RU2806944C2 - Forming sheet material - Google Patents

Abstract

FIELD: formation of sheet metal materials.

SUBSTANCE: sheet material (100) has a ridge and recess pattern formed on both of its major surfaces in a first portion (101) and a brand name (103) formed in a second portion at a break (102) of the ridge and recess pattern. At least the branding portion provides a visual and/or machine-readable indication of the alignment of the tools used to form the sheet material.

EFFECT: alignment mismatch between tools can be quickly and/or more easily identified.

19 cl, 13 dwg

Description

The present invention relates generally to sheet forming, and more particularly to sheet forming tools and methods and to molded sheet material. In particular, although not exclusively, the invention relates to methods and tools for cold forming one or more projections and/or one or more depressions on one or more surfaces of sheet material and to sheet material so formed.

Methods for forming sheet material with projections are known, many of which involve passing the sheet material between opposing tools to form one or more projections on the sheet. Some possible sheet forming methods include sheet forming, such as cold drawn section forming, stamping and extrusion, such as power punching or punching, blanking, embossing, bending, flanging, rolling or sizing.

Particularly, although not exclusively, the present invention relates to cold rolling, which is a process of forming materials by passing sheet material between a pair of rolls at a temperature below its recrystallization temperature, typically at room temperature. As the material passes between the rolls, it is strengthened through a process known as strain hardening.

Cold rolling is usually carried out on sheet material fed from a roll of material. The sheet material is passed between a series of pairs of rollers, positioned one behind the other, to successively shape the sheet material until it has a desired configuration, such as a C-shape, a U-shape, or a box section. The shaped sheet material (hereinafter referred to as the section) can then be cut to the desired length.

Typically, the sheet material may be a metal, such as steel, aluminum, copper, brass, silver, gold, titanium, etc., although plastics and other materials can also be cold rolled. Most often, steel is processed this way. The material may be coated (for example, galvanized) or uncoated.

Proper alignment and indexing of opposing tools can also be critical, particularly when high-density protrusions and/or complex geometries are involved. As a result of the large forces applied by the tools in any of these operations, and in particular in cold forming processes, the tools tend to become out of alignment with each other. Regular and careful inspection of the formed sheet material is often required to ensure proper alignment of the tools.

As should also be clear, it is important to ensure roll alignment during the start-up process, where the rolls are driven from rest until they reach or acquire operating rotation speed, to ensure accurate alignment, prevent damage, etc.

WO2009/063154, the contents of which are incorporated herein by reference, describes methods and tools for forming a sheet of material to provide on both surfaces thereof rows of projections and rows of recesses, the relative positions of the projections and recesses being such that lines drawn on the surface sheet between adjacent rows of protrusions are not straight. The described process leads to strain hardening of the sheet material. Each protrusion is formed to have a substantially continuous region of peak plastic strain near its tip, and the material thinning is 25% or less. Proper tool alignment in this case is of paramount importance to achieve the required balance between work hardening and material thinning. Even small tool alignment misalignments can have an impact, sometimes a significant impact, on the molded material, but detection of such small alignment misalignments can be difficult.

Consequently, the performance of sheet material that is cold-drawn into projections is highly dependent on the quality of workmanship. It follows that it is desirable to have some means of reliably ascertaining the workmanship and/or origin of such molded sheet material.

It is therefore a non-exclusive object of the invention to provide a means by which on-line monitoring of tool alignment and/or material origin can be carried out more easily and/or more efficiently. A further, more general, non-exclusive object of the invention is to provide an improved sheet forming tool and method that at least mitigates the problems associated with known forming tools and methods.

According to a first aspect of the invention, there is provided a method for forming sheet material, including the steps of placing or advancing sheet material between tools arranged in a pair, and moving the tools such that the tools, for example their respective first forming surfaces, form a pattern on the first portion of the sheet material, and such that the tools, for example their respective second forming surfaces, form a brand name or second pattern that is different or may be different from the first pattern, for example, on the second portion of the sheet material, wherein the brand name or second the pattern can be seen as an indication of the alignment between instruments.

The pattern can be formed by any forming method, such as cold drawn section forming, stamping and extrusion, punching, embossing, bending, flanging, rolling or sizing, or any other suitable forming method, but cold forming the pattern is preferred. The brand name or second pattern may also be formed by any suitable forming method, such as cold drawn profile forming, stamping and extrusion, die-cutting, embossing, bending, flanging, rolling or sizing, or any other suitable forming method. In a preferred embodiment, the brand name or second design is formed by embossing the relief. More preferably, the brand name or second pattern is formed by embossing the sheet material such that the brand name or second pattern projects from a plane of the sheet material, such as its neutral plane.

According to a second aspect of the invention, there is provided a method for forming sheet material, comprising the steps of placing or advancing sheet material between tools arranged in a pair, and moving the tools such that the tools, for example their respective first forming surfaces, cold deformation processing on the first section of the sheet material, and in such a way that the tools, for example their respective second forming surfaces, carry out embossing of the relief on the second section of the sheet material. The embossing of the relief preferably involves the formation of a brand name or provides protrusion from the plane of the sheet material, for example its neutral plane.

By forming both a brand name (and/or a single or second pattern) and a pattern, for example by having forming surfaces that expose the sheet material to embossing a relief in or on a cold forming tool, the invention provides a simple and effective means of implementing relatively unskilled people for operational control of tool alignment. The presence of a brand name or second pattern also makes it possible to identify products and/or obtain a brand name for tracking and/or branding purposes, indicating the origin of the products during the molding operation, rather than in a separate post-forming step, which would increase the complexity and cost of production. Thus, the invention provides a convenient means of ensuring both traceability, eg retrospective tracking, and traceability, eg the ability to track products through a supply chain. In fact, a brand name may include one or more anti-counterfeiting elements.

For the avoidance of doubt - and as should be clear to one skilled in the art - the term "cold work hardening" (also known as "cold work hardening") as used herein means the plastic deformation of a metal at a temperature below its temperature. recrystallization threshold, when strain hardening occurs as a result of such permanent deformation. In addition, as the term "embossing" is used herein, it denotes the operation of raising a profile or shape above and/or below the surface of a component by means of high pressure applied by pressing or pressing, and includes indentation .

It is known that relief embossing and cold strain hardening are different technologies. Embossing involves compressing a material, in this case sheet metal, between two tools (such as rolls) to reduce its thickness beyond its tensile strength into the range of purely plastic deformation; is a compression process involving the application of significant force to compress the material between two tools (such as rollers), one of which has a protrusion (or groove) and the other has a groove (or protrusion), causing the pattern on the tool (such as roller) ), is transferred to the material. In contrast, cold working by forming cold-drawn profiles involves strengthening the material by plastic deformation by stretching the material without compression. This is conveniently achieved in the inventor's patent applications GB2450765A, EP0891234A (the entire contents of which are incorporated herein by reference) by using pairs of matched male rollers, with the teeth of one rollers extending (as the rollers rotate) into the gaps between the teeth of other windrows. Undoubtedly, the specialist knows and understands that the methods of embossing relief and strain hardening are different methods, and they give different effects.

