JP5158681B2 - Roll forming method for channel cross-section material - Google Patents

Description

  In the present invention, when a long material having a groove-shaped cross-sectional shape is roll-formed from a metal plate or a metal strip, the roll is exchanged and the roll is attached in the axial direction to two or more types of metal plates or metal strips having different thicknesses. The present invention relates to a method of forming a roll without adjusting the position, and further, without changing the roll and adjusting the mounting position in the axial direction of the roll even in the groove-shaped cross-sectional materials having different external dimensions.

A lightweight groove-shaped cross-section with flanges on both ends of a flat web (bottom) is formed into a predetermined cross-section by a roll forming process in which a pair of upper and lower rolls are arranged in multiple stages, and then a predetermined length by a traveling cutting machine. Manufactured by cutting into two pieces.
In the normal roll forming process, the roll gap into which the material is bitten is set to be almost equal to the thickness of the material regardless of the position in the width direction of the material, and the corner radius of the roll contacting the inside of the bending corner is relative to the thickness of the material. For example, a forming roll set to an appropriate size, for example, about 1 to 2 times the material thickness is used. When forming materials with significantly different thicknesses, if the difference in thickness is small, adjust the axial mounting position of the roll so that the roll gap between the web and the flange is approximately equal to the thickness of the material, and the web and flange. If the roll position is adjusted so that the roll gap in the part is almost equal to the thickness of the material, or if the difference in thickness is large, the roll that contacts the inside of the corner should be The roll is replaced with a roll having a corner radius, and the roll is attached and molded so that the roll gap between the web and the flange portion is substantially equal to the thickness of the material.

  As described above, when the rolls are exchanged or the positions thereof are adjusted with respect to the plurality of thickness materials, the roll exchange and the adjustment time are increased, and the productivity is deteriorated. The roll forming method is a manufacturing method suitable for mass-producing a long material having the same shape, and when the manufacturing lot is small, a decrease in productivity due to roll replacement / adjustment work becomes a problem. For this reason, in the past, for materials with similar thicknesses, by adjusting the roll gap of some rolls for the purpose of omitting roll replacement / recombination, it is possible to form a section of multiple thicknesses with one type of roll. Molding has been widely performed.

  However, when the range of the thickness of the material formed by one type of roll is widened, the corner portion cannot be formed into a predetermined shape in a part of the material having a certain thickness. When forming multiple thickness materials with one type of roll, the roll gap of the web parallel to the roll axis is usually used when forming a thin material using a roll made to the thickest material. Only match the thickness of the material. In this case, in the flange portion having an angle with respect to the web, the roll gap becomes wider with respect to the thickness of the material, and the upper roll is disposed asymmetrically with respect to the web and the symmetrical axis of the flange and the web. When the range of the plate thickness is wide, a problem occurs in the shape of the corner portion.

In order to solve such a problem, for example, as disclosed in Patent Document 1 or Patent Document 2, at least the forming roll positioned inside the corner is arranged on the symmetry line between the web and the flange, whereby the thickness is different. Even so, the roll gap is not asymmetrical on both sides of the corner. In particular, in Patent Document 2, rolls on the corner outer side are also arranged at positions facing the inner roll.
Further, in Patent Document 3, the upper and lower rolls are of a one-side support system, and the upper roll chock is moved up and down along an angle of 45 degrees with respect to the vertical direction. A forming stand is disclosed in which the roll gap is always equal.

  Furthermore, as a method for forming the groove-shaped cross-section material having different web widths without exchanging the rolls, for example, as disclosed in Patent Document 4 or Patent Document 5, bending of the groove-shaped cross-section material is performed at two locations. A roll forming apparatus has been developed in which a roll is divided into left and right including a roll shaft to form a cantilever roll stand that supports only one of the rolls, and each of them is mounted so as to be relatively movable in the width direction.

