JPS62244528A - Method and device for forming cold roll - Google Patents

Abstract

PURPOSE:To make a working efficient by supporting so as to engage in parallel two pieces of the roll group for forming composed by penetrating plurally divided rolls through a piece of shaft and giving a forming force via a backup mechanism as well. CONSTITUTION:A pair of composite rolls 3, 4 composed of the roll group for forming axially fitted to a piece of a supporting shaft are supported in a parallel state to the roll shaft for forming and rotatably with bearings 5a, 5b, 6a, 6b. A forming force is given via hydraulic cylinders 17, 18, 19 by installing backup rolls 9, 10, 11 at the upper and lower parts of the lower part. By using the device of this composition the shortening in the changing work of a roll forming die, reduction in a roll working cost and the increase in the working capacity can be performed.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention relates to a cold roll forming device and a forming method for forming a flat plate into a predetermined shape using rotating rolls, and is particularly suitable for forming wide materials and thick plate materials. The present invention relates to a suitable cold roll forming apparatus W and forming method.

[Conventional technology]

As described in Japanese Patent Application Laid-Open No. 54-62160, the conventional device can easily form a molded shape by mounting split molding roll parts on a pair of roll shafts to form a group of molding rolls. It is made so that it can be changed. However, in conventional forming apparatuses, the reduction blade applied to the forming rolls was applied at the end of the rotating shaft that penetrated the group of forming rolls.

[Problem that the invention seeks to solve]

With the above conventional technology, it is difficult to apply sufficient forming force to the forming roll group, and it is difficult to increase the bending rigidity of the forming phase roll shaft. There was a problem that the forming force was insufficient.

An object of the present invention is to provide a cold roll forming apparatus and a forming method that enable the forming of wide materials and thick plate materials.

[Means for solving problems]

” - [First, by mounting a plurality of forming rolls on a pair of rotatably supported support shafts to form a forming roll group, it is possible to form one to several types of molded products. In addition to realizing a cold roll forming device that can perform forming, backup mechanisms are provided above and below the forming roll group, and forming force can be applied to appropriate positions of the forming roll group via the backup mechanism. This is achieved by making it possible.

[Effect]

The cold roll forming apparatus of the present invention can form one to several types of molded products using a group of forming rolls mounted on a pair of shafts, making it extremely easy to change the molded shape and convert the rolls. At the same time, processing costs for forming rolls can be saved. Furthermore, since the cold roll forming apparatus of the present invention applies the forming force of the forming roll group through the backup mechanism, there is almost no axial deflection of the forming roll shaft, and sufficient forming force can be applied. can. In addition, since the backup mechanism can correct the axial deflection deformation of the forming roll group, the forming t
1- It is not necessary to increase the diameter of the shaft of the loop group.

In addition, the cold roll forming apparatus of the present invention can apply a sufficiently large forming force to an appropriate position between the bearings of the forming roll group, so it is possible to form wide materials and also Good accuracy.

In addition, since sufficient forming force can be applied,
, it can be easily molded even when the plate is thick.

〔Example〕

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

1 and 2 show the construction of one embodiment of the cold roll forming apparatus of the present invention, FIG. 1 is a front sectional view of the forming apparatus, and FIG. It is an AA' cross-sectional view.

In the figure, 1 is a flat plate, 2 is a molded product, 3 and 4 are molding rolls, and 5 and 6 are bearings.