Rolling is also a well-known cold working process, which is different from cold working and relief embossing. Rolling is a process in which a series of sharp teeth on a hardened steel roller are pressed into the material to be rolled. Knurling is used to create a clamping surface or non-slip surface and involves moving the material laterally using teeth or projections rather than pushing the projections along the other side of the sheet.

For the avoidance of doubt, any of the features described herein are equally applicable to any aspect of the invention.

The embossing of the relief or the molding of the insignia or second design may be carried out simultaneously with cold working or cold forming of at least a portion of the design and/or embossing of the relief, or the insignia or the second design may be at least partially surrounded or encircled or limited by the pattern, or within its limits. The protrusion pattern may include one or more breaks, and/or a brand name or second pattern may be molded into either one or more or each of the breaks. The second region may contain one or more breaks or be located in or at one or more breaks.

Pattern formation may include forming projections into or on one or both major surfaces of the sheet material. Forming a projection into or on the main surface may include or result in the formation of a recess, for example a corresponding recess being formed into or on another main surface. The pattern may be molded, eg configured and/or distributed, such that lines drawn on the surface of the molded sheet material between adjacent rows of projections and recesses are not straight.

The process is preferably continuous or at least partially continuous, for example, forming the sheet material is preferably continuous or at least partially continuous or carried out continuously for at least a predetermined period of time. The placement or advancement of sheet material between tools arranged in pairs, and/or the movement of tools and/or the formation of a pattern and/or a brand name can be carried out continuously, for example, using rolls or by profiling the sheet metal with tools.

The tools may be moved such that teeth or protrusions on one tool force sections of sheet material into gaps between teeth or protrusions on another tool, thereby, for example, cold working the first section of sheet material and forming a pattern in or on it. In a preferred embodiment, the configuration and/or dimensions and/or dimensions of the tool spacing and/or gaps are such that cold deformation processing of the sheet material, for example, hardening with plastic deformation of the tips of the protrusions, occurs through local stretching of the material and/or ensuring its free flow, for example - without squeezing or pinching or squeezing.

Embossing a relief or molding a signature or second pattern may include molding a signature or second pattern that indicates alignment between tools. The tools may be moved such that one or more forming edges of some tools force or press the sheet material against other tools, thereby subjecting the sheet material, for example, to embossing a relief to form a brand name or a second design into or on it.

In an additional or alternative embodiment, embossing a relief or forming a brand name or second design may include forming, for example, a small or microscopic brand name or a small or microscopic pattern that is visible only under magnification, such as with a magnifying glass or microscope.

The method may further include shaping the molded sheet material, such as a profile or beam or product having a shaped cross section, such as a channel section.

In a third aspect of the invention, there is provided a forming tool for forming sheet material, for example for use in carrying out a method in accordance with any of the preceding claims, comprising a first forming surface, the configuration of which - when used - can provide pattern forming and/or cold working of the sheet material or a first section thereof, and a second forming surface, the configuration of which can provide the formation of a brand name or a second pattern, which may differ from the first pattern, and/or embossing of a relief of the sheet material or a second section thereof.

The configuration of the first forming surface may provide, in use, the formation of a pattern of protrusions. The configuration of the second forming surface may, in use, enable the brand name to be molded at a discontinuity in the pattern of protrusions.

The first forming surface may be a profiled forming surface that may contain or include or define at least a portion of a pattern. In an additional or alternative embodiment, the second forming surface may be a profiled forming surface that may contain, include or define, at least in part, a brand name or a second pattern. In some embodiments, the second forming surface of the tool is surrounded or encircled by or limited by its first forming surface, for example - such that - in use - the molded brand name or the molded second pattern is surrounded or surrounded or limited by the pattern, for example , the first forming surface, or are within it, or the pattern may contain one or more breaks, and/or the brand name or the second pattern can be enclosed or molded into or at one or more or each of the breaks. The second forming surface may be limited, for example, in first and second directions, the first and second directions being perpendicular to each other.

In an additional or alternative embodiment, the second forming surface or brand name or second pattern may comprise, for example, a small or microscopic brand name or a small or microscopic pattern or pattern that is visible only under magnification, such as with a magnifying glass or microscope.

The forming tool preferably comprises a support or a drum or roller or is substantially cylindrical, for example containing or formed with a first forming surface. In an additional or alternative embodiment, the forming tool may include a liner, for example containing or configured with a second forming surface, for example contained or enclosed on or in it. The insert may be enclosed and/or capable of being enclosed, for example enclosed and/or capable of being enclosed and then removed, within a recess or depression or hole or aperture of the forming tool. In some embodiments, the insert is attached or capable of being attached, for example, attached or configured to be attached and then released, to the tool, for example, within its recess or recess or aperture, for example, by means of a locking means. The liner may be positioned or positioned such that the first and second forming surfaces are substantially adjacent and/or adjacent to each other, and/or such that the second forming surface is surrounded or encircled by or limited or enclosed by the first forming surface, or embedded in one or more discontinuities in the first forming surface, or at one or more such discontinuities, for example, to mold - in use and/or simultaneously - at least a portion of a pattern and a brand name or a second pattern into or onto the sheet material. The second forming surface may be surrounded by or encircled by or limited by or enclosed by the first forming portion or first forming portions, in the axial or tool rotation axis direction and/or in the circumferential or rolling or processing direction. The second forming surface, eg the liner, may be surrounded by, or limited or encircled by, or within portions of the first forming surface on each side, for example each axial side and/or each circumferential side. The second forming surface is preferably surrounded or surrounded by or limited by the first forming section or first forming sections, or located in the axial direction or the rotation direction, and preferably in both of them.

In a fourth aspect of the invention, there is provided a forming tool for forming sheet material, for example for use in carrying out the method described above, comprising a backing, an insert and a fixing means, the backing having a first forming surface, which may be profiled, including a pattern, wherein the liner has a second forming surface, which may be profiled, including a brand name or a second pattern, wherein the substrate contains a recess within which the liner is enclosed and/or configured to be enclosed and then removed and is attached or configured to be attached, for example - attached or configured capable of being attached and then released by means of a locking means such that the first and second forming surfaces are substantially adjacent and/or adjacent to each other to form - in use and/or concurrently therewith - at least a portion pattern and brand name or second pattern in or on the sheet material.

