JP2515689B2 - Manufacturing method of corrugated metal sheet - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a corrugated metal plate such as a heat exchange plate mounted inside a heat exchanger such as a cooling machine and a heating machine.

[0002]

2. Description of the Related Art Generally, in the case of forming a flat plate material such as a metal plate into a corrugated shape, conventionally, as shown in FIG. 5, the plate material 1 is stamped by an upper die P1 and a lower die P2 of a press machine. The method of giving shaping | molding and processing the corrugated board material 1'is widely implemented.

[0003]

However, although the above-mentioned press forming is suitable for bending with a relatively large corrugated pitch, conversely there are various technical problems in forming a corrugated shape with a very small pitch. It is difficult to implement due to To be more specific, when the corrugated pitch is large, the shearing force applied to each corrugated bent portion during press molding is also small, but when the corrugated pitch is narrow, for example, a certain type of heat exchange plate Therefore, it is only 4
When corrugation with a minimum pitch of about mm is performed by press molding, in addition to the problem that the shearing force applied to each corrugated bending part becomes abnormally large and the plate material after processing has uneven thickness, It has a problem of breaking at the bent portion.

Further, by repeatedly using the press die, there is a problem that the corrugation peaks of the narrow-pitch die are damaged in a short period of time and the service life is remarkably reduced, and one corrugated product having a large number of corrugation peaks is produced. In order to produce it, several press forming processes have to be repeated, which causes a problem of extremely poor productivity. For example, in the present situation, the above-mentioned heat exchange plate has 36
It took about 3 minutes to perform the wave bending process on the mountain,
Moreover, the fact is that defective molding products are discharged as described above.

[0005]

In order to drastically solve the above problems, the present invention stops corrugation processing by press molding as in the past, and applies corrugated metal sheet by applying roll molding. The first roll forming is performed on the plate material by the first roll forming, and the second roll is formed on each primary bending oblique side of the plate material subjected to the primary corrugating bending process. Secondary corrugation bending is performed by forming, and the corrugated level of the plate material subjected to the primary and secondary corrugating bending is flattened by the third roll forming.

Further, according to the present invention, the secondary corrugation bending process by the second roll forming and the shaping process by the third roll forming are repeatedly performed so that the corrugated pitch can be narrowed.

Further, according to the present invention, the shaping process by the third roll forming is gradually performed from both ends to the center of the plate material.

According to the present invention, the corrugated sheet material is bent into an appropriate product shape.

[0009]

According to the present invention, the first, second, and third metal plate members are provided.
By performing primary, secondary corrugation bending and corrugating shaping in a roll forming process in a step-by-step manner, a narrow pitch corrugation can be beautifully and soundly without causing excessive thinning or breaking of the corrugated bending part. In addition, the corrugation can be performed by passing the plate material through the first, second, and third roll forming steps at a high speed, so that the productivity can be greatly improved.

[0010]

Embodiments of the present invention will be described below in detail with reference to the drawings.

FIG. 1 is a basic process diagram for performing a corrugated bending process on a flat metal plate material 1. R1 in the figure indicates a first roll forming step in which the plate material 1 is subjected to the primary corrugation bending process, in which the plate material 1 is continuously roll formed with corrugated peaks 2 of equal pitch through the hypotenuses 3. To do.
That is, the wave heights H of the primary corrugations 2 adjacent to each other through the primary bending hypotenuses 3 are made substantially uniform, and the wavelengths L of the respective corrugations 2 are processed to be substantially the same.

R2 is a second roll forming step showing a state in which the plate 1 having been subjected to the above-mentioned primary corrugated bending has been subjected to the secondary corrugated bending. In this step, each primary bending hypotenuse 3 of the plate material 1 is subjected to secondary corrugation bending with a curvature substantially equal to that of the above-mentioned primary corrugation 2 to form a secondary corrugation 4, and the secondary corrugation 4 and the above-mentioned primary corrugations are formed. Make mountain 2 continuous.

R3 represents a third roll forming step in which the plate material 1 that has been subjected to the above-mentioned primary and secondary corrugation bending processing is subjected to shaping processing to flatten the corrugation level of the above-mentioned primary corrugation peaks 2 and secondary corrugation peaks 4. That is, in the step, roll shaping is performed so that the wave heights H of the primary waveform peak 2 and the secondary waveform peak 4 are substantially equal to each other from the reference straight line, and the wavelength L is also shaped so as to be substantially equal. The primary and secondary waveform peaks 2 and 4 are arranged in a line. The corrugated crest formed by the third roll forming process is referred to as a tertiary corrugated crest 5. The wave-shaped plate material 1 obtained as described above has each wave height H1 and wavelength L
1 is molded into approximately one-third of the primary corrugation crest 2 molded in the first roll molding step R1, whereby the corrugation pitch becomes approximately one-third.

In each of the above roll forming steps, naturally, the upper forming roll 9a and the lower forming roll 9b having the peripheral surface shape suitable for the corrugated bending plate material of each step are used.

FIG. 2 is a process diagram showing an application example of the primary and secondary corrugated bending processes and the shaping process, which are the basic processes of the corrugated bending process. The corrugated bending process is performed by the first to third roll forming processes R1 to R3. It shows a case where the plate material 1 is repeatedly subjected to the secondary corrugation bending process by the second roll forming step R2 and the shaping process by the third roll forming step R3 to minimize the corrugation pitch.

FIG. R shows a flat metal plate material 1 before processing, and R0 shows a roll forming step of subjecting the plate material 1 to pre-corrugation bending. Further, R1 to R3 correspond to the above-described first to third roll forming steps, and the description thereof will be omitted.

