JP2010528862A - Assembly and method for press forming deformable material - Google Patents

Abstract

An assembly for press molding a deformable material, a first die array including a plurality of dies defining a first die profile, and a second die profile complementary to the first die profile A second die array that is complementary to the first die array and includes a plurality of dies, and a drive unit for driving at least one of the first die array and the second die array. In use, the plurality of dies in the first die array and the plurality of dies in the second die array sequentially transform the deformable material along the working length so as to transform the deformable material into a predetermined profile. The assembly that engages.
[Selection] Figure 4

Description

  The present invention relates to an assembly for pressing a deformable material and a method by which such an assembly can be used. More particularly, the present invention is an assembly for pressing a deformable material that includes a pair of opposing die arrays, each die array depending on the desired final configuration of the deformable material. An assembly having a determined complementary profile is provided. The above method can advantageously utilize the assembly of the present invention, generally allowing the deformable material to be gradually deformed to provide the desired final configuration. More particularly, the method is generally aimed at applying pressure to the deformable material along the working length of the material such that the deformable material is continuously deformed through the working length. In an alternative aspect, the present invention relates to an assembly for stamping deformable material comprising a single die array and a complementary second die that is not necessarily in the form of a die array. A method of using such an assembly is also provided. Furthermore, the present invention relates to a die set for use in an assembly for pressing a deformable material and a method for making such a die set.

  Systems and assemblies for forming a deformable material, such as a metal sheet, into a desired profile are known. One such system, known as roll forming, is an established process used in many industries such as the automotive and construction industries to create simple and complex shapes from metal sheets. Some profile examples 10, 11 and 12 produced by roll forming are given in FIG.

  Referring to FIGS. 2A-2C, roll forming includes passing the continuous sheet 20 through a series of spaced roll sets 21a-21f. Each roll set 21 gradually deforms the sheet 20 to a desired final profile 22. Each roll set 21 includes at least one upper roll 23a-23f and at least one lower roll 24a-24f. In some examples, side rolls 25 may also be provided depending on the desired final profile 22.

  As described above, the rolls 23, 24 and 25 are designed such that the material sheet 20 is gradually deformed to the final profile 22. In order to achieve this deformation, the roll sets 21 must be separated by a predetermined distance in order to facilitate sufficient deformation and stress relaxation between the roll sets 21. This results in inconveniently useless deformation energy. Also, the roll forming process is inherently accompanied by strain path differences due to unnecessary axial bending and stretching between each roll set 21. The plastic bending in the axial direction leads to product defects as shown in FIGS. These defects include so-called ear lobe (FIG. 3A), flare (FIG. 3B), sweep or warp (FIG. 3C), twist (FIG. 3D), etc. There is. Roll forming also has the disadvantage that the surface of the material sheet being molded is subjected to stresses due to the stretching of the material. In the case of coated metals, for example, this can adversely affect the quality of the surface finish.

  Roll forming has the further disadvantage that the distance between the first roll set 21a and the last roll set, in this case 21f, is relatively large. As a result, the space required to accommodate the roll forming assembly is substantial, especially when complex profile shaping is required. In addition, each desired final profile 22 requires a specific set up of roll sets 21. Thus, setting up a roll forming assembly is not a simple process and it is not possible to simply replace the roll set 21 to create another final profile 22.

  Alternatives to the above-mentioned conventional roll forming assemblies have been proposed, for example in German Patent 2,423,279 and European Patent 0,384,287.

  German Patent 2,423,279 describes a press-forming assembly comprising an upper die and a lower die. Each of the upper and lower dies has a profile that extends longitudinally along the length of the die, and the profiles of the upper and lower dies are complementary and designed to provide the desired final profile. More specifically, the profile of the upper and lower dies is such that a deformable material sheet, generally a metal sheet, supplied to the assembly is gradually deformed along the longitudinal length of the material sheet.

  The deformation of the sheet of material can be accomplished, for example, using an eccentric cam (shown in FIG. 19 of this document) or using pivot arms attached to the sides of the upper and lower dies (view of this document). This is accomplished by pushing the upper and lower dies together.

  Similarly, EP 0,384,287 describes an assembly comprising upper and lower dies that are designed to gradually deform a sheet of material by pushing the dies together using an eccentric cam. .

