JPH08174656A - Method and apparatus for roll molding of laminated metal panel - Google Patents

Abstract

PURPOSE: To prevent not only the generation of a wavy defect such as a pocket wave or an edge wave at the time of the roll molding of a laminated metal panel but also the deterioration of dimensional accuracy caused by the spring back of a bending corner part. CONSTITUTION: In a method subjecting a lamainated metal panel formed by bonding two metal panels through a viscoelastic substance with a thickness tr of 0.01mm or more to roll molding using stand groups arranged in a tandem state, the roll clearance of first and final stage stands is set to the range from [total thickness (t) thickness tr of viscoelastic substance/31mm to below (t) mum when the total thickness of the laminated metal panel is set to (t) and the roll clearance of other molding stands is set to 1.0-2.0 times the total thickness (t) of the laminated metal panel.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a roll of a laminated metal plate in which a viscoelastic substance is sandwiched and adhered between two metal plates.
The present invention relates to a method and an apparatus for preventing wave-like defects such as pocket waves and edge waves and deterioration of bending dimension accuracy with respect to molding. The term "pocket wave" as used herein refers to irregular wrinkles in which shallow bends appear wavy on the surface of a laminated metal plate and are periodically generated. The wrinkles that occur at the ends in the longitudinal direction are called "edge waves".

[0002]

2. Description of the Related Art Laminated metal plates exhibit remarkable vibration damping performance by interposing a viscoelastic material such as synthetic resin having vibration damping performance between two metal plates. Conventionally,
For roofing materials, flooring materials, and wall materials, a single metal plate that has been formed and processed has been used. In recent years, however, such laminated metal plates have been used because of their remarkable vibration damping and soundproofing effects. I'm getting more and more. Generally, these roofs, floors,
For forming wall materials, the caliber roll stands are arranged in tandem and the caliber rolls are installed on each stand.
A roll forming method is used in which bending deformation is sequentially applied depending on the roll. However, the laminated metal plate has a three-layer structure of metal plate / viscoelastic material / metal plate, and if the total plate thickness is made equal to that of a conventional single metal plate, the thickness per metal plate is (total thickness t
Since the thickness is about half that of viscoelastic material tr) / 2, a wavy defect such as an edge wave is apt to occur in a pocket wave or an edge portion of a molded product during roll molding. In addition, since the laminated metal plate has two thin metal plates and a large springback amount due to the displacement of both metal plates due to the shear deformation of the viscoelastic material layer between them, the bending corner portion has a predetermined bending. There is a problem that it is difficult to obtain the angle.

As described above, since the laminate metal plate is inferior in roll formability, when the laminate metal plate cannot be satisfactorily formed in the roll forming apparatus which has been able to form a single metal plate without any problems in the past. There are many. As a countermeasure in that case, as shown in JP-A-1-143723, defects are prevented by increasing the number of stand steps and gradually reducing the bending amount such as the bending angle for each step and gradually bending. Another method is to force the springback by setting the roll caliper at the post-forming stage to overbend. On the other hand, most of the current roll forming machines for forming roofs, floors, wall materials, etc., use a common drive as the drive method, and the roll reduction method as a constant clearance that unifies the roll clearance to the bare plate thickness. Since this is a system, the structure of the device is relatively simple and inexpensive, and it is widely used. However, since the roll caliber and the number of stand stages are designed for ordinary single plate forming, in order to realize the above method for a laminate metal plate in these ordinary roll forming apparatuses, , New measures are needed.

The following methods are known as methods for preventing pocket waves by applying tension in the longitudinal direction in wide roll forming of a thin plate in which pocket waves easily occur.

(1) A method of increasing the standard roll diameter of each forming stand by about 0.5 to 1.0% to apply tension ("Roll Forming" 1990 P edited by Japan Society for Plasticity Processing)
103).

(2) A method in which the standard roll diameter of the final 3 to 5 stands is increased by 5 to 10% and tension is applied (“Roll molding” 1990 P103, edited by Japan Society for Plastic Processing). (3) From the molding stands, find the stand causing the pocket wave, and immediately after that, separate the drive system into the upstream side and the downstream side, and use two motors for each. Driven by the motor, and the rotational speed on the downstream side is 1.15 to 1.2 times that on the upstream side (Japanese Patent Publication No. 61-16).
No. 204).