The configuration of the signature or second pattern may enable the presence or presence of a predetermined pattern that is configured to detect, for example, rapid and/or simplified detection of alignment mismatch between tools. In some embodiments, the configuration of the second forming surfaces provides a signature or second pattern formation that is disrupted if the tool alignment is misaligned. In an additional or alternative embodiment, the branding or second pattern can be made machine readable and/or an indicator of the alignment between the tool in question and another, for example, an opposing tool.

In the case of a complex moldable pattern, such as that discussed in the inventor's previously filed patent application WO2009/063154 (GB2450765A, EP0891234A), visually determining proper alignment may be difficult. At the same time, even untrained workers can determine the proper placement of certain brand marks or second patterns immediately and effectively.

The forming tool may be a cold forming tool, for example a cold forming tool for sheet material. In an additional or alternative embodiment, the forming tool may be, for example, a roller or roller with a circumferential surface, the first and/or second (first and/or second) forming surfaces being or provided on the circumferential surface of the roller or roller. The tool may be, for example, a cylindrical roll that is rotatable around its axis. The forming tool is preferably a cold forming roll, for example for shaping cold-drawn profiles of sheet material, such as sheet metal material, for example iron-based metal material, such as steel or any other metal material, or sheet material formed from any other material such as plastic.

The brand name or second pattern may comprise a means of identification or identifier, such as an alphanumeric brand name, one or more names or logos or images or bar codes or quick response (QR) codes. The identification means may comprise a specific identifier relating to the tool or tools arranged in pairs, or the forming machine or manufacturer, for example, a sheet forming machine manufacturer and/or a tool manufacturer.

The first forming surface may comprise one or more, for example two or more, for example three, four or more, say, a plurality and/or array of protrusions or forming projections or teeth that may protrude from the first main surface or the cavity surface or the diameter of the first main circumference or circumference of the depressions. The protrusion matrix may comprise a plurality of rows and/or columns, for example straight and/or spiral rows and/or columns, protrusions.

The second forming surface may include a brand or one or more projections, such as brand projections or second pattern projections or brand projections, which may protrude from the second main surface or dimple surface or the diameter of the second main circle or dimple circle. The second forming surface or its mark or protrusion or protrusions may or may be positioned at or in a discontinuity of a plurality or matrix of protrusions or forming protrusions or teeth of the first forming surface. The second forming surface or its mark or protrusion or protrusions may or may be recessed relative to the first forming surface and/or relative to at least one of its protrusion or protrusions or tooth or teeth, for example, the apex or apexes of the protrusion or protrusions or tooth or teeth

In some embodiments, the second main or recessed surface or the diameter of the second main or recessed circle is recessed or recessed relative to the first main or recessed surface or the diameter of the first main or recessed circle. In an additional or alternative embodiment, it is possible to recess at least a portion or one of the mark or protrusion or protrusions of the second forming surface, and preferably all of them, relative to at least a single protrusion or tooth or one of the protrusions or teeth of the first forming surface , such as the top or tops of its protrusion or protrusions or a tooth or teeth. In an additional or alternative embodiment, there may be a small or microscopic mark or brand name or design that is visible only under magnification, such as with a magnifying glass or microscope, on at least a portion of one of the mark or the projection or projections of the second forming surface. In some embodiments, the mark or protrusion or protrusions of the second forming surface is surrounded by, encircled by, or limited by, a protrusion or protrusions or a tooth or teeth of the first forming surface, and/or enclosed in or at one or more of the discontinuities.

The locking means may comprise a lock or locking mechanism. The locking means may comprise, for example, cooperating structures or locking structures located in or on each of the liner and recess or forming tool or substrate or drum or roll, or connected or associated with each of the liner and recess or forming tool or substrate or drum or roll. The interacting features may include a locking recess and a locking projection or member or a pin or ball, for example, to engage the locking recess. The interacting structural members may be switched, for example, between a locked and unlocked state, wherein the liner is secured within the recess by means of locking means when the interacting structural elements are in a locked state, and/or wherein the liner is removed from the recess when the interacting structural elements are in an unlocked state.

The locking protrusion or member or pin or ball may be movable, for example, between operative and inoperative or retracted positions or states and/or between latched and latched positions or states. The locking recess may include an engaging or bearing surface, for example a beveled or inclined or sloped or bearing surface that may extend at an angle or be oriented or routed or extend at an angle, for example non-perpendicular and/or non-parallel and/or at an acute or obtuse angle with respect to the direction of movement of the locking protrusion or element or pin or ball. The locking projection or member or pin or ball may be resiliently deflectable to an operative or locked position or condition. In other embodiments, the locking protrusion or member or pin or ball may be resiliently deflectable to a non-operating or retracted or unlocked position or condition, for example by resilient means or deflecting means or resilient deflecting means such as a spring, for example a compression spring .

In one preferred embodiment, the liner includes a locking recess and a locking projection or member or a pin or ball and is mounted, for example, movably mounted to, or otherwise connected to, a recess or forming tool or substrate or drum or roll. The locking protrusion or member or pin or ball and/or resilient means or deflecting means or resilient deflecting means may be enclosed or enclosed within a cavity or recess or recess or aperture or hole which may be or be located in a recess of the tool or forming tool or substrate or drum or roller, or may be connected to it. In an additional or alternative embodiment, the locking projection or element or pin or ball and/or resilient means or deflector means or resilient deflector means may abut and/or be fixed or secured or held in place, for example, within a cavity or recess or recess or aperture or a hole by means of a fastener such as a bolt.

The tool may have a first end and a second end, for example, with drive means mounted on or offset toward one of the first and second ends, and/or another end that does not include drive means. The tool may additionally contain a hole for housing a shaft.

In other aspects of the invention, there is provided an insert for use in the above-described tool and/or a tool or a backing or tool drum or roll for use in the above-described forming tool, and/or a set of parts for assembly in the above-described tool or a pair of the above-described tools. The insert and/or tool or backing or tool drum or roller and/or assembly of parts may include any one or more of the above-described components or features that one of ordinary skill in the art will appreciate may be advantageous and/or desirable.

In a further aspect of the invention, a pair of forming tools is provided for forming sheet material therebetween, for example for use in the method described above, wherein the first of the forming tools may comprise a forming tool, for example, such as those described above in relation to the third or fourth aspects of the invention.

In yet another further aspect of the invention, there is provided a pair of forming tools for forming sheet material, for example for use in the method described above, each forming tool comprising a first forming surface and a second forming surface, wherein the first forming surfaces of the forming tools can be configured to interact therewith - when used - for cold deformation processing of sheet material between them, and the configuration of the second forming surfaces of the forming tools can ensure their interaction for embossing the relief of sheet material between them, for example - in such a way that the structural element or structural elements obtained or obtained as a result of embossing relief, protrudes or protrude from the plane of the sheet material, for example, its neutral plane.