Japanese Patent Publication No. 7-34937 JP 2005-111497 A, JP-A-9-76024 JP-A-9-76024 JP 2004-82155 A

  In the techniques of Patent Documents 1 to 3, the problem of asymmetry of the corner shape can be solved by arranging the inner forming roll on the symmetry line of the corner, but the same inner roll is used regardless of the thickness of the material. Therefore, there is a problem that the corner R dimension is likely to be excessive for a thin material and excessively small for a thick material. Further, since the rolls are arranged along the symmetry line between the web and the flange, the roll shaft needs to be attached at different angles in each stand, and an expensive dedicated stand is required. Also, the roll position adjusting mechanism has a complicated structure, and it may be difficult to drive the roll. Furthermore, since the rigidity of the stand decreases as the structure of the stand becomes complicated, it is applied to the light-weight channel cross-section material with a thickness of about 4.5 to 6 mm, coupled with the problem of the corner R dimension described above. could not.

Even in the methods of Patent Documents 4 and 5 in which a groove-shaped cross-section material having a different web width is formed without roll replacement by a cantilever roll stand obtained by dividing the roll stand, the rigidity is lower than that of a roll stand in which both sides of the roll are supported. Further, it could not be applied to a thick lightweight groove-shaped cross-sectional material having a thickness of about 4.5 to 6 mm.
The present invention has been devised to solve such a problem, and while using a general-purpose roll forming stand having a high rigidity and a simple structure, for example, a structural material or the like without replacing the forming roll. An object of the present invention is to provide a method for forming a groove-shaped cross-sectional material having a thickness in the range of about 2.3 to 6 mm.

In order to achieve the object, the roll forming method of the groove-shaped cross-section material of the present invention is a roll forming apparatus in which a roll forming stand having a forming roll attached to an upper and lower shaft supported at both ends is arranged in multiple stages , and both ends are supported. Formed with a forming stand group attached with a forming roll that bends only one of the two bent portions of the groove-shaped cross-section material on the vertical axis, and a forming roll that bends only the other bent portion The width of the web of the channel-shaped cross-section material to be molded, in which a stand group is disposed and one of the stand groups is attached to the other stand group so as to be movable in a horizontal direction perpendicular to the molding flow direction the distance between the two bending portions forming the channel section member having a predetermined range of thicknesses having a flange on both sides of the flat web by adjustable and roles forming apparatus according to a method, wherein Using the roll designed to form the thickest channel cross-section material that can be molded by a tool, the thickest of the cross-section materials to be molded When forming a groove-shaped cross-section material that is thinner than the groove-shaped cross-section material, it is possible to remove residual stress and ensure dimensional accuracy from the latter half of the rough forming area where the groove-shaped cross-section material is molded to the final shape. Use the forming roll designed according to the thickness of the groove-shaped cross-section material formed by the gap between the web and the flange portion and the radius inside the corner portion sandwiched between the web and the flange between the regions including the finish forming for And correcting the corner dimensions.

  Then, the distance between the upper and lower shafts of the roll, which is attached to the vertical shaft supported at both ends and designed to be able to form the thickest groove-shaped cross-sectional material among the cross-sectional material to be molded, is adjusted. Therefore, it is preferable to match the gap at the position corresponding to the shape steel web portion of the forming roll to the thickness of the shape steel to be formed.

  According to the present invention, it becomes possible to form without changing the roll and adjusting the mounting position in the axial direction of the roll regardless of the outer shape and thickness dimension of the groove-shaped cross-section material to be formed, and the equipment cost is low, Since a general-purpose molding stand with a vertical axis supported at both ends with high rigidity of the stand is used, a wide range of plate thickness including thick materials that was difficult with conventional variable dimension molding machines such as cantilever stands Can be used as a roll.