7.8 is a bearing support frame, 9-13 is a backup roll, 14-16 is a backup roll support stand, 17-
1.9 is a hydraulic cylinder, 20.21 is a backup roll support base, 22 is an upper frame, 23 is a lower base, 2
4. ．． 25 is a universal joint, 26 is a synchronous tooth Jlf, 27 is a coupling, and 28 is a motor. As shown in FIG. 1, the cold roll forming apparatus of the present invention comprises a forming roll in which a forming roll for each element shape of a molded product divided into a plurality of pieces is passed through and mounted on a single support shaft. The group is used as a forming roll, and the forming force can be applied to the forming roll at an appropriate position and with an appropriate strength via a vine-up mechanism. The forming rolls 3 and 4 for forming the flat plate 1 into the molded product 2 are a pair of composite rolls constituted by a group of forming rolls mounted on a single support shaft. The forming roll 3.4 is
It is supported rotatably by bearings 5a, 5b, 6a and 6b in parallel to the forming roll axis. Further, the bearings 5 and 6 of the forming roll shaft are mounted on a bearing support frame 7.8.
It is supported parallel to the forming roll axis and slidably in the vertical direction. Further, the forming rolls 3 and 4 are supported from above and below by buffer tab mechanisms provided above and below, and forming force can be applied to the forming rolls via the backup mechanism. The upper backup mechanism includes a backup roll 9,1.0°11 and a backup roll support stand 14,1.
5° 16 and hydraulic cylinders 1.7, 18, and 19. Backup roll support stand 1415.
16 is equipped with a backup roll at the bottom and a hydraulic cylinder at the top, and can move in the axial direction parallel to the forming roll axis along the guide groove provided in the bearing support frame 7.8. It has a structure. Then, the shape, material, and molding position of the molded product are appropriately set, and the size of the round to which forming force is applied to the molding roll 3 is set appropriately, and the shape of the molded product installed in the subsequent stage is set as follows. The lower backup mechanism is configured to be able to modify the conditions of J:+ according to the controller (not shown).In addition, the lower backup mechanism is configured to support the backup rolls 1.2, 1.3. Like the upper backup mechanism, it can move in the axial direction parallel to the forming roll axis along a guide groove provided in the lower base 23.Structure The upper and lower backup mechanisms are installed on each backup roll support base so that the load position and the magnitude of the forming force can be set appropriately depending on the molding result of the molded product. The apparatus has a support drive mechanism for changing the position of the support in parallel with the forming roll axis and a support position detection means.

Further, the forming rolls 3.about.4 used in the present invention are constructed so that the distance between the forming roll axes is equal in the axial direction, as illustrated in FIG. In addition, the forming roll 3,
It is desirable that the outer diameter of No. 4 has an outer diameter portion wider than the width of the backup roll so that the backup roll can easily come into contact with it. The forming force of the forming rolls 3 and 4 is received by the upper frame 22 and the lower base through backup mechanisms provided above and below the axial pushing force of the hydraulic cylinders 17, 18, and 19. In addition, since the forming rolls 3.4 receive forming force through the upper and lower backup mechanisms, the forming rolls 3, 4 do not receive axial bending force that would cause axial deflection deformation, and therefore the support shaft diameter and 1c1. You can make your face look thinner. In addition, the backup mechanism can apply the force necessary for cold roll forming to the necessary position, so it can be used when forming products that are affected by axial deflection, such as wide materials, or when forming a thick plate. Optimum molding conditions can be achieved even when molding thick plate materials with large values.

Further, the cold roll forming apparatus of the present invention has a back, ゛;-
Forming force can be applied to an appropriate position in the middle between the bearings of the forming roll group through the up machine mechanism, which improves the shape of the molded product.
It is possible to achieve optimal forming conditions depending on the material, plate thickness, etc., and it is possible that the number of stages of forming roll stands can be reduced compared to conventional cold roll forming equipment. Furthermore, since the forming roll is divided into elements and used in appropriate combinations according to the forming shape, there is a large degree of freedom in the forming shape that can be formed, and the forming roll can be easily adjusted when changing the shape. Cost can be saved. Furthermore, since the forming rolls 3 and 4 of the present invention are a forming roll group made up of a combination of divided element rolls, even if a part of the forming roll group is worn out or damaged, only that part can be manufactured. It is only necessary to replace the molding roll, and it is possible to repair the molding roll, extend its life, and reduce the cost of the molding roll.

FIG. 3 shows the entire cold roll forming apparatus and system of the present invention. Conventional cold roll forming equipment requires several forming roll stands even when forming a simple shape, and several dozen forming roll stands when forming a complex shape. .