For the avoidance of doubt, each of the opposing forming tools described in connection with any relevant aspect of the invention may contain any one or more of the features described in connection with that or other forming tool or forming tools.

The second of the forming tools may comprise a first forming surface for interacting - in use - with the first forming surface of the first tool to form the pattern. In an additional or alternative embodiment, the single or second of the forming tools may comprise a flat surface, wherein the second forming surface of the first forming tool comprises a profiled forming surface which - when used - interacts with the flat surface to form a branding or second pattern on the sheet material being formed between them. In yet another embodiment, the single or second of the forming tools comprises a second shaped forming surface, wherein the second forming surface of the first forming tool - in use - cooperates with the second surface of the second forming tool to form a brand name or a second pattern on the sheet material being formed therebetween. . The second profiled forming surfaces may interact to form a signature or second pattern that is distorted when the tool alignment is misaligned. In an additional or alternative embodiment, the second forming surfaces may interact to form a brand name or second pattern, at least a portion of which or which may comprise, for example, a small or microscopic brand name or a small or microscopic pattern that can only be seen using a magnifying lens. glass or mirror or microscope. In some embodiments, the second forming surface of the second forming tool is surrounded by or encircled or bounded by or within the first forming surface, or is enclosed in or near discontinuities thereof, for example, such that the molded brand name or the formed second pattern - in use - appears surrounded or encircled or limited by this pattern or located within its limits.

In yet another aspect of the invention, a pair of forming tools is provided for forming sheet material therebetween, wherein, for example, one or each of the tools may be a forming tool as described above, each of the forming tools comprising a corresponding first forming surface and a corresponding second forming surface, wherein wherein the first forming surfaces - in use - interact to form a pattern, and the second forming surfaces interact to form, for example - simultaneously, a brand name or a second pattern, which may become distorted if the alignment of the tools is misaligned.

The second forming surfaces may, when in use, interact to form a signature or second pattern that is noticeably distorted, for example in the event of a tool alignment mismatch, such distortion being readily visible to the naked eye. In some embodiments, the portion of the brand name or second pattern may be small or microscopic, for example, visible only with a magnifying glass or microscope, and/or machine readable, for example, by scanning with a scanning tool or scanner. The configuration of the insignia or second pattern may be such that an alignment misalignment can be detected or identified, or the extent of a tool alignment misalignment can be determined, by employing sensing or scanning of the insignia or second pattern, such as with a scanning tool or scanner, and/or by applying processing brand name or second pattern after reading or scanning, carrying it out using a processing tool or algorithm or a computer. One non-limiting example of such a brand name or such a second pattern would be a bar code or a quick response (QR) code. In some embodiments, the second forming surface of one or each tool is surrounded or encircled or delimited by or within the first forming surface, for example, such that the molded brand name or the molded second pattern is, in use, surrounded or encircled or delimited by the pattern or located within it and/or enclosed in or near one or more of its breaks.

The first forming surfaces can - in use - interact to form a pattern containing one (or one) or more projections and/or recesses, which can be arranged in a matrix and/or which - in use - can be molded on one, and preferably - on both major surfaces of the sheet material, thereby limiting, for example, the effective thickness or amplitude, for example limited between the tops of the projections on each side of the sheet material. The pattern may comprise a plurality of rows and/or columns - for example, straight and/or spiral rows and/or columns - projections and/or depressions. The configuration and/or distribution of the pattern or matrix may be such and/or such that lines drawn on the surface of the molded sheet material between adjacent rows of projections and recesses are not straight. The second forming surfaces may interact to form a brand name at a discontinuity in the protrusion pattern.

The second forming surfaces preferably comprise cooperating forming edges which - in use - can be separated by a predetermined distance when the sheet material is formed between the tools and/or when the alignment of the tools is proper. In some embodiments, one of the second forming surfaces includes a male forming surface or a male protrusion, and the other of the second forming surfaces includes a corresponding female forming surface or a corresponding female protrusion or a corresponding female recess that can be molded on a single main surface or recess surface, or on the diameter of the second main circle or the circle of the depressions, or on each of such surfaces or each of such diameters, and/or may be limited or outlined by one or more projections that can be offset relative to the male molding surface or the male molding lip. It is possible that the male molding surface or male molding lip and the female molding surface or valley interact such that a predetermined degree of alignment mismatch will result in a visual indication of distortion.

The tools may be first and second tools with which the sheet material can be structured when used. Each tool preferably has a first end and a second end with drive means mounted on or offset closer to one of the first and second ends, the other end preferably not including drive means, wherein the drive means can, for example, engage in use , providing tool drive.

In yet another aspect of the invention, a sheet forming apparatus is provided, comprising, for example, the pair of opposing tools described above. The tools are preferably movable relative to each other, each of the tools may include or be provided with forming surfaces, for example, forming projections or teeth, which can be configured to engage with forming projections or teeth on another tool. In embodiments where the device includes the above-described pair of opposing tools, the first forming surfaces may include projections or teeth, and the geometry and/or position of the projections or teeth and/or tool spacing are such that the projections or teeth on one tool - in use - are exposed and/or fit into gaps between lugs or teeth on another tool.

In another aspect of the invention, there is provided a device for forming sheet material, for example a cold rolling device, comprising first and second tools, each of which is provided with forming protrusions, which are configured to engage with forming protrusions on the other tool, and by means of the tools - at using them, sheet material can be structured, each tool having a first end and a second end and each having drive means mounted on or offset closer to one of the first and second ends, the other end preferably not including drive means, wherein the drives, for example - when in use - can engage, providing drive for tools.

Each of the first and second tools may include a hole for receiving a shaft therein.

In yet another aspect of the invention, there is provided a forming tool for forming sheet material, for example for use in the apparatus described above, for example a cold rolling tool, provided with forming ridges which are configured to engage - in use - with forming ridges on another tool for structuring sheet material, the tool having a first end and a second end, drive means mounted on or offset towards one of the first and second ends, the other end preferably not including drive means.

The tool may contain a hole to accommodate a shaft.

It has surprisingly been discovered that, rather than introducing a potentially destabilizing force when driving the rolls, having the drive means at one end of the rolls rather than both has no detrimental effect on alignment accuracy and continued alignment of the structured sheet material, and reduces the cost of the roll and associated rolls. drive means (electric motors, gear chains, etc.) and reduces changeover time.

The drive means preferably comprise gears, for example spur gears.

In embodiments where the tool is cylindrical in shape, the tips of the lugs or teeth may define the nominal tooth tip diameter, d _VZ (which, for example, is equal to the nominal diameter of the roll on the circumferential surface defined by the tooth tips) in the circumferential direction.

Spur gears preferably have an outer diameter _dH .