  As a result of examining the combination of the thickness of the roll and the material, the present inventors have found that even if the roll gap in the flange portion is excessive due to the combined use of the roll and the inner roll is arranged asymmetrically with respect to the bending corner symmetry line at the corner portion, It has been found that the web part and the flange part excluding the part can be molded with almost no problems with respect to flatness and molding angle. Moreover, after shape | molding rough cross-sectional shape with the combined use roll, it discovered that a corner part was correctable to a predetermined shape by each sheet thickness exclusive roll. And by combining the flange standing processing of the groove-shaped cross-section material with the dual-purpose roll and the shape correction of the corner portion with the roll exclusively for the plate thickness, the present invention that can share most rolls with different thickness materials has been achieved. .

Hereinafter, the present invention will be specifically described.
In the present invention, a forming roll in which the shape of the roll gap and the corner R is set in accordance with the thickest one among the groove-shaped cross-section materials to be formed is applied to all thickness materials. A molding stand is used that has a pair of roll shafts arranged in parallel at the top and bottom, which is highly rigid and versatile, and supports both ends with a chock and a roll stand.
In this forming roll, when the roll gap of the web part of the shape steel is matched to the thickness of the thickest material, the roll gaps of the flange parts on both sides thereof are set to substantially the same roll gap. For example, as described in JIS G3350, the upper roll that presses the inside of the bending corner portion is provided with a corner R that is approximately the same as the plate thickness so as to be about 1.5 times the plate thickness at the plate thickness center. ing.
When the thickest material is formed into a groove-shaped cross-section using such a roll, both the rough cross-sectional shape and the corner portion are formed into a predetermined shape.

  Next, when using this roll to form a material whose thickness is thinner than the design thickness of the roll, it is possible to form with the roll gap as it is, but because the roll gap is excessive for both the web and flange, the material can be held by the roll. Insufficient slipping or meandering may occur. For this reason, it is preferable to adjust a roll gap according to the thickness of the raw material to shape | mold. At this time, since the roll can be moved only in the vertical direction by the stand structure, only the roll gap of the web portion parallel to the roll axis is adjusted to the thickness of the material. At that time, in the flange portion having an angle with respect to the web, the roll gap becomes excessive compared to the material thickness according to the angle, and the degree becomes more prominent in the post-molding stage where the flange rises.

  When molding is performed with a gap in the flange portion in this way, since the material of the flange portion is bent in contact with the lower roll 2 on the outside of the bend, the flatness of the flange and the outer dimensions when bent to the final shape Is molded in substantially the same way as a flange bent without a gap. Since the corner portion between the web and the flange is bent while being in contact with the corner of the upper roll 1 inside the bending, the bending radius is excessive with respect to the thickness of the material (see FIG. 1).

In the corner formed excessively with respect to the plate thickness, the roll gap between the web and the flange arranged in the latter half of the bending process is set to be almost equal to the thickness of the material, and the corner radius of the upper roll 1 is set to the thickness of the material. On the other hand, by forming with a roll set appropriately, the corner portion is corrected to a shape appropriate to the thickness (see FIG. 2). When the flange angle of the product is a right angle, it is preferable to perform the corner correction with a roll having a slightly opened flange, for example, a bending angle of about 80 degrees.
After corner correction, bend the flange angle to the final product angle, remove residual stress as necessary, correct warping and bending, and then cut to a predetermined length if the material is a coil. Get the material. When corner correction is performed at an angle of around 80 degrees, corrective roll stands for each thickness are arranged along the molding direction, and the roll gap is set to the thickness of the material only for the rolls to be used for other thicknesses. By releasing the roll so that the roll gap is wider than the material to be molded, it is not necessary to replace the roll even if the thickness of the material to be molded changes.

When the flange angle is bent to the final product angle after corner correction, the flange part is formed with a gap, but the flange part material is not in contact with the upper roll 1 and is bent to the lower roll 2 on the outside. Since it is bent by contact (see FIG. 3), the flatness of the flange and the outer dimensions when bent to the final shape are formed in substantially the same manner as that of the flange portion without a gap.
In addition, when forming in an overbend excessively than 90 degrees in the subsequent forming stand, a slit is provided so that the flange portion enters the upper roll, and the lower roll has a flat structure that only supports the lower surface of the web portion. Since the formed molding roll is used, it is slightly different from the above form. That is, when the bending angle is 90 degrees or more due to overbending, the upper roll provided with a slit into which the flange portion enters the outside of the flange comes into contact, and when returning the overbend in the next stand, the inside of the flange Contacts the upper roll. In rough forming, the flange is unilaterally raised by the outer roll, so almost the entire surface of the flange comes into contact with the lower roll, but in the overbending process, the bending angle is finely adjusted with one roll, so it is the flange that comes into contact with the roll. In many cases, it is only near the tip.

