JPH07100181B2 - Cold roll forming method and apparatus - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a cold roll forming method and apparatus, and more particularly, when forming a product of different cross-section and same-thickness with an open cross section using a roll having a combined thickness. The present invention relates to a cold roll forming method and apparatus to be applied.

[Prior Art] In cold roll forming, when forming a product with an open cross section and the same external dimensions but different thicknesses but different thicknesses,
It is practiced to use a roll having a combined thickness. The plate thickness / combination roll refers to a forming roll that forms a roll hole die corresponding to each plate thickness by adjusting the roll width direction position of the plurality of divided rolls according to each plate thickness. For example, the fourth
Explaining the grooved steel 1 with a lip consisting of the web 1a, the flange 1b and the lip 1c shown in the figure as an example, the product size is the outer dimensions (web dimension W, flange dimension F, lip dimension P). Since it is specified, the development length of the material (theoretical total material width: length of the center line of the plate thickness) will differ if the plate thickness differs, and the web part length L _w and the flange part length of the expanded length L _F and lip length L _p change depending on the plate thickness. Therefore, even for products of the same size, if the plate thickness is different, the bending position at the time of molding changes and the edge position changes. For example, regarding the lip bending process of FIG. 5, the A dimension, B dimension, and C dimension differ depending on the plate thickness. However, in the plate thickness / combination roll, the positions of the upper horizontal roll 2 and the lower horizontal roll 3 in the roll width direction are adjusted by adjusting the thickness of the shim 4 to adjust the A dimension and the B dimension, but the C dimension is adjusted. Since the position adjustment cannot be performed, the C dimension, that is, the edge height position dimension is not specified.
As described above, the plate-thickness roll has a roll hole type in which the position of the roll is adjusted to correspond to the bending position for each plate thickness, but the height position of the edge is not restricted. In this case,
The roll hole type is designed with reference to the maximum plate thickness in the combined range, and the position of the roll in the width direction is adjusted when forming a product having a small plate thickness.

[Problems to be Solved by the Invention] By the way, the allowable dimensional accuracy of the light-weight shaped steel specified by JIS is ± 1.5 to ± 2.0 mm, and the above-mentioned plate thickness / combined roll is sufficient for such dimensional accuracy. We can handle it, but for example ± 0.
It is not easy to satisfy this when an allowable dimensional accuracy of about 5 mm is required. In order to realize such high precision, it is desirable to use a dedicated roll for each plate thickness as a roll hole type that defines not only the above A dimension and B dimension but also C dimension, that is, the edge height position. . However, having a dedicated roll for each plate thickness means that a dedicated roll is provided for each plate thickness for all forming stands, which significantly increases the equipment cost (roll cost). As a result, the cost is significantly increased. Under such circumstances, it is desired to realize high dimensional accuracy while using a roll having a combined thickness.

By the way, it is common in forming a closed cross section such as a round tube or a square tube to obtain the dimensions of the final cross-sectional shape by performing forming that applies compressive stress in the plate width direction of the material, that is, draw forming. It has not been carried out on grooved steels that obtain the final shape by forming, grooved steels with lips, and other lightweight steels with open cross-sections. This is because in forming an open cross section by bending, the bending itself corresponds to determining the dimensions, so the idea is to adjust the dimensions by drawing (so-called sizing) as in the case of forming steel pipes. It is because there is no such thing. However, even in the forming process of the open cross section, the application of the compressive stress in the plate width direction of the material is carried out for the purpose different from the above. For example, Japanese Patent Publication No. 1-348686 discloses that a compressive stress in the plate width direction is applied to two sides on both sides of the corner radius in order to sharpen the corner radius of the bending molding. Further, Japanese Patent Publication No. 62-36769 discloses that a compressive stress in the plate width direction is applied to the flange portion in order to reduce the deformation of the cutting edge in forming channel steel or the like. However, these are not done for the purpose of improving the dimensional accuracy of the product.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a cold roll forming method and apparatus that can realize high dimensional accuracy for each plate thickness while using a roll also having a plate thickness. To do.