The ratios of the nominal diameter of the tooth tips, d _VZ , to the outer diameter d _H are preferably in the range from 0.5 to 1.5, say from 0.6 to 1.4, from 0.7 to 1.3, from 0, 8 to 1.2, from 0.9 to 1.1, for example - from 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99 to 1.1, 1.09, 1.08, 1.07, 1.06, 1.05, 1.04, 1.03, 1.02, 1.01, and most preferably equal to 1, 0.

The spur gears preferably have a pressure angle between 16 and 30°, say between 18 and 27°, for example between 19 and 26°. Pressure angles of 20° and/or 25°, or angles between these values, can be used.

The pitch diameter (D _TO ) of a spur gear is preferably calculated according to the following formula:

D _TO = d _OT - (g + k), (1)

Where

g is the standard diameter of the material to be processed;

k is a constant selected within the range from 0.01 to 0.5, say from 0.02, 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0, 09 to 0.45, 0.40, 0.35, 0.30, 0.25, 0.2, 0.15, for example - from 0.05 to 0.15, say from 0.06, 0, 07, 0.08, 0.09 to 0.14, 0.13, 0.12, 0.11; in the most preferred embodiment, the constant k is 0.1.

Then the number of teeth (N) required for a particular spur gear can be calculated from modulus m as follows:

D _TO = (N + 2) × m. (2)

Then the diametric pitch (P) can be calculated using the formula:

P = N/D _TO . (3)

Then, depending on the pressure angle, the tooth thickness, tooth head height (A) and tooth root height (D) can be calculated for spur gear teeth.

Surprisingly, it has been found that matching the pitch diameter, D _TO , with d _VZ within the above relationship has the effect of reducing damage caused to the spur gear during use.

At least one of the tools may include a body portion that carries forming projections at its periphery. The forming projections may be integral with the body portion, or may be attached thereto. At one end, the housing portion may include a recess outside the shaft opening. The recess may be limited by a peripheral wall. There may be a groove inside the recess that limits the origin coordinate. A reference key may be located, at least partially, inside the recess.

The drive means, for example a gear or spur gear, may include a groove for receiving a reference key to limit the reference position of the spur gear. Preferably, the drive means, for example a gear or spur gear, also includes an extension which is shaped to engage a single recess or recess in the tool. The drive means, for example a gear or spur gear, may comprise an intermittent extension in which a discontinuity is made to enclose therein an end or key of reference.

In a further aspect of the invention there is provided a method for manufacturing a rolling device, comprising:

provide a smooth tool having a cylindrical periphery and a central hole for housing a shaft;

determine the reference position for the tool;

forming a cold rolling structure on the cylindrical periphery;

attaching the drive means to one end of the tool such that the reference position for the drive means is aligned with the reference position for the tool.

The method may further include using a reference position for the tool to constrain the reference position for the drive means, which is preferably used to provide an alignment position for the cold rolling structure.

A tool for cold rolling is also proposed, having a cylindrical profile, a central hole for enclosing a shaft and at one end a groove, inside of which a key is or can be placed to establish the position of the reference point, and this key is or can be enclosed in the drive means , which is or can be attached to the end of the tool.

It has been found that by aligning the molded structure and drive means to a reference position, the process allows for more accurate pattern alignment and less damage to the pattern by the rolls and/or drive means when used.

Said hole preferably defines a circumferential portion and an elongated radial portion of a shaft enclosed or configured to be enclosed therein, having a shape complementary to the shape of the hole, allowing rotation of the tool during use.

In yet another aspect of the invention, a sheet material is provided, for example a molded sheet material, for example formed by a tool or tools arranged in pairs as described above. The sheet material preferably includes a pattern formed on or in its first portion or first region, and a brand name or second pattern formed on or in its second portion or second region. In an additional or alternative embodiment, the sheet material may comprise a first portion or region that is or has been cold worked and a second portion or second region that has been or has been profile embossed. It may be possible to emboss a profile of the brand name or second pattern or a second section or second region such that the brand name or second pattern projects from a plane of the sheet material, for example its neutral plane.

The branding or second pattern preferably provides a visual and/or machine-readable indication of the alignment and/or identification of tools, eg, opposing tools used to form the sheet material. For example, the signature or second pattern may comprise a predetermined pattern configured specifically to provide quick and/or simplified detection of alignment mismatch between tools. In some embodiments, the brand name or second pattern is distorted if there is a tool alignment mismatch, and/or the degree of distortion of the brand name or second pattern or embossed relief corresponds to the degree of tool alignment mismatch. In an additional or alternative embodiment, at least the portion of the brand name or pattern may be small or microscopic, for example, visible only with the help of a magnifying glass or mirror or microscope. In one or some embodiments, the brand name or second pattern is formed on a flat, e.g., unmolded, surface of the sheet material, and/or is at least partially (e.g., completely) surrounded or encircled or delimited by or located within the pattern . For example, the pattern may include one or more breaks, and/or the branding or second protrusion pattern may be provided at or about one or more - or each - of the breaks.

The pattern preferably comprises one or more projections which may be arranged in a matrix and/or molded, for example, on one, and preferably both, major surfaces of the sheet material, thereby limiting, for example, the effective thickness or amplitude, for example - limiting it between the tops of the projections on each side of the sheet material. The pattern may include projections or peaks and/or valleys in or on one or both major surfaces of the sheet material. One or more or each of the depressions in one of the main surfaces may have a corresponding projection or a corresponding peak on another of the main surfaces, or vice versa. In embodiments, the pattern includes projections in or on one or both major surfaces of the sheet material, with each projection having, for example, a corresponding depression on the other or opposite major surface of the sheet material. The sheet material preferably has a central or neutral plane, for example corresponding to the plane or central plane of the sheet material before forming. The projections formed on the first main surface of the molded sheet material may be molded on the first side of the central or neutral plane, and/or the projections formed, for example, on the second main surface of the molded sheet material may be formed on the second side of the central or neutral plane. for example - opposite to the first side. Likewise, depressions formed on the first main surface, which may correspond to projections formed on the second main surface, may also be formed on or extending through the first side of the central or neutral plane, and/or depressions formed on the second main surface, which may correspond to projections formed on the first main surface, may also be formed on or extend through the first side of the central or neutral plane.

The pattern may contain a plurality of rows and/or columns, for example, straight and/or spiral rows and/or columns, and projections. The configuration and/or distribution of projections and depressions, for example patterns or matrices, may be such that lines drawn on the surface of the material between adjacent rows of projections and depressions are not straight.

Each protrusion is preferably subjected to hardening with plastic deformation of the apex, for example obtained by locally molding the sheet material, for example leaving a corresponding depression on the opposite face of the material.

The sheet material may be steel, for example mild steel, and may be galvanized. Alternatively, the sheet material may be any other material, preferably, but not necessarily, a material having the ability to be strain hardened and/or plastically deformed.

