions at both ends and the lower roll provided with the convex portion having the upper flat portion having a width narrower than the interval between the convex portions in the center. Four-direction roll rolling in which a pair of upper and lower horizontal rolls and a pair of smooth left and right vertical rolls arranged adjacent to each other in a profile corresponding to a predetermined cross-sectional shape are subjected to second preforming for bending the center of the rolled plate upward Through the machine, it is characterized in that a modified cross-section material having flanges at both ends is manufactured.
It is preferable to provide a gap for forming a flange between the upper horizontal roll and the left and right vertical rolls.
Further, when performing the first preforming with the left and right side rolls having a substantially V-shaped groove, it is preferable to use a side roll in which the upper cut angle that forms the wall forming the substantially V-shaped groove is sharper than the lower cut angle. .

The modified cross-section material manufacturing apparatus of the present invention is narrower than the first preforming machine having left and right side rolls having substantially V-shaped grooves, the upper roll having convex portions at both ends, and the interval between the convex portions. A second preforming machine provided with a lower roll provided with a convex portion having an upper flat portion in the center, a pair of upper and lower horizontal rolls and a pair of smooth left and right vertical rolls according to a predetermined cross-sectional shape; The four-direction roll mills that are adjacent to each other are arranged in series.
It is preferable to arrange a four-way roll mill in which a gap for forming a flange is provided between the upper horizontal roll and the left and right vertical rolls.
Moreover, it is preferable to arrange | position the roll which made the upper cutting angle which forms the wall which forms a substantially V-shaped groove sharper than the lower cutting angle as the left and right side roll which comprises a 1st preforming machine.

  In the production method of the present invention, a flat material plate is passed through a four-way roll mill in which a pair of upper and lower horizontal rolls arranged in a predetermined profile and a pair of flat left and right vertical rolls are arranged adjacent to each other. When producing the cross-sectional material, by performing the first and second preforming to give a predetermined preliminary processing to the raw material plate, the material inflow to the flange portion formed at both ends is smoothly performed. It becomes possible to manufacture a modified cross-section material with excellent dimensional accuracy at low cost.

  As described above, the present inventors directly use a flat metal plate as a material, and directly by a four-way roll mill in which a gap capable of forming a flange is provided between a horizontal upper roll and a vertical side roll. I tried rolling. And when the cross section was observed, the desired flange part was not formed as shown in FIG. In addition, the biting of the material occurred, and the end portion was distorted. This is presumably because the material was not stably supplied to the gap provided to form the flange, the material was difficult to enter the flange forming gap at both ends, and the flange could not be molded sufficiently.

In view of this, a means for making it easier for the material to enter the flange forming gap was examined.
As a result, it has been found that it is effective to pre-form the material plate into a shape that easily enters the gap before rolling with a four-direction roll mill. That is, it has been found that it is effective to curve both ends of a flat material plate in advance in the direction in which the flange extends in order to facilitate the insertion of both ends of the flat material plate into the flange forming gap.
Hereinafter, a method of bending in advance will be described.

As a means for bending, a two-stage preforming means is adopted.
First, as shown in FIG. 4, first preforming is performed by using a side roll having a substantially V-shaped groove on a flat material plate and imparting C warpage by reduction in the plate width direction. At this time, a side roll having an upper cutting angle (θ _{1 in} FIG. 4) that forms the wall forming the substantially V-shaped groove is smaller than a lower cutting angle (θ _{2 in} FIG. 4), that is, a vertically asymmetric groove shape. By using it, it is possible to give a convex C-warp shape to the lower side where the end portion is preferentially curved (in this case, the upper side) in the direction in which the warp direction of the material is smaller.

Next, the center of the plate provided with the C warp by the upper roll provided with convex portions at both ends and the lower roll provided with the convex portion having the upper flat portion having a width narrower than the interval between the convex portions at the center. In contrast to the C warp, the second preforming is performed to bend upward.
Specifically, as shown in FIG. 5, the lower roll provided with a convex portion having an upper flat portion at the center portion while restraining both ends of the material plate with an upper roll provided with convex portions at both ends, the C The center of the warped plate is bent upward. It is molded so as to have a so-called W-shaped cross section. At this time, since the convex portion provided at the center portion of the lower roll is provided with the upper flat portion, it comes into two-point contact with the material plate. Therefore, the shift and inclination in the plate width direction are suppressed as compared with the one-point contact.