[Means for Solving the Problems] According to the invention of claim 1 for solving the above problems, products having the same outer size but different outer thickness but different plate thickness are commonly used for each plate thickness. A cold roll forming method of forming using a plate thickness / combination roll to be used, which is formed into a substantially final cross-sectional shape by the plate thickness / combination roll, and then contacts the outer surface of a molding material formed into the substantially final cross-sectional shape. It has a roll hole type unique to the plate thickness, consisting of upper and lower horizontal rolls that roll down from above and below and from the left and right, and left and right side rolls, and edge side rolls that contact the left and right edges of the forming material and restrain this edge. It is characterized in that a final desired cross-sectional shape is obtained by applying a compressive stress in the plate width direction to the molding material by means of a draw forming roll.

A second aspect of the present invention is a cold roll forming apparatus for forming channel steel with a lip by using the cold roll forming method according to the first aspect, wherein a web portion that comes into contact with a web portion of a forming material from an outer surface is horizontal. Rolls, horizontal lip rolls that contact the lip from the outside, left and right flange side rolls that touch the left and right flanges from the outside, and the left and right lip parts that are placed between the left and right lip parts, respectively. It is characterized in that it is provided with a draw-forming roll consisting of contacting edge side rolls.

The invention of claim 3 relates to the support structure for the edge side rolls according to claim 2, wherein a pair of core-type holders supported so as to be located inside the grooved cross section with a lip and having a vertical axis is provided. Is mounted, and a shaft provided integrally with the edge side roll is fitted into each bearing so that the shaft can be freely inserted and removed.

According to a fourth aspect of the present invention, the bearing according to the third aspect is mounted on the core-type holder so that the outer peripheral surfaces of the outer rings contact each other, and the collar having the same diameter as the bearing and the outer peripheral surfaces contact each other on the edge side roll. It is characterized by having a section.

The invention of claim 5 provides the horizontal lip roll of claim 2,
A small-diameter outer peripheral surface is provided near the end surface of the edge side roll.

[Operation] When forming a product with a certain plate thickness in products with different plate thicknesses, a normal forming using a roll that also serves as a drawing roll with a unique roll hole type corresponding to the plate thickness Place it downstream of the roll stand. By forming with the roll also having a plate thickness, for example, a formed material having a substantially final cross-sectional shape with a dimensional accuracy within ± 1.5 mm can be obtained.

The molding material molded into a substantially final cross-sectional shape is subjected to compressive stress in the plate width direction when passing through the drawing roller. That is,
The upper and lower horizontal rolls and the left and right side rolls apply compression to the outer surface of the forming material from above and below and from the left and right.In this state, the edge side rolls restrain the edges of the material and compress the material in the plate width direction. Works. The deformation of the material due to the compressive stress escapes to the corner radius (that is, the corner radius becomes smaller), so that the outer dimension of the cross section of the molding material becomes a desired dimension corresponding to the roll hole die. That is, draw forming is performed.

When the plate thickness is changed, the position of the roll also serving as the plate thickness in the roll width direction is adjusted according to the corresponding plate thickness, and the position of the edge side roll of the draw forming roll is adjusted or replaced to obtain the roll hole. The die is changed to a roll hole die having the plate thickness.

By the above, for example, ± 1.5 when molding with a roll that also serves as plate thickness
Even if an error of about ± 2 mm occurs, it is possible to realize a high dimensional accuracy of ± 0.5 mm or the like with the subsequent draw forming roll.

The invention of claim 2 is applied to the forming of channel steel with a lip. In this case, the horizontal roll of the web and the horizontal roll of the lip exert a compressive stress on the flange of the molding material, and the left and right flange side rolls exert a compressive stress on the web of the molding material. A compressive stress is applied to the lip portion by the roll and the two edge side rolls in the middle, and a compressive stress in the plate width direction of the forming material is applied. That is, draw forming is performed.