Furthermore, the roll for forming the material into a channel-shaped cross-section material is divided into two in the width direction, and one stage of roll is attached to a roll stand having a vertical axis supported at both ends of the two stages, and two bending processes are performed separately. You may make it carry out with a roll stand. That is, as shown in FIGS. 4 and 5, the roll stand group for forming one corner portion can be moved in the material width direction by changing the roll stand group for forming the other corner portion. The groove-shaped cross-section material can be roll-formed without exchanging the roll. FIG. 4 shows a case where the web width is wide, and FIG. 5 shows a case where the web width is narrow. In either case, a front view is shown in (a) and a plan view is shown in (b). In the case of the figure of the roll stand group designed and arranged so that a wide web can be processed as shown in FIG. 4, the work side roll stand group 3 forming the left corner is moved to the material width direction drive side roll stand group 4 side. By doing so, a narrow web can be processed as shown in FIG.
The flange length can also be adjusted by changing the material width in the conventional method. By using a combination of the above means, the roll can be replaced with one roll forming machine and the axial mounting position of the roll. It is possible to manufacture channel-shaped cross-sections having different thicknesses, web widths, and flange lengths without adjusting the above.

  The above description is about a groove-shaped cross-section material having two bent portions. However, by adding a lip bending process based on the present invention before the roll-shaped process of the groove-shaped cross-section material, the lip It is also possible to apply to a grooved cross-sectional material (C channel material). In addition, forming is basically performed with a roll stand having a vertical axis supported at both ends, but a side roll stand having a cantilevered shaft arranged vertically for the purpose of adjusting the position in the width direction of the material in the middle of forming. May be used in combination. Further, in the latter overbend process where the molding load is small and a rigid molding stand is not necessarily required, the web dimensions of the channel steel can be easily changed. For example, a cantilever roll disclosed in JP-A-9-76024 A stand or a stand disclosed in Japanese Utility Model Laid-Open No. 7-33414 in which the shaft can be expanded and contracted at the sacrifice of the shaft rigidity may be used.

Example 1;
As shown in Table 1, a 6-stage flange stand roll designed for a plate thickness of 4.5 mm, a flange forming and corner straightening roll designed for a plate thickness of 2.3 mm, and a plate thickness of 4.5 mm An overbend roll designed for a plate thickness of 4.5 mm including the flange stand roll and the final stage designed for a total of 14 stages of lower shaft drive type consisting of two vertical axes supported at both ends. A groove-shaped cross-section material roll forming apparatus attached to a roll forming stand was used. In addition, the bending angle in Table 1 points out the design value of the angle formed by the extension line of a web part and a flange part, as shown in FIG.
The roll gap of the web part of each roll is set to about 2.3 mm corresponding to the plate thickness, a steel strip having a nominal plate thickness of 2.3 mm and a width of 290 mm is roll-formed, and a groove having a web width of 200 mm × flange length of 50 mm. A cross-sectional material was obtained.

The dimensional accuracy (web width, flange length, web-to-flange angle, corner dimension, cross-sectional shape of the front and rear ends, etc.) of the molded groove-shaped cross-section material was designed for a plate thickness of 2.3 mm for all rolls. It was inferior to the groove-shaped cross-section material formed with the forming roll.
Next, all the roll gaps of the above-mentioned forming apparatus were set to about 4.5 mm, and the roll gap of the flange portion of the No. 7 stage 80-degree forming roll designed for a plate thickness of 2.3 mm was less than 4.5 mm. And a steel strip having a nominal plate thickness of 4.5 mm and a width of 283 mm was roll-formed to obtain a groove-shaped cross-sectional material having a web width of 200 mm and a flange length of 50 mm. The obtained groove-shaped cross-sectional material had no problems with respect to dimensional accuracy, surface quality and the like.