The sheet material may be a profiled or shaped or bent cross-section, such as a channel section or similar section, intended for use as a frame partition or channel post or part thereof. A pattern and/or branding or a second pattern may be molded over the entire shaped section or a portion thereof. The brand name or second design is preferably formed into or on a flat, eg unmolded, surface of the sheet material that, for example, does not have any bends or folds.

In another aspect of the invention there is provided a profile or beam or product having a shaped cross section, wherein the profile or beam or product may have a shaped section containing the above-described sheet material. The profile or beam or product may comprise a first portion having peaks and valleys that can be formed by cold forming the sheet material. The profile or beam or product may contain a second section, which may be located at the peak and valley discontinuity. The second portion may comprise one or more raised or recessed areas formed by embossing a relief, such as embossing a sheet material, such that said areas protrude from or are recessed into a plane of the sheet material, such as its neutral plane. The second portion preferably provides a brand name.

The pattern may be continuous, for example, the projections and/or recesses may together provide a continuous structure. The pattern may comprise a continuous region of peaks and valleys, which may be arranged such that the surface of the sheet material does not have straight lines. In a preferred embodiment, the pattern and branding together form a repeating structure that can be formed, for example, by forming sheet metal with tools.

In yet another aspect of the invention, there is provided a method for determining the quality of a molded sheet material, for example a method for quality control or for implementing this control, which consists in determining, for example by means of a brand mark, whether the tools are aligned.

In a further aspect of the invention, a quality control method is provided which consists of forming a pattern on or in a first portion of sheet material using tools in a pair, forming a brand name on or in a first portion of the sheet material, for example tools of the same pair. in the second portion of the sheet material, and check or visually inspect or evaluate or determine, for example by means of a brand mark, whether the tools are aligned.

In yet further aspects of the invention there is provided a molded sheet material, a tool, a pair of tools and a device for use, for example specifically adapted for use, in the above method.

Embodiments of the invention will now be described, by way of example only and with reference to the accompanying drawings, wherein:

Figure 1 is an end view of a forming tool in accordance with one embodiment of the invention;

Figure 2 is a perspective view of the forming drum segment of the forming tool according to Figure 1;

Figure 3 is a cross-section along line A-A according to Figure 1;

FIG. 4 is a plan view of a radial hole in the tool of FIG. 1;

Figure 5 is a perspective view of the marking insert for insertion into the forming tool according to Figures 1-3;

Figure 6 is a side view of the marking insert according to Figure 4;

Figure 7 is a cross-section along line B-B according to Figure 5;

FIG. 8 is a side view of a forming tool designed to interact with the tool of FIG. 1;

Figure 9 is an exploded view of the forming tool according to Figure 1, illustrating in more detail a possible drive unit;

Figure 10 is a perspective view of the first end of the tool according to Figures 1 and 9;

Figure 11 is a perspective view of the second end of the tool according to Figures 1 and 9;

FIG. 12 is a perspective view of an aligned pair of tools in accordance with an embodiment of the invention; FIG. And

FIG. 13 is a top view of sheet material in accordance with an embodiment of the invention.

Turning now to FIGS. 1 to 4, these drawings show a forming tool 1 which is a cylindrical roll 1 for profiling sheet material, in this embodiment for profiling cold-drawn profiles of sheet material. The tool 1 includes a central forming drum 2, first and second end pieces 3, 4, an insert 5, a pair of mounting rings 6, and a locking mechanism 7 for releasably securing the insert 5 inside the forming drum 2.

The forming drum 2 is designed as a hollow cylinder or roller which provides a substrate which includes a first profiled forming surface 21 on the outer circumferential surface. In this embodiment, the first profiled forming surface 21 includes a pattern of projections 21a arranged in a matrix having a plurality of rows and columns. The forming drum 2 includes at least one, and preferably a pair of coaxial radial holes 22, 23, preferably located centrally along its longitudinal axis, and a single hole 22, 23 or each of them includes a counterbored portion 22a , 23a extending inwardly from the outer circumferential surface of the forming drum 2. The countersunk portions 22a, 23a are substantially rectangular in plan having rounded corners, as more clearly shown in FIG. 4. The countersunk portion 23a of one of the radial holes 23 includes one chamfer 20a having a larger diameter than the other chamfers of the countersunk portion 23a. The holes 22, 23 and the corresponding countersunk portions 22a, 23a need not have the same dimensions. The holes 22, 23 and corresponding countersunk parts 22a, 23a do not necessarily have to be coaxial.

The forming drum 2 also includes eight longitudinal through holes 24 extending parallel to the axis of the forming drum 2, equidistant from and around the longitudinal axis. At each end of each longitudinal hole 24, a female thread is cut for engagement with a corresponding threaded bolt 30, 40. Each axial end of the forming drum 2 includes a recess 25, 26 for enclosing a portion of a corresponding one of the first and second end portions 3, 4.

The first end piece 3 is made in the form of a substantially cylindrical disk with a central hole 31, a radial flange 32 on its first side and eight holes 34 extending through the thickness of the central portion of the disk in positions corresponding to the positions of through holes 24 in the forming drum 2. Each of the through holes 34 includes a countersunk portion 34a on the first side of the first end of the portion 3 receiving the head of a corresponding bolt 30. The second side of the first end piece 3 is enclosed within the first of the end recesses 25 of the forming drum 2 and is secured thereto by eight bolts 30 extending through through holes 34 of the first end part 3 and engaged with the turns of the female thread in the through holes 24 of the forming drum 2, and between the end of the forming drum 2 and the radial flange 32 there is one of the mounting rings 6.

The second end piece 4 is configured as a hollow cylindrical spur gear type member 4 with a through axial hole 41, a plurality of gear teeth 42 extending outward therefrom, a radial groove providing a shoulder 43 on its first side, and eight through holes 44 at positions that correspond to the positions of the through holes 24 in the forming drum 2. Each of the through holes 44 includes a countersunk portion 44a on a second side of the second end piece 4 opposite the first side receiving the head of a corresponding bolt 40. A shoulder 43 on the first side of a groove of the second end piece 4 is enclosed inside the second of the end recesses 26 of the forming drum 2 and is attached to it with eight bolts 40 passing through the through holes 44 of the second end part 4 and engaged with the threads in the through holes 24 of the forming drum 2 with another mounting ring 6 located between the teeth 42 gears of the second end piece 4 and the end of the forming drum 2.

As more clearly shown in FIGS. 5-7, the liner 5 is formed as a substantially rectangular blank with rounded vertical corner edges 50, 50a to provide a top forming edge 51 that is substantially rectangular in plane with rounded edges. One of the corner edges 50a has a slightly larger radius than the others to engage the rounded corner 20a of the countersunk portion 23a within which the liner 5 must be enclosed to ensure proper orientation.