  In both examples, the upper and lower dies engage and disengage the sheet material so as to deform the sheet material along the working length. As the sheet engages and is displaced horizontally through the upper and lower diesets during the disengagement operation, the sheet is gradually deformed to the final profile.

  The present invention seeks to provide an alternative to the press forming assembly and method described above. The assembly and method of the present invention advantageously avoids or reduces problems associated with unnecessary deformation of the deformable material that can be observed during disengagement of the material during processing. The present invention also aims to provide a method of making a die set suitable for use in such an assembly and method.

According to one aspect of the invention, an assembly for press molding a deformable material comprising:
A first die array comprising a plurality of dies defining a first die profile;
A second die array that is complementary to the first die array and includes a plurality of dies that defines a second die profile that is complementary to the first die profile;
A drive unit for driving at least one of the first die array and the second die array;
In use, the plurality of dies in the first die array and the plurality of dies in the second die array sequentially engage the deformable material along the working length so as to deform the deformable material into a predetermined profile. An assembly is provided.

  As used herein, the sequential engagement of the deformable material causes the deformable material to have a first die arrangement and a second die so as to avoid or at least reduce unnecessary deformation of the deformable material. Shows that they are sequentially engaged by an array of dies. The dies of the first die array and the second die array simultaneously engage and do not disengage the deformable material along the entire working length of the deformable material. Sequential engagement should not be inferred to mean ordered engagement, but can include random engagement.

  In order to achieve sequential engagement along the work length of the deformable material, the first die arrangement advantageously includes a primary set of die and a secondary die set. The primary die set and the secondary die set sequentially engage the deformable material sheet along the working length during use. However, it should be understood that the invention is not so limited. For example, the first die arrangement can include a tertiary die set, a quaternary die set, etc., if desired.

  To give an example where an array includes a primary die set and a secondary die set, in one embodiment, the primary die set includes an odd number of dies in the first die array, and the secondary die set is the first die set. Contains an even number of dies in the array. In that case, the odd and even dies of the first die arrangement are advantageously driven separately by the drive. It should be understood that any combination of dies can be used to form a primary die set and a secondary die set. This may depend on the predetermined profile desired after forming the deformable material.

  The dies of the primary die set, as well as the dies of the secondary die set, can be related to each other by any suitable means. In one embodiment, odd dies in the first die array are associated with the first drive plate, and even dies in the first die array are associated with the second drive plate, the first drive plate and the first Each of the two drive plates is driven by a drive unit. In certain embodiments, the first drive plate is defined by a pair of longitudinal plates that extend along the lateral edges of the first die array, and the second drive plate defines the first drive plate. A defining pair of longitudinal plates is defined by a longitudinally extending central plate spanning the longitudinal direction.

  In some embodiments, the first die array and the second die array each include a primary die set and a secondary die set, and the primary die set and the secondary die set of the first die array and the second die array, respectively. Preferably sequentially engage the deformable material along the working length during use. In that case, the primary die set of the first die array and the second die array can also include an odd number of dies in the first die array and the second die array, respectively, The secondary die set of the second die array can include an even number of dies in the first die array and the second die array, respectively.

  As was the case with the previous embodiment, the odd and even dies in the first die array are now separately separated from the odd and even dies in the second die array, respectively. It can be driven by a drive unit.

  Again, the various die sets can be related to each other by any suitable means as desired. In one embodiment, odd dies in the first die array are associated with the first drive plate, even dies in the first die array are associated with the second drive plate, and odd numbers in the second die array. Dies are associated with the third drive plate, and even dies in the second die array are associated with the fourth drive plate, each of which is driven by a drive. The various drive plates can take the same form as described above.

  It should be understood that some reciprocation of the die is required to effect sequential engagement of the deformable material with the dies of the first and second die arrangements. According to one embodiment, the dies of the first die arrangement and the second die arrangement are driven in a linear reciprocating motion. This linear motion can be, for example, in the plane of individual dies in a die array. Alternatively, the linear motion can be at an angle of inclination with respect to the face of the individual die, or an angle of inclination down. According to yet another embodiment, the reciprocating motion can be an orbital or elliptical reciprocating motion. The reciprocation of the odd dies of the first die arrangement and the second die arrangement is preferably offset with respect to the reciprocation of the even dies of the first die arrangement and the second die arrangement. Such an arrangement advantageously facilitates drawing of the deformable material through the assembly.