The edge side rolls between the left and right lip parts that contact the edges of the left and right lip parts have a smaller diameter than the case where the edges of the lip parts are constrained using a horizontal roll. Due to the short length, there is less slip between material and roll and less friction. Therefore, the material is not scratched or the like.

In the invention of claim 3, the edge side rolls can be exchanged according to the plate thickness simply by removing and inserting the edge side rolls, and the plate thickness can be easily changed.

In the invention of claim 4, the outer ring outer peripheral surfaces of the two bearings contact each other, and at the same time, the flange portions integrated with the edge side rolls also contact each other, so that the two edge side rolls act from each edge of the lip portion. The force moments cancel each other out, reducing the demands on the rigidity of the edge side roll support structure.

Further, since the collar portion is located on the lower surface of the lip portion of the molding material, when the edge side roll is about to come off during molding, the collar portion comes into contact with the lip portion and acts as a stopper.

In the invention of claim 5, since the small-diameter outer peripheral surface of the horizontal roll of the lip portion covers the edge side roll,
The edge side rolls are prevented from coming off.

[Embodiment] An embodiment of the present invention will be described below with reference to FIGS. 1 to 5.

FIG. 1 shows a draw forming roll used for forming grooved steel with a lip, which is arranged on the downstream side of a forming roll stand by a roll also serving as a plate thickness. The plate thickness / combination roll is as described above with reference to FIG. 5, and the upper horizontal roll 2 and the lower horizontal roll 3 attached to the horizontal upper and lower roll shafts of the molding stand (not shown) are both It is a roll which is divided into a plurality of parts and whose position in the roll width direction is adjusted by adjusting the thickness of the shim 4 so as to correspond to each plate thickness. Therefore, the bending procedure and the like are the same as those of the normal forming roll unless otherwise combined.

The draw forming roll 10 is a web portion horizontal roll 11 that contacts the lower surface of the web portion 1a of the forming material 1 (note that the product of the channel steel with a lip and the product in the forming process are both indicated by the same reference numeral 1). And the left and right lip portion horizontal rolls 12 that contact the upper surfaces of the left and right lip portions 1c, the left and right flange portion side rolls 13 that contact the outer surfaces of the left and right flange portions 1b, and the left and right lip portions 1c. The left and right edge side rolls 14 contact the edges 1d of the left and right lip portions 1c, respectively.

The web portion horizontal roll 11 and the lip portion horizontal roll 12
Although not shown in detail, it can be moved up and down according to the product size. Further, the left and right flange side rolls 13 can also be moved and adjusted left and right according to the product size. Further, the lip portion horizontal roll 12 has a small diameter outer peripheral surface 12a close to the upper end surface of the edge side roll 14.

The edge side roll 14 is attached to a core holder 15 which is supported so as to be located inside the grooved section with a lip. That is, a pair of bearings 16 having a vertical axis is attached to the core-type holder 15 so that the outer peripheral surfaces of the outer rings thereof are in contact with each other, and the shaft portion 14a of the edge side roll 14 is fitted into the bearings 16 as well. A flange portion 14b having the same diameter as the bearing 16 is provided integrally with the edge side roll 14, and the flange portions 14b are also in contact with each other. In the edge side roll 14, the shaft portion 14a is simply fitted into the bearing 16 so that it can be easily inserted and removed. Further, since the edge side roll 14 is the most worn, it is preferable to use a wear-resistant sintered alloy or the like having high hardness.

The draw forming roll 10 may be movably attached to a face plate having a passage hole for the forming material, similarly to a turks head roll for correcting warpage, lateral bending, and twist of the forming material, or the web portion. The horizontal roll 11 and the lip portion horizontal roll 12 may be attached to the horizontal roll shaft of the molding stand, and the flange portion side roll 13 and the edge side roll 14 may be separately installed in accordance with this.