In addition, the convex part provided in the lower roll does not make it easy to form the central convex part of the irregular cross-section material as shown in FIG. It is intended to bend the central portion of the plate without causing a shift or inclination in the plate width direction by two-point contact.
The material plate after the second preforming has been bent at the center, but after passing through the preforming machine, the spring back is raised and the degree of curvature is reduced. It becomes larger than that at the time of pre-molding, and as a whole, it becomes a wavy cross-sectional shape in which curved portions exist only at both ends, so-called W-shaped cross-sectional shape.

Then, as shown in FIG. 6, the raw material board in which the curved part was formed only in the both ends is rolled with a four-way roll mill.
At this time, if a gap for forming a flange is provided between the left and right vertical rolls as well as the end of the upper horizontal roll constituting the four-direction roll rolling mill, the gap is provided at both ends of the material plate. The bent portion is easy to enter, and flanges are easily formed at both ends of the material plate.
That is, as shown in FIG. 7, it is possible to obtain a deformed cross-sectional material with excellent dimensional accuracy in which a desired flange is formed without occurrence of biting.
In addition, although the attached figure has introduced a modified cross-sectional material having irregularities in the central part, the present invention only needs to have flanges at both ends, and the central part has an irregular shape. It is not limited to what is.

An apparatus for carrying out the method of the present invention is sufficient if it comprises a preforming machine for performing the first and second preforms arranged in series and a four-way roll mill capable of four-way rolling.
That is, a first preforming machine having left and right side rolls having substantially V-shaped grooves, a convex part having an upper roll having convex parts at both ends and an upper flat part having a narrower width than the distance between the convex parts. A four-direction roll rolling mill in which a second preforming machine having a lower roll provided at the center, a pair of upper and lower horizontal rolls and a pair of smooth left and right vertical rolls arranged in profile according to a predetermined cross-sectional shape are arranged adjacent to each other It is sufficient to arrange them in series.

However, in order to stably project the direction of the C warp to be formed downward, as the left and right side rolls constituting the first preforming machine, the upper cut angle that forms the wall forming the substantially V-shaped groove is set downward. It is preferable to arrange a roll that is sharper than the cutting angle.
In order to form a flange having excellent dimensional accuracy, it is preferable that a gap for forming a flange is provided between the upper horizontal roll and the left and right vertical rolls constituting the four-direction roll rolling mill. .

Actually, a metal coil slitted to a desired width is used as a raw material, and after being formed into a desired cross-sectional shape, it is wound up to be transported to a process that is processed into a bearing retainer or the like. Each device is preferably arranged in such a manner. Between the payoff reel 1 and the take-up reel 2, it is preferable to arrange in series the preforming machines 3 and 4 for performing the first and second preforming and the rolling mill 5 capable of four-way roll rolling.
Further, in order to further improve the shape accuracy and dimensional accuracy of the irregular cross-section material, it is preferable to provide a cross-section correction roll stand 6, an end flange correction side roll stand 7, and a camber correction roll stand 8. In FIG. 8, 9 is a guide roll.

Using an SPCC material having a plate thickness of 1.0 mm and a plate width of 28 mm as a material, a modified cross-section material having the shape shown in FIG.
Comparative Example First, the steel sheet that had been subjected to the first preforming shown in FIG. 4 and provided with C warpage was directly subjected to the four-direction roll rolling shown in FIG. At this time, the wall surface cut angle θ ₁ constituting the substantially V-shaped groove shown in FIG. 4 was 2 °, and θ ₂ was 25 °. And the preforming board which produced various changes in the amount of C curvature defined in Drawing 10 by adjusting the rolling force by a side roll was produced.

As a result, if the C warp was not applied at all, the flange could not be formed sufficiently, and biting occurred on the end surface opposite to the flange forming direction. Further, when the amount of C warp was small, the flange was not sufficiently molded, and a desired flange height could not be obtained. On the other hand, if the amount of C warp is too large, biting has occurred outside the front end of the flange.
Thus, it has been found that in order to obtain a desired flange height, it is important to adjust the amount of C warpage applied at the preliminary molding stage. Incidentally, in order to manufacture the odd-shaped cross-section material of the above size, the appropriate amount of C warp was 2.2 to 3.0 mm. However, details will be described in the examples described later, but even if the C warp amount of 2.2 to 3.0 mm considered to be appropriate is given, a stable and stable flange height cannot be obtained. .