The main surface of the forming edge 51 of the liner 5 is curved to provide a constant depth of recess in the circumferential surface of the forming drum 2 when the liner 5 is inserted into the recess. The upper forming edge 51 includes forming edges 52 that define the brand name in this embodiment. The shaping edges 52 define the outline of the logo's letters, with the letters themselves appearing as depressions 52a within the defined outline or between the shaping edges 52.

On its first side, liner 5 also includes a locking recess 53 with a flat edge 54 that is substantially parallel to the forming edge 51, and a beveled surface 55 opposite the flat edge 54 to provide a wide-opening locking recess 53 that is beveled toward a narrow base 56 extending from the flat edge 54. The liner 5 also includes a groove 57 on its second side opposite the first side at the bottom of the liner 5. The groove 57 is inclined to provide an insertion edge in the same direction as the beveled surface 55 of the locking recess 53 .

The locking mechanism 7 includes a locking pin 70 and a compression spring 71, both of which are enclosed within one of the through holes 24 in the forming drum 2 between one of the bolts 40 and the locking recess 53 of the liner 5. As more clearly shown in FIG. 3, the liner 5 is enclosed within a countersunk portion 23a of one of the radial holes 23 of the forming drum 2, with a locking recess 53 facing the second end piece 4. The locking pin 70 has a first rounded end which is enclosed within the locking recess 53 and engages the beveled surface 55. The locking pin 70 is biased by a spring, which is compressed between the end of the bolt 40 and the second - flat - end of the locking pin 70. The presence of a biased locking pin 70, which is engaged with the beveled surface 55, provides locking forces both along the axis of the liner 5 and and along the axis of the locking pin 70.

With the help of the insert 5, enclosed in the countersunk part 23a of the radial hole 23 of the forming drum 2 and fixed therewith, the forming edge 51 is made adjacent and adjacent to the first profiled forming surface 21, although somewhat recessed relative to it. Thus, when the tool 1 forms the sheet material, both the brand name and the pattern portion are formed simultaneously.

Turning now to FIG. 8, we note that the forming drum 8 of the second tool is shown, which is also made in the form of a cylindrical roll for profiling sheet material and is essentially similar to the forming drum 2 of the first tool 1, with similar structural elements designated by similar positions, in which the value 2 preceding the proper name or the first digit is replaced by the number 8. The second tool assembly includes a forming drum 8, first and second end parts 3, 4, installation rings 6 and a locking mechanism 7, the assembly of which is carried out in the same way as the assembly described above in connection with the first tool 1. The radial hole 83 is adapted to enclose an insert (not shown), which may be a blank having a forming surface without features designed to interact with the forming edges 52 of the insert 5 of the first tool 1 for the purpose of marking the sheet brand name material.

Alternatively, and in accordance with one aspect of the invention, the liner (not shown) may include forming edges that cooperate with forming edges 52 of the liner 5 to provide a branding. For example, the forming edges of the additional liner may include forming edges that are contained within and/or aligned with the recesses 52a within the defined contours or between the forming edges 52. Those skilled in the art will understand that with such an arrangement, any misalignment between instruments 1, 8 can be easily noticed by the distortion of the logo.

In further preferred alternative embodiments, the forming edges 52 may outline a branding symbol that is configured to be machine readable and is embodied, for example, in the form of one or more bar codes and/or quick response (QR) codes. In such embodiments, even slight distortion resulting from alignment mismatch between tools 1, 8 can be detected by computerized scanning and computerized processing. In fact, it is assumed that the brand name can be selected in such a way that the nature of the alignment mismatch can be recognized based on the degree and nature of the distortion. The use of BR codes or a similar type of brand name could become the basis for such a recognition organization.

The tools 1, 8 are mounted rotatably inside the device (not shown) at a predetermined distance from each other and are interconnected by their respective drive means (not shown), which drives the gear teeth 42 of the second end piece 4, ensuring their counter-rotation with that the same speed. The rotation of tools 1, 8 causes the matrix of protrusions 21a on the first tool 1 to align and enter into the gaps between the protrusions (not shown) on the other tool 8.

When used, the tools 1, 8 interact to form a pattern of protrusions and depressions in the sheet material fed between the tools, and the mounting rings 6 fix the sheet material between them. As the tools 1, 8 rotate, the projections 21a on one tool 1 entrain portions of the sheet material into the gaps between the projections (not shown) on the other tool 8, thereby limiting the effective thickness or amplitude between the tips of the projections on each side of the sheet material. In this embodiment, the material is sheet steel, and the formation of the pattern of ridges and valleys results in plastic deformation strengthening of the sheet material, wherein the formation of the sheet material occurs due to local deformation thereof, as explained in more detail in the document WO2009/063154 (and/or one of the documents GB2450765A and EP0891234A).

In addition, when the tools 1, 8 form a pattern of ridges and valleys into the sheet material, the forming edges 52 of the liner 5 are supported by a blank (not shown) in another tool 8, resulting in the embossing of a brand name relief on the sheet material. Alternatively, if the insert (not shown) in another tool includes additional forming edges, then they can cooperate with the forming edges 52 of the insert 5 to emboss a relief or otherwise form a brand name.

Referring now to FIGS. 9-12, each of the recesses 25, 26 (of which only one is shown) of the forming drum 2 is circular in plan and is delimited by an annular wall 26A. At equal circumferential distances around the recess 26 and internally from the annular wall 26A there is a group of grooves 27A, 27B, 27C for receiving the ends of the respective reference keys 28A, 28B, 28C. The shoulder 43 of the spur gear type cylindrical member 4 includes three breaks 45 (of which only one is shown), the shape of which is complementary to the shape of the other end of the reference keys 28A, 28B, 28C.

In the engaged state, the intermittent shoulder 43 extends along the mounting ring 6, lies against the circular recess 26 and is limited by the annular wall 26A, with the reference keys 28A, 28B, 28C being partially enclosed in the breaks 45.

The center hole 31 of the first end piece 3 includes a keyway 31A, and the center hole 41 of the spur gear type member 4 includes a corresponding keyway 41A aligned with the keyway 31A of the first end piece 3 when the tool 1 is in an assembled state due to whereby a keyed drive shaft (not shown) can be enclosed in the central hole.

In order to produce a set of tools 1, 8 in accordance with the invention, the following process is carried out.

First, it is determined what kind of appropriate structuring process is required. The type of tooth shape, tooth height, pitch between teeth (in rows and columns) - all these characteristics are important for the implementation of structuring when searching for a technology for manufacturing a specific structured sheet material. Thus, immediately after determining the tooth shape, a smooth roller 2 is provided. One of the notches (eg 26) is used to determine the reference position DP. Then, a tooth shape is provided on the outer periphery 21 of the forming drum 2, for example, by one or more of cutting, milling, grinding, etching, and the like, and the reference position DP is used to determine the starting position for the forming operation.