Therefore, in order to change the molding shape, it is necessary to replace a large number of molding rolls and to adjust the position and molding force of each roll, which requires a large amount of cutting time. On the other hand, the cold roll forming apparatus of the present invention can achieve sufficient forming force and appropriate forming force distribution as described above, and therefore can perform forming using several forming roll stands. Therefore, the setup time required for exchanging the forming rolls and adjusting the roll position and forming force can be greatly reduced, and it is possible to form products of multiple shapes simultaneously or individually into 111 pieces without changing the equipment. Is possible.

In FIG. 3, the forming roll stands :)0, 31.32 for forming the qZ plate 1 into the molded product 2 are of the structure explained in FIGS. 1 and 2, and the flat plate 1 is (I) A group of forming rolls is configured to sequentially form the final shape. In addition, the molding roll stand 3
A material supply guide 29 is installed at the front stage of 0, and a molded product guide mechanism 33 is installed at the rear stage of the forming roll stand 32. The material supply guide 29 is for supplying and positioning the flat plate 1 to a predetermined position of the molding roll stand 30 according to the molding shape. The molded product guide mechanism 33 also controls the vertical position, left and right position of the molded product 2 sent out from the molding roll stand 32 so as to correct in-plane and out-of-plane bends and twists of the molded product 2 after molding. It is used to adjust the directional position, rotation angle, etc.

FIGS. 4(a) to 4(c) show examples of forming roll groups used in the present invention. FIG. 4(a) shows the configuration of a forming roll group when forming a wide corrugated sheet material. Forming rolls 3 and 4 are constructed by combining element forming rolls corresponding to the respective element shapes for forming the molded product 2.

All of the element forming rolls are simple cylindrical or shoulder-shaped rolls. FIG. 4(b) shows a case in which beats are applied to a wide board. This forming roll group is composed of a cylindrical roll and a disc-like protruding roll.

FIG. 4(c) shows that a plurality of shapes can be formed using a pair of forming rolls. This forming roll group is also constructed by suitably combining element forming rolls with simple shapes, as in the case described above.

As described above, the cold roll forming apparatus of the present invention can perform forming using a group of forming rolls configured by suitably combining rolls for forming elements with simple shapes, so that processing of the forming rolls is easy. You can easily change the shape on the top. Moreover, since the forming rolls 3 and 4 are supported and pressed from below by the backup mechanism, almost no axial deflection deformation occurs in the forming rolls. Therefore,
In the cold roll forming apparatus of the present invention, the diameter of the forming rolls can be reduced, and a wide variety of shapes can be formed using a small number of rolls. Furthermore, since the number of forming roll stands can be reduced, the number of forming rolls can be reduced.

FIGS. 5 and 6 are explanatory diagrams for explaining the effect when forming force is applied via a backup mechanism in the middle of the forming roll, which is a feature of the cold roll forming method of the present invention. In order to simplify the explanation, FIGS. 5 and 6 are explained using flat rolls, but this principle also holds true for forming rolls of other shapes. In Fig. 5 and (s), 34 is a flat plate, and 35 and 36 are smooth rolls. In Fig. 5, the flat plate 34 is between a pair of smooth rolls;
Both shaft ends 35a, 3 of each smooth roll: 35.36
When pressing forces P and -P are applied to 5b and 86n, :3f;h, a compression pressure (i.e., molding pressure) distribution as shown in the figure is generated on the flat plate 34. This is due to the smooth roll 35. :This occurs because the shaft deflection deformation of i6 is larger at the shaft center than at the shaft ends. In the rolling of flat plates, etc., differences in axial deflection are corrected by applying a bending moment to the axial ends of the rolling rolls or by making the rolling rolls or backup rolls drum-shaped to provide a roll crown.

FIG. 6 is an improved version of FIG. 5, and shows a case in which a pressing force can be applied to appropriate positions of the smoothing rolls 35, 36 via a backup mechanism. When appropriate pressing forces P and -2/3P are applied to the intermediate portion 35C235d of the smooth roll 35 and the intermediate portions 36c, 36d, and 36e of the smooth roll 36, respectively, the compression pressure (i.e., molding pressure) distribution of the flat plate is shown in FIG. It becomes like that. Since the pressing force applied to the smooth rolls 35 and 36 is applied at appropriate positions between the bearings, almost no axial deflection deformation of the smooth rolls 35 and 36 occurs. Moreover, the compression pressure is distributed almost uniformly. By making the molding pressure, that is, the compression pressure, uniform, the molded shape becomes better and the dimensional accuracy improves.