EXAMPLE As described above, after confirming that the adjustment of the amount of C-warp application at the pre-forming stage is important for obtaining a desired flange height, it is shown in FIG. 5 after the first pre-forming. A second preform was performed. At this time, as the upper roll, a roll having a height of 2 mm and an interval of 24 mm formed with convex portions on both ends was used, and the center of the steel sheet in the width direction of the steel sheet was pressed upward by the lower roll while restraining both ends of the C-warped steel sheet. .
As shown in FIG. 11, the cross-sectional shape of the steel sheet after the second pre-forming is a shape in which curved portions exist only on both end sides. When the waviness amount was defined as shown in FIG. 11, a two-stage pre-formed steel sheet having the waviness amount of 2.4 mm was rolled in four directions as shown in FIG.

And the flange height was continuously measured about each test material.
The result is shown in FIG. In addition, in FIG. 12, the result of the test material which carried out the four-way roll rolling directly without performing the 2nd preforming also shown the C warpage provision steel plate of the curvature amount 2.2mm examined by the said comparative example is also shown. .
As is clear from the results, a stable flange height is continuously obtained by performing the four-direction roll rolling after the second preforming after the first preforming.
On the other hand, it is understood that when the four-direction roll rolling is performed as it is after simply imparting the C warp, the flange height gradually becomes unstable.

Diagram explaining the shape of general irregular cross-section material Sectional drawing explaining the shape of the irregular cross-section material of this invention Cross-sectional view introducing examples of shape defects that are likely to appear in the irregular cross-section material of the present invention The figure explaining the outline of the present invention first preforming The figure explaining the outline of this invention 2 preforming The figure explaining the outline of 4 direction roll rolling The figure explaining the flange shape of the irregular section material obtained by the method of the present invention The figure explaining the arrangement | positioning condition of the apparatus for manufacturing an irregular cross-section material by the method of this invention Sectional drawing explaining the shape of the irregular cross-section material produced in the Example The figure which defines the amount of C warp of the steel plate which gave C warp The figure explaining plate | board cross-sectional shape after giving the 2nd preforming of this invention method The figure which shows the stable formability of the flange height accompanying adoption of pre-forming

Claims (6)

  A first preform for imparting C warpage so that the edge portion is oriented in the direction of raising the flange by left and right side rolls having substantially V-shaped grooves, and an upper roll provided with convex portions at both ends; After performing the second preforming to curve upward the center of the plate provided with the C warp, by the lower roll provided in the center with a convex portion having an upper flat portion with a width narrower than the interval between the convex portions, A modified cross-section material having flanges at both ends is manufactured through a four-way roll mill in which a pair of upper and lower horizontal rolls and a pair of smooth left and right vertical rolls having a profile corresponding to a predetermined cross-sectional shape are arranged adjacent to each other. The manufacturing method of the irregular cross-section material.   The method for producing a modified cross-section material according to claim 1, wherein a gap for forming a flange is provided between the upper horizontal roll and the left and right vertical rolls.   3. When performing the first preforming with the left and right side rolls having a substantially V-shaped groove, a side roll is used in which the upper cut angle that forms the wall forming the substantially V-shaped groove is sharper than the lower cut angle. The manufacturing method of the odd-shaped cross-section material as described in 2.   A first preforming machine having left and right side rolls having substantially V-shaped grooves, an upper roll provided with convex portions at both ends, and a convex portion having an upper flat portion having a width narrower than the interval between the convex portions. A four-direction roll rolling machine in which a second pre-forming machine having a lower roll provided in the above and a pair of upper and lower horizontal rolls and a pair of smooth left and right vertical rolls having a profile corresponding to a predetermined cross-sectional shape are arranged in series An apparatus for producing a modified cross-section material, characterized in that it is arranged.   The manufacturing apparatus of the irregular cross-section material of Claim 4 which has arrange | positioned the 4-direction roll rolling mill by which the space | gap for flange formation was provided between the upper horizontal roll and the right-and-left vertical roll.   The variant according to claim 4 or 5, wherein the left and right side rolls constituting the first preforming machine are provided with rolls having an upper cut angle that forms a wall that forms a substantially V-shaped groove, which is sharper than the lower cut angle. Cross-section material manufacturing equipment.

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