Both of the techniques (1) and (2) are methods of applying tension to the object to be molded by increasing the roll peripheral speed in the latter stage, but in the case of forming a laminated metal plate. No findings have been disclosed. In a roll forming device that adopts a constant clearance method that keeps the roll clearance constant, a single plate serves as a cushioning material with a small elastic modulus, such as an intermediate viscoelastic material layer, unlike a laminated metal plate. Since there is no layer, if the roll clearance is less than the plate thickness, the amount of reduction will be excessive, and roll flaws, defective shapes, and peeling and misalignment of the upper and lower metal plates are likely to occur on the surface. On the other hand, if the clearance is equal to or larger than the plate thickness, it is not possible to effectively apply the tension by utilizing the difference in roll peripheral speed between the stages.
Similarly to (1) and (2), (3) is also a method that utilizes the difference in roll peripheral speed, but the drive system is separated between the upstream and downstream sides of the stand that causes pocket waves. Since it is divided into two, if the stand that causes the shape defect differs for each molding shape or if the shape defect occurs in multiple stands, there is no choice but to change the upstream and downstream divisions. ， Correspondence is extremely difficult.

[0008]

As described above, by using the conventional roll forming apparatus, the laminar metal plate is subjected to wavy defects such as pocket waves and edge waves, and deterioration of dimensional accuracy of spring bags and the like. It is necessary to modify the equipment and add several new molding stands in order to perform roll molding without causing the above. Among the problems in roll forming of a laminate metal plate, there is a method of applying tension to the object to be formed by using the peripheral speed difference of the roll to prevent the pocket wave. If the clearance is set too narrow, many roll flaws and shape defects will occur on the surface of the object to be molded, and the upper and lower metal plates will be separated or misaligned. On the other hand, if it is too wide, appropriate tension cannot be applied. is there. Also, since the number of locations that cause waves is not limited to one, it must be a method that has the effect of preventing waves during the entire molding process from the early stages of molding to the latter stages. The present invention has been made in view of the above circumstances, and is applied to the production of roofs, floors, wall materials and the like for forming a single plate with a common drive and a roll reduction method with a constant clearance method. In the designed roll forming device, without adding a forming stand, it is possible to prevent wave defects such as pocket waves and edge waves, which are likely to occur during roll forming of the laminated metal sheet, and to bend at the same time. It is an object of the present invention to provide a roll forming method for a laminated metal plate and an apparatus therefor capable of preventing deterioration of dimensional accuracy due to corner springback.

[0009]

When roll-forming a laminate metal plate in which a viscoelastic material having a thickness tr of 0.01 mm or more is sandwiched and adhered between two metal plates, the rolls in each forming stand are rolled. -By specifying the size of the roll clearance and the standard roll diameter of the final stand, and further specifying the shape of the roll caliber in the final stand, the pockets can be formed without causing roll flaws on the surface of the molded body. It has been found that the generation of waves and edge waves is prevented and the spring bag is prevented. The characteristic configuration is as follows.

(1) Rolling of the first and last molding stands
The clearance is (total thickness t-viscoelastic material thickness tr / 3) (mm) or more, where t is the total thickness of the laminated metal plate, and t
(Mm), and the roll clearance of the other forming stand is more than 1.0 times and 2.0 times or less of the total thickness t of the laminated metal plate.

(2) In (1), the standard roll diameter ΦDL of the last stand, and the standard roll diameter Φ of the immediately preceding stand.
It is more than 1.1 times and less than 1.3 times DL-1. (3) In (1) and (2), the roll shape of the final stand is such that it is brought into contact with the object to be molded only on a surface horizontal to the roll axis. (4) In (1), (2), and (3), copper alloy rolls are used for the final stand to prevent roll flaws on the surface of the molded body.