  The directions of the first die arrangement and the second die arrangement are not particularly limited. For example, the two arrays can be arranged in a vertical plane.

  However, for convenience, the first die array and the second die array are preferably arranged in a horizontal plane.

In some instances, it may be desirable to include an additional die array for further shaping of the deformable material, particularly when forming more complex profiles. For example, in one embodiment, the assembly is
A third die array comprising a plurality of dies defining a third die profile;
A fourth die array that is complementary to the third die array and includes a plurality of dies that defines a fourth die profile that is complementary to the third die profile;
A drive unit for driving at least one of the third die array and the fourth die array;
In use, the plurality of dies in the third die array and the plurality of dies in the fourth die array are arranged along the working length with a first die array and a second die so as to transform the deformable material into a final profile. Are sequentially engaged with the pre-formed deformable material.

  When the first die array and the second die array are arranged in a generally horizontal plane, the third die array and the fourth die array are generally offset or at an angle with respect to the horizontal plane. Placed in-plane. In some examples, the third die array and the fourth die array are arranged in a vertical plane. This advantageously allows the shaping of a wide variety of profiles from deformable materials.

  In some examples, it may be difficult to supply the deformable material into the assembly. Thus, in a preferred embodiment, the assembly includes a guide for guiding the deformable material between the first die array and the second die array.

  The drive of the assembly is not particularly limited, and variations will be readily apparent to those skilled in the art. For example, the drive can be a mechanical or hydraulic drive. In some embodiments, the drive includes a mechanical drive having a gear device.

  The above description relates to an assembly that includes at least one pair of die arrays that cooperate with each other and complement each other and that may be useful in shaping the deformable material into a desired profile. In some instances, it is also envisioned that, for example, when creating a less complex profile, it may be possible to effectively produce the desired result with a single die arrangement that fits into a complementary solid die. Is done.

Thus, according to an alternative aspect of the present invention, an assembly for press molding a deformable material comprising:
A first die defined by a die array including a plurality of dies defining a first die profile;
A second die that is complementary to the first die;
A drive unit for driving the die arrangement of at least the first die,
In use, an assembly is provided in which a plurality of dies in a first die array sequentially engages a deformable material along a working length so as to deform the deformable material into a predetermined profile.

  According to this aspect, the second die can be a solid die. In that regard, the second die can define a second die profile that is complementary to the first die profile. In that case, the second die may be formed of the same or similar material as the first die. Alternatively, the second die may be formed of an elastic flexible material that deforms into a complementary profile to the first die profile when engaged with the die array of the first die. For example, it is envisioned that a suitable elastic flexible material may include a hard rubber material or a relatively rigid plastically deformable material.

  It should be understood that the embodiments and features described above with respect to the previous aspect of the invention are equally applicable to this aspect of the invention. Therefore, for convenience, reference is made to them and not all features are repeated with respect to this aspect.

The inventors have identified various advantages that can be provided by forming a deformable material into a desired profile using a die arrangement, as described in further detail below. Accordingly, the present invention also provides a die set for use in the assembly described above,
A first die array comprising a plurality of dies defining a first die profile;
A die set is also provided that includes a second die array that is complementary to the first die array and includes a plurality of dies that defines a second die profile that is complementary to the first die profile.

  As gathered from the above description of the assembly of the present invention, in one embodiment, the first die array and the second die array each include a primary die set and a secondary die set, The primary die set and the secondary die set are mounted separately, and the primary die set and the secondary die set of the second die arrangement are mounted separately.

  Again, the primary die set of the first die array and the second die array can include odd numbers of dies in the first die array and the second die array, respectively. And the secondary die set of the second die array may include an even number of dies in the first die array and the second die array, respectively.

  Similarly, as described above, odd dies in the first die array can be associated with the first drive plate, and even dies in the first die array can be associated with the second drive plate. The odd dies in the second die array can be associated with the third drive plate, and the even dies in the second die array can be associated with the fourth drive plate.

According to an alternative aspect of the invention, a die set for use in the assembly described above, comprising:
A first die defined by a die array including a plurality of dies defining a first die profile;
A die set is provided that includes a first die and a second die that is complementary.

  As was the case above, the second die can be a solid die and can define a second die profile that is complementary to the first die profile, or It may be formed of an elastic flexible material that deforms into a complementary profile to the first die profile when engaged with the die array of the first die.