Reference numeral R2 'shown in the figure indicates a second roll shaping step of subjecting the corrugated sheet material 1 shaped in the third roll forming step R3 to secondary corrugation bending again, and the corrugated sheet material 1 is formed. Each of the third-order bent hypotenuses 6 is subjected to a second-order wavy bending process with a curvature substantially equal to that of the third-order wavy peak 5 to form a fourth-order wavy peak 7, and the fourth-order wavy peak 7 and the third wavy peak 5 are continuous. .

The plate material 1 corrugated in the second roll forming step R2 'is gradually shaped from both ends of the plate material 1 to the center by a third roll forming step R3' consisting of the following steps a to c. Apply Waveform level is flat. More specifically, in the steps a to c in the forming step R3 ', the corrugated plate material 1 is stepwise shaped step by step from the both ends to the center of the corrugated plate material 1 to form the tertiary corrugated peaks 5 and the quaternary corrugated peaks. The wave height H of the crests 7 is made substantially uniform, and the wavelength L is similarly shaped to be substantially equal to flatten the waveform level, so that each of the tertiary and quaternary waveform crests 5 and 7 is linearly shaped. In other words, the corrugated sheet material 1 is formed by applying a fine pitch wave pattern 8 consisting of continuous fifth-order corrugations 8 in which the corrugation levels of the third and fourth-order corrugations 5 and 7 are flattened in the third roll forming step R3 '. Shape into shape. Thereby, the wave height H of the corrugated plate 1
2 and the wavelength L2 are approximately one-third of the tertiary wave peak 5 formed in the third roll forming step R3, and the wave pitch is formed to approximately one-third.

Further, the width W of the corrugated sheet material 1 after the waveform shaping by the third roll forming step R3 'is substantially the same as the width W of the corrugated sheet material 1 formed in the preceding second roll forming step R2'. To do.

FIG. 3 is a schematic view of a roll forming apparatus for forming the corrugated metal sheet of the present invention. Incidentally, reference numeral R0 shown in FIG.
To R3 and R2 ', R3', and R3 'a to c respectively have an upper forming roll 9a and a lower forming roll 9b that are subjected to corrugated bending by the roll forming process of the same reference numerals shown in FIG. Each unit roll forming device 9 is shown.

In the roll forming apparatus, the roll forming apparatus 9 used in the roll forming step R0 for preforming the plate material 1 is arranged on the carry-in end side of the plate material 1, and then the first corrugated bending process is performed in the sheet feeding direction. The unit roll forming devices 9 for the one roll forming step R1, the second roll forming step R2 for performing the second corrugated bending process, and the third roll forming step R3 for performing the shaping process are sequentially arranged in parallel.

Each of the unit roll forming devices 9 is provided with an upper forming roll 9a and a lower forming roll 9b, and the outer peripheral surfaces of the upper and lower forming rolls 9a and 9b are respectively formed into rolls as shown in FIG. A peripheral surface shape corresponding to the corrugated bending of the process is formed, and both rolls 9a and 9b are driven to feed the plate material 1 between the upper and lower forming rolls 9a and 9b to perform the roll forming. As a result, the plate material 1 is bent into a corrugated shape corresponding to the shape of the outer peripheral surfaces of the rolls 9a and 9b.

Further, each unit roll forming device 9 is provided with a handle 10.
The distance between the upper forming roll 9a and the lower forming roll 9b is adjusted in advance according to the thickness of the plate material 1.

The corrugated sheet material 1 formed as described above is bent into a shape corresponding to the final product shape such as a hook shape as shown in FIG.

[0025]

According to the present invention, the corrugated sheet is formed by stepwise roll-forming the primary, secondary corrugated bending and corrugating processes in the order of the first, second and third roll forming steps. Narrow-pitch corrugation processing can be properly performed without applying excessive concentrated machining load to the bent part, effectively preventing the unevenness of corrugated ridge thickness that accompanies corrugation, and It is possible to provide a corrugated metal sheet that reliably prevents breakage of the corrugated sheet material and is sound.

In addition, the corrugation can be performed by passing the plate material through the first, second and third roll forming steps at high speed, so that the productivity can be greatly improved and the cost can be reduced.

[Brief description of drawings]

1 is a basic process diagram of a method for manufacturing a corrugated metal sheet showing an embodiment of the present invention.

2A to 2C are process diagrams showing an application example of the method for manufacturing the corrugated metal sheet shown in FIG.

FIG. 3 is a side view showing an outline of a roll-forming apparatus for corrugated metal sheets for carrying out the application example shown in FIG.

FIG. 4 is a side view showing a state in which a corrugated metal plate is bent into an appropriate shape for practical use.

FIG. 5 is a schematic cross-sectional view of a method of manufacturing a corrugated metal plate by a pressing machine showing a conventional example.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Plate material 2 Primary corrugated mountain 3 Primary bending hypotenuse 4 Secondary corrugated mountain 5 Tertiary corrugated mountain R1 1st roll forming process R2 2nd roll forming process R3 3rd roll forming process

Claims (3)

(57) [Claims] 1. A first roll forming step of subjecting a plate material to a primary corrugated bending step, and a second roll forming step of subjecting each primary bending hypotenuse of the plate material subjected to the primary corrugated bending step to a secondary corrugated bending step. A third roll forming step of performing a shaping process for flattening the waveform level of the plate material subjected to the primary and secondary waveform bending processes, and performing the second roll forming process of performing the secondary waveform bending process and the shaping process. A method for producing a corrugated metal sheet, characterized in that the corrugated pitch is narrowed by repeating the third roll forming step. 2. The method for producing a corrugated metal sheet according to claim 1, wherein the third roll forming step comprises a multi-step step in which shaping is performed stepwise from both ends of the sheet material to the center. . 3. The method for producing a corrugated metal sheet according to claim 1, wherein the corrugated plate material is bent.