[0012]

Operation Roll forming is not a two-dimensional deformation like press bending but a three-dimensional deformation, and since the forming path is different at each position in the width direction of the blank in the forming process, different amounts of longitudinal direction are applied. Strain is added. The pocket wave and the edge wave are a kind of buckling phenomenon caused by the longitudinal residual stress caused by these additional strains causing an imbalance in the width direction of the molded product. These phenomena can be eliminated by applying sufficient tension to the molded body during molding and stretching the molded body uniformly in the longitudinal direction. In addition, the spring bag peculiar to the laminated metal plate has a three-layer structure, so that the two metal plates are thin, and the viscoelastic material layer in the middle is easily sheared and deformed, resulting in the displacement of both metal plates. Although it occurs, it is also possible to minimize the spring bag of the molded product by applying sufficient tension during molding to increase the equivalent plastic strain of the metal plate in each bending corner.

In order to generate tension, the reference roll diameter of the last stage stand is made larger than the reference roll diameter of the stand immediately before it, and the roll peripheral speed at the last stage is increased.
Then, tension is applied by a method of pulling out by friction between the molded body and the roll. The standard roll diameter after the first stage may be constant, but only in the final stage, the standard roll diameter ΦDL is
The required tension can be generated by exceeding 1.1 times the standard roll diameter ΦDL-1 of the stand immediately before that. In this case, all of the energy generated by the difference in the standard roll diameter, that is, the difference in the roll peripheral speed, does not contribute to the generation of tension, and a part or most of it becomes a slip with the surface of the molded body and is consumed. To be done. If the final standard roll diameter is increased, a greater amount of tension is likely to be generated, but on the other hand, the slip between the molded product and the molded product is increased and roll defects are more likely to occur. In that case, by using a copper alloy as the material of the roll of the final stand, it is possible to suppress the roll flaw in the range of the standard roll diameter ratio up to 1.3 times.

In the constant clearance type roll forming device, the pinch force is determined by the set value of the roll clearance, but in order to obtain the pulling effect by increasing the reference roll diameter in the final stage, it is different from that in the first stage. It is necessary to reliably pinch the molded body at the final stage. Therefore, the upper limit of the roll clearance in the first stage and the final stage is set to less than the total thickness t (mm) of the laminated metal plate. In addition, the lower limit is (total thickness t-
The thickness of the viscoelastic substance tr / 3) (mm) is defined as
This is because the metal plate has a relatively soft viscoelastic substance interposed between the two metal plates, and it serves as an appropriate cushioning material. The metal plate itself is not affected, and roll flaws are less likely to occur. In this case, the thickness of the viscoelastic substance must be at least 0.01 mm in order to act as a buffer material. If the roll clearance is (total thickness t-thickness of viscoelastic substance tr / 3) (mm) or more, the viscoelastic substance is pressed down, so it is not an unreasonable reduction, but if the clearance is further narrowed Since the amount of reduction is excessive, roll flaws and upper and lower metal plates are likely to be displaced or peeled off on the surface of the molded product. The roll clearance in the stand from the second stage to immediately before the final stage is set to a slightly wider lower limit so that the tension generated by the final stand is transmitted to the first stage and the tension is evenly transmitted to the entire body being molded. It is assumed that the total thickness t of the laminated metal plate exceeds 1.0 times.
This also has the effect of minimizing surface roll flaws. The reason why the upper limit value is set to 2.0 times or less is that proper bending cannot be performed in the bending corner portion if the clearance is further opened. In the final stand, the roll clearance should be less than the total thickness t (mm) of the laminate metal plate because it is necessary to reliably pinch and pull out the molded product that has been molded to the final cross-sectional shape. If the roll caliber has a shape in which the molded body is filled in the sloping portion of the caliber, the roll shape of the final stand is such that the rolled body is in contact with the molded body only on a surface horizontal to the roll axis. In addition, depending on the molding shape, the contact width with the roll to obtain the required pinch force is not sufficient, so it is necessary to arrange multiple stands with the same roll shape, size, and material as the final stand. In some cases On the other hand, in the final stand, in order to suppress the occurrence of roll flaws on the surface of the molded body, a copper alloy material (MS50, Hv20 kgf =
The roll of (330) is used, but if it is made to contact with the roll shaft only on a horizontal surface, it does not need to be refurbished even if the roll itself is worn and it must be used for a long time. You can

[0015]