FIG. 7 is a diagram for explaining the forming force P required for V-shape bending in press bending (Reference: Press Working Handbook, p. 217, edited by Japan Society for Plastic Working, Maruzen Publishing).

In FIG. 7, 37 is a flat plate, 38 is a punch, and 30 is a die. ■For the shape weighting force P in press working, a pressing force corresponding to the free bending force is used. Further, in general, in the cold roll forming method, the forming force P is smaller than the forming force P of press working because the forming force is sequentially formed into the final shape with a small forming force. According to the reference literature, the shape weighting force P is cbt2σn P=□...(]). This forming force P corresponds to free bending force, and a molded product formed with this forming force is affected by springback. Forming to reduce springback and form to accurate dimensions (]I5 Force PV is: Pv= (1~2)bQ ae '''
(2) a: Horizontal projected length that receives the surface pressure of the plate, which corresponds to the die width) σ0: Yield stress of the material. For example, t = 0.5mn, b = 10
0wn.

Assuming W = Q = 25 mn and σn = 2σe, P and Pv are each p = (0,66~1.8) XσB Pv = (1~2) XI250cre, and PV is more than 1000 times P. Two must be big. That is, in order to improve dimensional accuracy and molded shape, it is necessary to apply a much larger molding force compared to conventional molding conditions. In the conventional cold roll forming method, in order to obtain molded products with good dimensional accuracy and shape with small forming force,
It was necessary to use a large number of forming roll stands. The cold roll forming method of the present invention differs from the conventional cold roll forming method by realizing sufficient forming force and appropriate forming pressure distribution.
(This is intended to enable good molding of F and molding shape. Considering the principle of this molding method, it is possible to significantly reduce the number of L1-ru stands for molding.

FIG. 8 shows one embodiment of a backup mechanism used in the present invention. The backup mechanism of the present invention is as follows.

In order to apply a large pressing force to the forming roll, it must have a structure that can handle the large pressing reaction force applied to the backup roll. In FIG. 8, 40 and 41 are forming rolls, 42, 43, and 44 are backup rolls, and 45 and 46 are backup roll supports. Forming roll 4
．． The forming force applied to 0.41 mm can be adjusted by the oil pressure of a hydraulic cylinder (not shown) attached to the upper part of the backup support base 45. Moreover, the backup support stand 45 can move parallel to the axis of the forming roll 40,
The position at which forming force is applied can be set as appropriate. The upper backup roll is composed of two rolls 42 and 43, and includes a backup support stand 45.
It is rotatably supported. On the other hand, the lower backup roll supports all the pressing force of the hydraulic cylinder attached to the upper part with one cylindrical smooth roll 44.

Therefore, since the lower backup roll does not need to move parallel to the forming roll axis, the structure of the lower backup mechanism can be simplified. The load position of the forming rolls is set using the upper backup mechanism. Further, the forming roll is rotationally driven by rotating the lower backup roll 44. The roll stand for molding is
The upper forming rolls 40 and 41 are rotated via a backup roll 44 installed at the bottom, and the forming force is adjusted in part by a plurality of hydraulic cylinders (not shown) attached to the backup roll support. It is structured so that it can be given in any position and size. Also,
The drive element for driving the lower backup roll and the reducer for adjusting the rotation speed are housed at the bottom of the forming roll stand or under the floor, making it easy to convert the upper forming roll.

FIG. 9 shows one embodiment of the support shaft of the forming roll of the present invention. In FIG. 9, 47 is a support shaft, 48 is a forming roll, and 49 is a nut. The support shaft 47 has a bearing support part 47a that fits into a bearing at both ends, a forming roll attachment part 47b in the center, a protrusion 47C for restraining the divided forming roll, and a threaded part 47d. The divided element forming rolls are combined 11:'' [forming rolls 48 are constructed, and these forming L1-rule groups are mounted on the support shaft 47, and they are connected with the key attached to the keyway/I7e. While restraining it from rotating, the nut 49 is attached to the threaded part 4.7d and tightened to assemble the forming roll.Additionally, a key attachment part for transmitting rotational force is attached to one end of the support shaft as necessary. establish.