In the case of forming with the above-mentioned plate thickness roll, for example ± 1.5 mm
It is possible to obtain a molding material having a substantially final cross-sectional shape with dimensional accuracy within the range. The molding material 1 molded into the substantially final cross-sectional shape is subjected to compressive stress in the plate width direction when passing through the drawing roll 10. That is, the compressive stress acts on the flange portion 1b of the molding material 1 under the pressure exerted by the web horizontal roll 11 and the lip horizontal roll 12, and the compressive stress acts on the web portion 1a under the lateral pressure exerted by the left and right side rolls. The left and right flange side rolls 13 and the intermediate edge side rolls 14 exert a compressive stress on the lip portion 1c, thus exerting a compressive stress in the plate width direction on the entire formed material. The deformation of the material due to the compressive stress escapes to the corner radius (that is, the corner radius becomes smaller), so that the outer dimension of the cross section of the molding material becomes a desired dimension corresponding to the roll hole die. As a result, high dimensional accuracy of, for example, ± 0.5 mm is realized.
The plate width direction mentioned above means the length direction of the plate thickness center line of the material indicated by the one-dot chain line in FIG.

In the draw forming described above, the edge side rolls 14 which are between the left and right lip portions 1c and contact the edges 1d of the left and right lip portions 1c, respectively, are compared with the case where the edge 1d of the lip portion 1c is constrained using a horizontal roll. , The diameter is small. Therefore, the length of the contact surface of the material from the upstream is short, the slip between the material and the roll is small, the friction is small, and the material is not scratched or the like.

Further, when the molding material is drawn into the draw forming roll 10, the web horizontal roll 11 and the lip horizontal roll 12 are formed on the molding material.
First hits and presses the flange portion 1b of the molded material 1.
Next, the web portions 1a are pressed against the left and right flange side rolls 13. Finally, the edge side roll 14 is hit and the lip portion 1c is pressed. According to such a pressing sequence, the web portion is pressed in the state where the flange portion 1b is pressed and restrained.
Since the pressure is applied to 1a, there is no risk of the flange portion 1b falling over, fluctuations in the position of the edge 1d of the lip portion 1c are prevented, and it is considered that the throttle effect at the corner portion is high.

Further, when changing the plate thickness, it is sufficient to pull out the edge side roll 14 from the bearing 16 and simply insert the edge side roll 14 having an outer diameter corresponding to the next plate thickness into the bearing 16, so that when changing the plate thickness The work is extremely easy.

Further, the outer ring outer peripheral surfaces of the two bearings 16 come into contact with each other, and at the same time, the flange portions 14b integral with the edge side rolls 14 also come into contact with each other, so that the forces acting on the two edge side rolls 14 from the respective edges of the lip portion are applied. The moments cancel each other out, reducing the demands on the rigidity of the edge side roll support structure.

Further, since the brim portion 14b is located on the lower surface of the lip portion 1c of the molding material 1, when the edge side roll 14 tries to come off during molding, the brim portion 14b hits the lip portion 1c and acts as a retaining member. .

Further, since the small-diameter outer peripheral surface 12a of the horizontal lip roll 12 covers the edge side roll 14, this also prevents the edge side roll 14 from coming off.

In addition, although the grooved steel with a lip is described in the examples, it has an open cross-section having a shape broadly similar to the grooved steel with a lip, and the edge width of the edge side roll that contacts the left and right edges of the material causes the forming material to move in the plate width direction. The present invention can be applied as long as it has a cross-sectional shape capable of exerting the compressive stress.

[Effects of the Invention] Since the present invention is configured as described above, the following effects are achieved.

Since the final cross-sectional shape is obtained by applying compressive stress in the sheet width direction to the forming material with a draw forming roll that has a roll hole type unique to the sheet thickness after forming with the roll that also serves as the sheet thickness, the edge height position of the material Despite forming by bending using a roll that also serves as a plate thickness that does not constrain, it is possible to obtain high shape dimension accuracy for products of all plate thicknesses.

In addition, when changing the plate thickness, the roll hole type of the draw forming roll can be made unique to the plate thickness simply by adjusting the position of the edge side roll or replacing the edge side roll. It's easy.