  The nature of the deformable material is not particularly limited, provided that it can be formed into the desired final profile. For example, the deformable material can be a low gauge sheet of material, or a high gauge plate of material. It should be understood that although material gauges can be selected from a wide range, the above-described assemblies and dies can be used appropriately without modification of their general design. For example, thicker material (heavier gauge material) requires the use of a stronger drive for the assembly or larger die set compared to the drive that may be required for lower gauge sheet material. And

  Similarly, the deformable material can include any material suitable for deformation to a desired final profile. For example, the deformable material can be a sheet or plate of metal such as aluminum, brass, copper, cold rolled steel, mild steel, tin, nickel, magnesium, titanium. Alternatively, the deformable material can be a sheet of thermoplastic material that can be fiber reinforced if desired. Suitable thermoplastic materials will be readily understood by those skilled in the art. For example, these materials include polyethylene, polypropylene, polycarbonate, polyethylene terephthalate, polyacrylate, polymethacrylate, and the like.

  If the modifiable material is not very malleable at room temperature, desirably the deformable material can be heated before and / or during the deformation process. Thus, in certain embodiments, the assembly includes a heater for preheating the deformable material. Similarly, in certain embodiments, the die of the assembly can be heated to provide heat to the deformable material during deformation.

  As mentioned above, the present invention relates not only to assemblies for press molding deformable materials, but also to die sets for use in such assemblies. These die sets can be designed as needed for a particular desired final profile. During the development of the present invention, an advantageous method of making such a die set has also been developed.

Thus, in another aspect, the present invention is a method of fabricating a die set having a profile for continuously deforming a deformable material from an initial profile to a final profile comprising:
Mapping the die set profile;
Forming a die set, including a first die and a second die defining a die set profile;
Dividing at least one of a first die and a second die to form a die array.

  The mapping of the die set profile may be achieved by any suitable means. In general, the mapping is implemented using differential geometry that takes into account the path from the initial profile to the final profile. In particular, computer-based mapping can be suitably used according to this aspect of the invention.

  The mapping is preferably done so that each part of the deformable material passes the same distance through the die set during the deformation process. This can advantageously avoid problems associated with excessive stretching of the deformable material, such as damage to the surface treatment that may be applied to the material.

  The mapping is also preferably performed so that redundant deformation is minimized or the length of the die set profile is minimized.

  Forming the die set, including the first and second dies that define the die set profile, may be accomplished in any suitable manner known in the art. In certain embodiments, the die set is formed by casting a suitable material. Alternatively, the die set may be machined.

  Similarly, the division of at least one of the first die and the second die can be achieved by any suitable means. For example, this can be accomplished using an electrode wire cutter (ie, spark cutting) or other suitable cutting device.

  In accordance with another aspect of the present invention, a method for press molding a deformable material between a first die array including a plurality of dies and a second die array including a plurality of dies. A plurality of dies in the first die array and a plurality of dies in the second die array sequentially engage the deformable material along the working length to cause the deformable material to have a predetermined profile. A method is provided for transforming into

  As previously described, sequential engagement may be achieved by any suitable means. In one embodiment, the plurality of dies in the first die array and the plurality of dies in the second die array sequentially engage the deformable material with offset reciprocation along the working length of the deformable material. For example, reciprocation of odd dies in the first die arrangement and the second die arrangement may facilitate sequential engagement along the working length of the deformable material to facilitate the first die arrangement and the second die arrangement. Are offset with respect to the reciprocal motion of an even number of dies in the die array.

  In some examples, desirably the deformable material can function after it has been deformed into a predetermined profile. Thus, in certain embodiments, the method can include post working of the deformable material after it is pressed into a predetermined profile. For example, post-processing can include roll forming, strain relief, and / or welding of the deformable material. Other options for post processing will be readily appreciated by those skilled in the art.

  In accordance with an alternative aspect of the present invention, a method of pressing a deformable material, wherein the deformable material is fed between a first die and a second die defined by a die array including a plurality of dies. A method is provided in which a plurality of dies of the first die array are sequentially engaged with the deformable material along the working length to deform the deformable material into a predetermined profile.

  As described above, in some examples, the deformable material may desirably be preheated before it is subjected to the deformation process, or heat may be applied to the deformable material during the deformation process. Thus, the method can include heating the deformable material to a predetermined temperature before and / or during the deformation of the deformable material.