Example 2;
Among the rolls shown in Table 1, eight sets of rolls up to a forming angle of 80 degrees are divided into two parts, the work side and the drive side, and the two-stage forming stand is continuous with a 200 mm stand interval. In the same manner as in Example 1, a groove-shaped cross section was used, using a roll forming apparatus having a total of 22 stages mounted with rolls as shown in Table 2 attached in a state where the relationship of the width direction positions of the corner portions of the shape steel was maintained. The material was molded to obtain two types of groove-shaped cross-sectional materials having a plate thickness of 2.3 mm and 4.5 mm × web width of 200 mm × flange length of 50 mm.
Next, the even-numbered forming stand from No. 2 to 16 to which the work-side forming rolls are attached is moved 50 mm to the drive side in the width direction, and the thickness of the material for forming the gap of the web portion of each roll is further increased. Adjusting the upper and lower rolls on the work side to 50mm by changing the position of a horseshoe-shaped spacer with a notch wider than the outer diameter of the shaft in part of the circumferential direction for No. 17-22 No. 17-22 forming stands In a state of moving to the drive side, a steel strip having a thickness of 2.3 mm × a plate width of 240 mm and a thickness of 4.5 mm × a plate width of 233 mm is roll-formed, and a thickness of 2.3 mm and 4.5 mm × web width of 150 mm × Two types of groove-shaped cross-sectional materials having a flange length of 50 mm were obtained. Each of the obtained groove-shaped cross-sectional materials had quality with no problems with respect to dimensional accuracy, surface quality, and the like.

Schematic explaining the aspect of flange standing molding in the present invention Schematic explaining the aspect of corner correction in the present invention Schematic explaining the aspect of 90 degree flange standing molding in this invention Schematic explaining the aspect which shape | molds the channel steel with a wide web part by this invention Schematic explaining an aspect of forming a grooved steel having a narrow web portion in the present invention The figure explaining the bending angle in this invention Example

Claims (2)

It is a roll forming device in which a roll forming stand with a forming roll attached to the vertical axis supported at both ends is arranged in multiple stages, and only one of the two bent portions of the groove- shaped cross-section material is provided on the vertical axis supported at both ends. A molding stand group to which a molding roll for bending is attached and a molding stand group to which a molding roll for bending only the other bending part is arranged, and either one of the stand groups with respect to the other stand group is arranged. It is mounted so that it can move in the horizontal direction perpendicular to the forming flow direction, and is flat by a roll forming device in which the distance between the two bent portions can be adjusted according to the width of the web of the channel-shaped section material to be formed. A method for forming a groove-shaped cross-sectional material having a predetermined range of thickness with flanges on both sides of a simple web, wherein the thickness is the largest among the groove-shaped cross-sectional materials formed by the roll forming device When using a roll that is designed to form a cross-sectional material, and forming a thin channel-shaped cross-sectional material that is thinner than the thickest channel-shaped cross-sectional material to be molded, the groove Between the second half of the rough forming region where the cross-section material is formed to the final shape, and the region including the subsequent forming for removing residual stress and ensuring dimensional accuracy, A grooved cross section roll characterized by correcting the dimensions of the corner section using a forming roll designed according to the thickness of the groove shaped cross section material formed by the radius inside the corner section sandwiched between the web and the flange. Molding method.   By adjusting the distance between the upper and lower shafts of the rolls that are attached to the upper and lower shafts supported at both ends and are designed so that the thickest groove-shaped cross-section material can be formed. The method for forming a groove-shaped cross-section material according to claim 1, wherein a gap at a position corresponding to the shape steel web portion of the forming roll is matched with the thickness of the shape steel to be formed.

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