According to the invention of claim 2, since the diameter of the edge side roll is small and the length of the material which is guided in from the upstream is short, the slip between the material and the roll is small and the friction is small. Therefore, the material is not scratched or the like.

According to the invention of claim 3, the exchange of the edge side rolls can be performed only by the insertion / removal operation, and the work is extremely simple.

According to the invention of claim 4, the outer circumferential surfaces of the outer rings of the two bearings are in contact with each other, and the flange portions of the two edge side rolls are also in contact with each other, so that the moments due to the forces acting on the respective edge side rolls are cancelled. The requirements for the rigidity of the edge side roll support structure are reduced.

Further, since the brim portion is located on the lower surface of the lip portion of the molding material, it also serves to prevent the edge side roll from coming off.

According to the fifth aspect of the invention, the edge side roll is prevented from coming off by the small-diameter outer peripheral surface of the horizontal roll of the lip portion.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows an embodiment of the present invention. FIG. 1 is a front view of a drawing roll used for forming channel steel with a lip, FIG. 2 is a plan view of the roll, and FIG. FIG. 4 is a side view, FIG. 4 is a cross-sectional view of a channel steel with a lip, and FIG. 5 is a front view of a plate thickness / combining roll in a lip bending process in forming a channel steel with a lip. 1 ... Channel steel with lip, 1a ... Web part, 1b ... Flange part, 1c ... Lip part, 1d ... Edge, 2 ... Top horizontal roll (thickness roll), 3 ... Bottom horizontal roll (thickness roll) 4 ... Shim, 10 ... Drawing forming roll, 11 ... Web part horizontal roll, 12 ... Lip part horizontal roll, 12a ... Small diameter outer peripheral surface, 13 ... Flange side roll, 14 ... Edge side roll, 14a ... Shaft part, 14b … Brim part, 15… Core holder, 16
…bearing.

Claims (5)

[Claims] Claim: What is claimed is: 1. A cold roll forming method for forming a product having an open cross-section and having the same outer dimensions but different plate thicknesses but different plate thicknesses and the same size by using a roll having a combined plate thickness commonly used for each plate thickness. The upper and lower horizontal rolls (11), which are formed into a substantially final cross-sectional shape by the roll also serving as the plate thickness and then come into contact with the outer surface of the molding material (1) formed into the substantially final cross-sectional shape, and roll down from the vertical and horizontal directions (11). ), (12) and left and right side rolls (13)
And the edge side rolls (14) that come into contact with the left and right edges (1d) of the forming material and restrain this edge, the drawing forming roll (10) having a roll hole shape unique to the plate thickness A cold roll forming method, characterized in that a final desired cross-sectional shape is obtained by applying compressive stress in the plate width direction to. 2. A cold roll forming apparatus for forming grooved steel with a lip by using the cold roll forming method according to claim 1, wherein a web portion horizontal roll that contacts the web portion of the forming material from the outer surface ( 11), the lip horizontal rolls (12) that come into contact with the lips from the outside, the left and right flange side rolls (13) that come into contact with the left and right flanges from the outside, and the left and right lips arranged between the left and right lips. A cold roll forming apparatus comprising: a draw forming roll (10) including edge side rolls (14) that come into contact with the edges of the lip portions of the. 3. A pair of bearings (16) having a vertical axis is attached to a core-type holder (15) supported so as to be located inside the grooved cross section with lips, and each bearing (16) is attached to each bearing (16). The cold roll forming apparatus according to claim 2, wherein a shaft (14a) provided integrally with the edge side roll (14) is fitted so as to be detachable. 4. The bearing (16) is attached to the core-type holder (15) so that the outer peripheral surfaces of the outer rings thereof are in contact with each other, and the edge side rolls (14) have the same diameter as the bearing (16). 4. The cold roll forming apparatus according to claim 3, further comprising a flange portion (14b) whose outer peripheral surfaces are in contact with each other. 5. The cold roll forming apparatus according to claim 2, wherein the lip horizontal roll (12) has a small-diameter outer peripheral surface (12a) adjacent to a side surface of the edge side roll (14). .