【Example】

Example 1 A molded article having a final shape of the cross-sectional shape shown in FIG. 1 was roll-molded by a 15-stage roll molding machine. Reference numeral 1 shows a forming roll of the final stand, and 2 shows a final shape of a molded product of the laminated metal plate. The transition of the cross-sectional shape in the roll forming process is shown in FIG. # 0 is the original shape of the laminated metal plate, # 3 to # 12
Indicates the intermediate deformation angle and the bent shape, and # 15 indicates the final shape. The test materials are No. 1 and No. 2 shown in Table 1.
The metal plate material is cold rolled steel plate SPCC and color steel plate CGCC, the intermediate viscoelastic material layer is acrylic thermosetting synthetic resin, and the plate thickness composition is 0.3 / 0.10 / 0.3 (mm).
Is. The roll clearance condition is 0 for the first and last stages.
67 mm, 0.80 mm from the second step to the 14th step was constant. The standard roll diameter was constant from the first stage to the 14th stage, and was changed only in the final stage. As shown in Fig. 1, the shape of the roll in the final stand is such that only the horizontal part can be pressed up and down, and the material of the roll is copper alloy roll.
(Inventive roll, MS50, Hv20 kgf = 33
0) or a hard chrome plating roll (comparative roll) was used. 5 to 10 show the measurement results of the pocket wave steepness of the flat part of the molded product, the edge wave steepness of the edge part, and the springback amount of the double-sided bent part. The springback amount is represented by the ratio (H / H0) of the height H of the bending portion to the reference value H0 of the single plate as shown in FIG. Figure 5,
7 and 9 show the ratio (ΦDL / ΦDL-1) of the final stage standard roll diameter ΦDL to the 14th stage fourth standard roll diameter ΦDL-1 when the copper alloy roll is used. If greater than 1,
It is possible to reduce the steepness of the pocket wave, the steepness of the edge wave, and the amount of spring back. The standard roll diameter ratio is 1.
In the range up to 30, no roll flaw was generated on the surface of the molded body. On the other hand, as shown in FIGS. 6, 8 and 10, when the hard chrome plated roll was used, the roll flaw was generated when the standard roll diameter ratio was 1.1 or more.

Example 2 A 16-stage roll molding machine was used to roll-mold a molded product whose final shape was the cross-sectional shape shown in FIG. Reference numeral 3 indicates a forming roll of the final stand, and 4 indicates a final shape of a formed product of the laminated metal plate. The transition of the cross-sectional shape in the roll forming process is shown in FIG. # 0 is the original shape of the laminated metal plate, # 3 to # 13
Shows the intermediate deformation angle and the bent shape, and # 15 shows the final shape which is the same as the final stage # 16. Table 1 shows the test materials
No. 3 and No. 4 shown in Fig. 4, the metal plate material is cold rolled steel plate SPCC and galvanized steel plate SGCC, the intermediate viscoelastic material layer is acrylic thermosetting synthetic resin, and the plate thickness composition is 0.
It is 4 / 0.10 / 0.4 (mm). Roll clearance conditions are 0.87mm for the first step, the 15th step and the 16th step,
From the second stage to the 14th stage, it was fixed at 1.00 mm.
The standard roll diameter was constant from the first stage to the 14th stage, and the 15th stage and the 16th stage were changed simultaneously. The rolls at the 15th and 16th stages have the same shape, and as shown in FIG. 2, only the horizontal portion can be pressed vertically. Further, as the roll material, a copper alloy roll (the present invention roll MS50, Hv 20 kgf = 330) or a hard chrome plating roll (comparative roll) was used. 11 to 16 show the measurement results of the pocket wave steepness of the flat portion of the molded product, the edge wave steepness of the edge portion, and the spring bag amount of the entire width of the molded product. The spring bag amount is represented by the ratio (W / W0) of the full width W of the molded product to the reference value W0 of the single plate as shown in FIG. 11, FIG. 13, and FIG.
5 is a case where a copper alloy roll is used, as shown in FIGS.
No. 6 is the result when a hard chrome plating roll is used. When copper alloy rolls are used as shown in FIGS. 11, 13, and 15, the 14th-stage standard roll diameter ΦDL of the final 15th and 16th stage standard roll diameters ΦDL If the ratio to -1 (ΦDL / ΦDL-1) is larger than 1.1, it is possible to reduce the steepness of the pocket wave, the steepness of the edge wave, and the springback amount, and the standard roll diameter ratio 1 .3
In the range up to 0, roll flaws did not occur on the surface of the molded article. On the other hand, as shown in FIGS. 12, 14 and 16, when the hard chrome plated roll was used, the roll flaw was generated when the standard roll diameter ratio was 1.1 or more.