  Next, the present invention will be described in more detail with reference to the accompanying drawings. The following detailed description is provided for purposes of illustration only and should not be construed as limiting the invention in any way.

FIG. 2 shows some simple profiles of molded sheet material. (A)-(C) are figures which show the conventional roll forming assembly. (A)-(D) are the figures which show the defect accompanying the conventional roll forming process. FIG. 2 shows a press-molding assembly according to an embodiment of the present invention. 1 is a side cross-sectional view of a press molding assembly according to an embodiment of the present invention. FIG. 6 illustrates an example of progressive sequential engagement of dies of a press-formed assembly according to an embodiment of the present invention. FIG. 3 is a diagram illustrating a die arrangement according to an embodiment of the present invention. FIG. 8 shows a die array that is complementary to the die array of FIG. 7. It is a figure shown in the state which combined the die array of FIG. 7, and the die array of FIG.

  Referring to FIG. 4, a press forming assembly 40 including an upper die array 41 and a lower die array 42 is shown. In the following, a deformable material sheet 43, referred to as a metal sheet for convenience, is fed between the upper die array 41 and the lower die array 42 and gradually deformed to the desired final profile 44.

  Upper die array 41 and lower die array 42 each include a plurality of separate dies. The upper die array is defined by a primary die set consisting of an odd number of dies 45 in the upper die array 41. The odd dies 45 are supported by a drive plate defined by two longitudinally extending plates 46a and 46b. Plates 46 a and 46 b extend longitudinally along the lateral edges of odd dies 45 and are engaged by the drive to facilitate reciprocating drive of odd dies 45.

  A secondary die set composed of an even number of dies 47 in the upper die array 41 is also provided. The even dies 47 are supported by a drive plate 48 that extends longitudinally along the even dies 47 and that spans the plates 46 a and 46 b that support the odd dies 45. Again, the drive plate 48 is engaged by the drive to facilitate reciprocating drive of the even dies 47.

  Similarly, the lower die array 42 includes a primary die set comprised of odd dies 49 and a secondary die set comprised of even dies 50. As shown in FIG. 4, an odd number of dies 49 are associated with and supported by the drive plate 51, while the even number of dies 50 are drive plates defined by longitudinally extending plates 52a and 52b. Supported by.

  Referring to FIG. 6, the reciprocation of a pair of odd dies 45 and 49 and a pair of even dies 47 and 50 is shown. Die pairs 45, 49 and 47, 50 are driven so that they operate in offset reciprocation. More specifically, die pairs 45, 49 and 47, 50 sequentially engage a metal sheet 43 passing through the upper and lower die sets. This advantageously facilitates progressive deformation of the metal sheet 43 while minimizing unnecessary deformation due to disengagement between the die array and the sheet 43.

  Referring to the first frame in the series of frames shown in FIG. 6, the dies 45 and 49 are engaged with the metal sheet 43 when the metal sheet 43 enters the assembly. It should be understood that 50 is disengaged from the metal sheet 43. In the second frame, all dies are disengaged from the seat 43. In this example, it should be further understood that dies located along the die array of the assembly engage sheet 43. The offset reciprocating motion of the die can be seen from the explanatory diagram of the third frame in FIG. In that frame, the dies 45 and 49 that were previously engaged with the metal sheet 43 have completely disengaged from the metal sheet 43, but have previously been disengaged from the metal sheet 43. 47 and 50 are engaged with the metal sheet 43 at this time. Such movement of the dies in the upper and lower die arrays advantageously assists in feeding or withdrawing the metal sheet 43 through the assembly.

  Referring to FIGS. 7-9, embodiments of the upper die array 70 and the lower die array 80 and their mutual positioning are shown in more detail. However, it should be understood that this is only one of many embodiments that can be used depending on the desired final profile of the metal sheet.

  The upper die array 70 includes a primary die set composed of odd dies 71 and a secondary die set composed of even dies 72. The dies 71 and 72 define a die profile 73 along the longitudinal length of the upper die array 70, ie, the machining length. The die profile 73 has a relatively low profile at the supply end 74 and a relatively high profile at the exit end 75. Accordingly, the metal sheet is gradually deformed along the processing length of the upper die array 70.