〔Effect of the invention〕

According to the present invention, one to several types of molded products can be appropriately formed without replacing the forming rolls using a forming roll group configured by mounting a plurality of forming rolls on a pair of support shafts. (1) Reduces stage changeover work associated with changing molds, such as exchanging molding rolls, changing processing conditions, and adjusting the position of molding rolls, and reduces waste of material due to translation molding after mold replacement. (2) The processing cost of the forming roll can be reduced because the forming roll can have a small diameter. (3) It is possible to form a wide molded product or a thick molded product. (4) Sufficient Since forming force can be applied to an appropriate position, optimal forming conditions can be achieved, and molded products with good dimensional accuracy and good shape can be formed. (5) By combining divided element rolls. Since a group of forming rolls can be formed, it is possible to form many types of molded products with a small number of forming rolls, and the forming shape can be easily changed, and processing costs for forming rolls can be saved. There are effects such as being able to.

Furthermore, the molding method of the present invention is similar to the conventional cold roll molding method in that (1) the molding speed is fast and mass production is possible; (2)
The molding cost is low; (3) the dimensional accuracy of the molded product is good, the variation in dimensions is small, and the reproducibility of the molded shape is good; (
4) Molding work can be performed continuously or fully automatically,
(5) Less power is required for molding, resulting in energy savings.

Furthermore, the molding device of the present invention can apply sufficient molding force to the molding rolls and achieve an optimal molding pressure distribution, so the number of molding roll stands can be significantly reduced compared to conventional devices. can be reduced to Therefore,
The molding method of the present invention is a molding method that makes it possible to downsize and simplify a molding device and reduce equipment costs.

[Brief explanation of drawings]

FIG. 1 is a front view of the cold roll forming apparatus of the present invention. Fig. 2 is a sectional view taken along the line A-A' in Fig. 1, Fig. 3 is a configuration diagram of the cold roll forming system of the present invention, Fig. 4 is a relationship between the forming roll and the forming shape, and Fig. 5 is a diagram showing the relationship between the forming roll and the forming shape. Fig. 6 is an explanatory diagram of the load position of the pressing force and the distribution of compression pressure, Fig. 7 is an explanatory diagram of V-shaped press bending, Fig. 8 is a structural diagram of the backup mechanism,
FIG. 9 is a structural diagram of the support shaft. ” - Flat plate, 2 Molded product, 3, 4 Molding roll, 5.6 Bearing, 7, 8 Bearing support frame, 9 to 13 Backup roll , 22...
Upper frame, 23...lower base.

Claims (1)

[Claims] 1. A pair of rotatable support shafts supported in parallel;
A cold roll forming apparatus comprising a plurality of forming roll groups mounted on the support shaft and a backup mechanism for the forming roll groups attached above and below the forming roll group. 2. It is configured so that forming force can be applied to the forming roll group via a backup mechanism, and the load position of the forming force applied to the forming roll group can be changed as appropriate. A cold roll forming apparatus according to claim 1. 3. A material feeding mechanism is installed in front of the forming roll, and the material feeding mechanism is configured to supply material to the forming roll, and the position at which the material is fed to the forming roll can be changed as appropriate. A cold roll forming apparatus according to claim 1, characterized in that the cold roll forming apparatus is constructed as follows. 4. A molded product in which a means for detecting the molded shape is installed at the rear stage of the molding roll, and the position of the molded product in the vertical direction or in the horizontal direction, or in the vertical and horizontal directions, can be changed based on a signal from the detection means. The cold roll forming apparatus according to claim 1, further comprising a guide mechanism. 5. A forming roll group configured by having a single shaft pass through a roll divided into a plurality of rolls, and a forming unit configured by supporting two of the forming roll groups rotatably and parallel to each other and interlocking with each other. A cold roll forming method in which the forming roll stand is provided with a backup mechanism for a group of forming rolls, and a flat plate is formed into a set shape while applying forming force via the backup mechanism.