[0017]

[Table 1]

[0018]

According to the present invention, in a roll forming apparatus which has been widely used in the past for the purpose of forming a single plate,
By changing the roll shape, size, and material of the final stand, it becomes possible to roll-form the laminated metal plate.
It is possible to prevent wavy defects such as pocket waves and edge waves and dimensional accuracy deterioration of spring bags and the like, which have been a problem in the past when forming a laminated metal plate. The laminate metal plate can be easily applied to roll-formed products without the need for major modification of the roll-forming equipment or the addition of a new forming stand.

[Brief description of drawings]

FIG. 1 is a view showing a roll shape of a final 15-stage stand and a sectional shape of a molded product.

FIG. 2 is a view showing a roll shape of the final 15-stage and 16-stage stands and a sectional shape of a molded product.

FIG. 3 Transition of cross-sectional shape in roll forming process

FIG. 4 Transition of cross-sectional shape during roll forming process

FIG. 5 is a graph showing a relationship between a standard roll diameter ratio and a pocket wave when a copper alloy roll is used.

FIG. 6 is a graph showing the relationship between the standard roll diameter ratio and the pocket wave when a hard chrome plated roll is used.

FIG. 7 is a graph showing the relationship between the standard roll diameter ratio and the edge wave steepness when a copper alloy roll is used.

FIG. 8 is a graph showing the relationship between the standard roll diameter ratio and the edge wave steepness when a hard chrome plating roll is used.

FIG. 9 is a graph showing a relationship between a standard roll diameter ratio and a spring bag amount when a copper alloy roll is used.

FIG. 10 is a graph showing a relationship between a standard roll diameter ratio and a spring bag amount when a hard chrome plated roll is used.

FIG. 11 is a graph showing the relationship between the standard roll diameter ratio and the pocket wave when a copper alloy roll is used.

FIG. 12 is a graph showing the relationship between the standard roll diameter ratio and the pocket wave when a hard chrome plated roll is used.

FIG. 13 is a graph showing the relationship between the standard roll diameter ratio and the edge wave steepness when a copper alloy roll is used.

FIG. 14 is a graph showing the relationship between the standard roll diameter ratio and the edge wave steepness when a hard chrome plating roll is used.

FIG. 15 is a graph showing the relationship between the standard roll diameter ratio and the amount of spring bag when a copper alloy roll is used.

FIG. 16 is a graph showing a relationship between a standard roll diameter ratio and a spring bag amount when a hard chrome plated roll is used.

FIG. 17 is a diagram showing measurement points of a spring bag amount.

FIG. 18 is a diagram showing measurement points of a spring bag amount.

[Explanation of symbols]

 1 ... Roll 2 ... Molded product 3 ... Roll 4 ... Molded product

Claims (4)

[Claims] 1. A thickness tr is 0.01 between two metal plates.
Laminate with a viscoelastic substance of mm or more sandwiched and bonded
In the roll forming method, in which a metal plate is used as the base plate, and the base plates are passed through the forming rolls of a group of forming stands arranged in tandem to sequentially bend and deform the plate to form a desired cross-sectional shape, And the roll clearance of the forming stand at the final stage, where t is the total thickness of the laminated metal plate (total thickness t
-Thickness of the viscoelastic substance is set to tr / 3) (mm) or more and less than t (mm), and the roll clearance of the other forming stand exceeds 1.0 times the total thickness t of the laminated metal plate. A roll molding method in which it is 0 times or less. 2. The method according to claim 1, wherein the standard roll diameter ΦDL of the final stand is set to be more than 1.1 times and 1.3 times or less the standard roll diameter ΦDL-1 of the immediately preceding stand. Device to do. 3. The apparatus used in the method of claim 1 or 2, wherein the roll shape of the final stand is such that the roll shape is brought into contact with the object to be molded only on a surface horizontal to the roll axis. 4. The apparatus according to claim 1, wherein the final stand is made of copper alloy roll material.