  Similar to the upper die array 70, the lower die array 80 includes a primary die set comprised of odd dies 81 and a secondary die set comprised of even dies 82. Again, the dies 81 and 82 define a die profile 83 along the longitudinal length of the lower die array 80, ie the working length. The die profile 83 again has a relatively low profile at the supply end 84 and a relatively high profile at the outlet end 85. Thus, die profiles 73 and 83 are complementary to each other.

  The complementary nature of the profile 73 of the upper die array 70 and the profile 83 of the lower die array 80 can be better understood with reference to FIG. In this figure, it can be seen that profiles 73 and 83 are complementary along the working length of die arrays 70 and 80. Profiles 73 and 83 are such that a metal sheet is passed between die array 70 and die array 80 and gradually deformed to the desired final profile. Further, the sequential engagement of the metal sheets to be formed by the individual dies 71, 72, 81 and 82 of the upper die array 70 and the lower die array 80 reduces or eliminates the rebound of the metal sheet during forming. This is generally due to at least one or more dies engaging the metal sheet at any point during molding. The assembly also advantageously reduces or eliminates axial bending of the metal sheet during forming.

  The assembly of the present invention has various other advantages including reduced power consumption due to reduced wasted molding energy. The size of the assembly is smaller than the counterpart on which the assembly rolls. Thus, the assembly has a smaller “footprint”, thereby reducing manufacturing costs. The assembly of the present invention also allows for a reduction in maintenance costs and operating costs.

  Of course, the above is given only as an exemplary embodiment of the present invention, and all modifications and variations to that embodiment that should be apparent to those skilled in the art are described in this document. As described in the specification, it is deemed to be within the broad scope and scope of the present invention.

10, 11, 12, 22, 73, 83 ... profile, 20 ... material sheet, 21 ... roll set, 23 ... upper roll, 24 ... lower roll, 25 ... side roll, 40 ... press molding assembly, 41 ... upper die Array, 42 ... lower die array, 43 ... metal sheet, 45, 49, 71, 81 ... odd number die, 46, 52 ... plate, 47, 50, 72, 82 ... even number die, 48, 51 ... drive plate, 70 ... Upper die arrangement, 74, 84 ... Supply end, 75, 85 ... Outlet end, 80 ... Lower die arrangement.

Claims (32)

An assembly for pressing a deformable material,
A first die array comprising a plurality of dies defining a first die profile;
A second die array that is complementary to the first die array and includes a plurality of dies that defines a second die profile that is complementary to the first die profile;
A drive unit for driving at least one of the first die array and the second die array;
In use, the plurality of dies of the first die array and the plurality of dies of the second die array can be deformed along a working length so as to deform a deformable material into a predetermined profile. An assembly that sequentially engages the material.   The first die array includes a primary die set and a secondary die set, and the primary die set and the secondary die set sequentially engage the deformable material along the working length during use. The assembly according to claim 1.   The assembly of claim 2, wherein the primary die set includes an odd number of dies in the first die array and the secondary die set includes an even number of dies in the first die array.   4. An assembly according to claim 3, wherein the odd and even dies of the first die array are driven separately by the drive means.   The odd dies of the first die array are associated with a first drive plate, the even dies of the first die array are associated with a second drive plate, the first drive plate and the first drive plate 5. An assembly according to claim 4, wherein each of the two drive plates is driven by the drive means.   The first die array and the second die array each include a primary die set and a secondary die set, the primary die set and the secondary die of the first die array and the second die array, respectively. The assembly of claim 1, wherein the set sequentially engages the deformable material along a working length during use.   The primary die sets of the first die array and the second die array each include an odd number of dies in the first die array and the second die array, the first die array and the The assembly of claim 6, wherein each of the secondary die sets in a second die array includes the first die array and an even number of dies in the second die array.   The assembly according to claim 7, wherein the odd and even dies of the first and second die arrays are each separately driven by the drive means.   The odd dies of the first die array are associated with a first drive plate, the even dies of the first die array are associated with a second drive plate, and the odd die of the second die array An odd number of dies is associated with a third drive plate, the even number of dies in the second die array is associated with a fourth drive plate, and each of the first to fourth drive plates is provided by the drive means. 9. The assembly of claim 8, wherein the assembly is driven.   The assembly of claim 9, wherein the dies of the first die array and the second die array are driven in a linear reciprocating motion or an annular reciprocating motion.   Reciprocal movement of the odd dies of the first die arrangement and the second die arrangement is offset relative to the annular reciprocation of the even dies of the first die arrangement and the second die arrangement; 11. The assembly of claim 10, wherein:   The assembly of claim 1, wherein the first die array and the second die array are disposed in a horizontal plane. A third die array comprising a plurality of dies defining a third die profile;
A fourth die array complementary to the third die array and including a plurality of dies defining a fourth die profile that is complementary to the third die profile;
Driving means for driving at least one of the third die array and the fourth die array;
The third die array and the fourth die array are disposed in a plane that forms an angle with respect to the horizontal plane, and the plurality of dies and the fourth die of the third die array are in use during use. The plurality of dies in an array is formed into the deformable material pre-formed by the first die array and the second die array along a working length so as to transform the deformable material into a final profile. The assembly of claim 12, wherein the assemblies engage sequentially.   The assembly of claim 1, comprising a guide for guiding the deformable material between the first die array and the second die array.   The assembly of claim 1, wherein the drive comprises a mechanical or hydraulic drive. An assembly for pressing a deformable material,
A first die defined by a die array including a plurality of dies defining a first die profile;
A second die that is complementary to the first die;
A drive unit for driving at least the die arrangement of the first die,
In use, the plurality of dies of the first die array sequentially engages the deformable material along a working length so as to deform the deformable material into a predetermined profile.   The assembly of claim 16, wherein the second die defines a second die profile that is complementary to the first die profile.   17. The second die is formed of an elastic flexible material that deforms into a complementary profile to the first die profile when engaged with the die array of the first die. Assembly. A die set for use in an assembly according to claim 1,
A first die array comprising a plurality of dies defining a first die profile;
A die set comprising: a second die array that is complementary to the first die array and includes a plurality of dies that defines a second die profile that is complementary to the first die profile.   The first die array and the second die array each include a primary die set and a secondary die set, wherein the primary die set and the secondary die set of the first die array are separately attached; 20. The die set of claim 19, wherein the primary die set and secondary die set of a second die array are attached separately.   The primary die sets of the first die array and the second die array each include an odd number of dies in the first die array and the second die array, the first die array and the 21. The die set of claim 20, wherein each of the secondary die sets of a second die array includes the first die array and an even number of dies in the second die array.   The odd dies of the first die array are associated with a first drive plate, the even dies of the first die array are associated with a second drive plate, and the odd die of the second die array The die set of claim 21, wherein an odd number of dies is associated with a third drive plate and the even number die of the second die array is associated with a fourth drive plate. A die set for use in an assembly according to claim 16, comprising:
A first die defined by a die array including a plurality of dies defining a first die profile;
A die set comprising a second die that is complementary to the first die.   24. The die set of claim 23, wherein the second die defines a second die profile that is complementary to the first die profile.   24. The second die is formed of an elastic flexible material that deforms into a complementary profile to the first die profile when engaged with the die array of the first die. Die set. A method of making a die set having a profile for continuously deforming a deformable material from an initial profile to a final profile, comprising:
Mapping the profile of the die set;
Forming the die set comprising a first die and a second die defining the profile of the die set;
Splitting at least one of the first die and the second die to form a die array.   A method of press molding deformable material, comprising the step of supplying the deformable material between a first die array including a plurality of dies and a second die array including a plurality of dies. The plurality of dies in one die array and the plurality of dies in the second die array sequentially engage the deformable material along a working length to deform the deformable material into a predetermined profile. ,Method.   The plurality of dies in the first die array and the plurality of dies in the second die array are offset linearly or annularly reciprocated into the deformable material along a working length of the deformable material. 28. The method of claim 27, wherein the methods are sequentially engaged.   The reciprocating motion of the odd numbered dies of the first die array and the second die array facilitates sequential engagement along the working length of the deformable material. 29. The method of claim 28, wherein the method is offset with respect to the annular reciprocation of an even number of dies of the array and the second die array.   28. The method of claim 27, comprising post-treatment of the deformable material after the deformable material is pressed into the predetermined profile.   32. The method of claim 30, wherein the post treatment includes roll forming, strain relief, and / or welding of the deformable material.   A method of pressing a deformable material, the method comprising the step of supplying the deformable material between a first die and a second die defined by a die array including a plurality of dies. The plurality of dies of the die arrangement sequentially engages the deformable material along a working length to deform the deformable material into a predetermined profile.

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