As shown in FIG. 12, the spur gear 4 is also aligned with the reference position DP to provide the gear reference position DA _G in both the gear (for example, the spur gear 4 of the first tool 1) and the gear DA _P ( for example, spur gear 4 of the second tool 8).

Thus, it is clear that the pattern formed on the rollers 1, 8 and the position of the spur gears 4 are aligned with a single limited point on each roller 1, 8.

Moreover, immediately after establishing the desired structuring process, the shape of the spur gear is calculated in accordance with equations (1) - (3):

d _vz = 162 mm.

In one possible embodiment, the sheet material to be rolled is steel with a thickness of 0.6 mm (ie, g = 0.6 mm).

In this case, spur gear 4 has the following characteristics (provided k = 0.1 and d _in :d _H = 1):

D_BEFORE= 162 - (0.6 + 0.1) = 161.3 mm

N = 80

P = 0.5

Tooth head height (A) = 2

Tooth stem height (D) = 2.3

Tooth thickness (T) = 3.14

Pressure angle = 20°

The shaft (not shown) passing through the first tool 1 is driven by an electric motor with a first “jog” speed, which causes rotation of this tool 1, and - due to the action of the meshed spur gears 4 - causes counter rotation of the other roll 8.

When the rollers 1, 8 are driven at the first speed, the sheet material is fed through the contact zone between the rollers and onto the next forming rollers. Immediately after feeding the material through all technological positions, the drive of rolls 1, 8 is carried out at a higher operating speed and the manufacturing process begins.

It is noteworthy that as soon as the material to be structured passes into the contact zone, the rollers 1, 8 move slightly apart, thereby causing the spur gears 4 to move apart. This movement ensures that the teeth of the gear wheels do not contact on the previous line of action, so that their meshing is simultaneous is eliminated by the drive. At this moment, the drive of the rolls 1, 8 is carried out by the action of the drive means directly on the shafts.

Referring now to FIG. 13, sheet material 100 is shown comprising a cold-worked region 101 in which a pattern of projections is formed on both major surfaces, each projection having a corresponding recess on the opposite major surface. The pattern is formed in such a way that the lines drawn on the surface of the molded sheet material between adjacent rows of projections and depressions are not straight. The sheet material 100 also includes a series of breaks 102 in the cold-worked pattern into which the branding mark 103 is formed.

Those skilled in the art will appreciate that it is within the scope of the invention to make modifications to the above embodiments. For example, other sheet materials can be formed by means of the present invention, which may, but need not, be steel or metal or even plastic. The configuration of the forming edges 52 may provide for the delineation or delimitation of any brand name, such as an alphanumeric brand name, one or more images, or a special identifier related to the tool or tools arranged in a pair, or the molding machine or manufacturer, such as the company - the manufacturer of sheet-forming machines and/or the tool manufacturer. Moreover, the locking mechanism 7 does not necessarily include a spring-biased locking pin 70, but may include, for example, any suitable locking device, such as a ball and locking device, or even a bayonet-type locking mechanism, or any type of locking mechanism or means. another type. Based on the description given here or his own knowledge, a specialist will easily understand several other options.

Those skilled in the art will also appreciate that any number of combinations of features mentioned above and/or illustrated in the accompanying drawings provide distinct advantages over prior art and are therefore within the scope of the invention described herein.

Thus, the essence of the invention lies, in particular, in the following.

1. A method of forming sheet metal material, including the steps of placing sheet material between tools arranged in a pair, and moving the tools such that the tools simultaneously form a pattern of projections on or in a first portion of the sheet metal material and a brand name in a second portion. sheet metal material in a gap in a pattern of projections, the shape of the brand mark being an indication of the alignment between the tools.

2. The method according to claim 1, in which forming the pattern includes forming on both main surfaces of the sheet material projections, the configuration and/or distribution of which is such that lines drawn on the surface of the molded sheet material between adjacent rows of projections and depressions are not straight .

3. The method according to claim 1 or claim 2, in which the tools are moved in such a way that the teeth or protrusions on one tool press sections of the sheet material into the gaps between the teeth or protrusions on the other tool, thereby performing cold deformation processing on the first section of the sheet material material and forming a pattern in or on it.

4. The method of any of the preceding claims, wherein the tools are moved such that one or more of the forming protrusions of one of the tools force or press the sheet material against another tool, thereby subjecting the sheet material to embossing a relief to form a brand name into or On him.

5. The method according to any of the preceding paragraphs, wherein the second section is surrounded or limited by the first section.

6. A molded sheet metal material comprising a pattern of projections formed on or in a first portion or first region thereof, and a brand name formed on or in a second portion or second region thereof in a discontinuity in the pattern of projections, the pattern comprising projections on both main surfaces of sheet material.

7. The molded sheet metal material of claim 6, wherein cold working is provided in a first portion or region and embossing is provided in a second portion or region, wherein due to the configuration and/or distribution of the pattern, lines are drawn on the surface molded sheet material between adjacent rows of projections and depressions are not straight.

8. The formed sheet metal material of claim 6 or claim 7, wherein the mark is an indicator of the alignment of tools used to cold form the sheet material.

9. The molded sheet metal material according to any one of claims 6 to 8, wherein at least the portion of the brand name or embossed relief is microscopic.

10. The formed sheet metal material of any one of claims 6 to 9, wherein at least the branding portion provides a visual and/or machine readable indication of the alignment of the tools used to form the sheet material.

11. The molded sheet metal material of claim 10, wherein the degree of trademark distortion corresponds to the degree of tool alignment mismatch.

12. The formed sheet metal material according to any one of claims 6 to 11, wherein the second portion is defined by the first portion.

13. A forming tool comprising a first forming surface that, when used, is configured to form a pattern of protrusions in a first portion of sheet metal material, and a second forming surface that is configured to form a brand name in a second portion of sheet metal material located in a discontinuity in the pattern protrusions

14. The tool of claim 13, comprising a substrate including a first forming surface, and a liner removably enclosed within a recess of the substrate, including a second forming surface.

15. The tool of claim 14, wherein the liner is secured or configured to be secured within the recess by means of a locking means.

16. A forming tool for forming sheet metal material, comprising a backing, a liner, and a fixing means, the backing having a first forming surface including a pattern, the liner having a second forming surface including a branding, the backing having a recess within wherein the insert is enclosed in a removable manner and secured by means of locking means such that the first and second forming surfaces are substantially adjacent and/or adjacent to each other for molding - in use and/or simultaneously therewith - at least , area of pattern and brand name in or on sheet material.

17. The tool of any one of claims 13 to 16, wherein the configuration of the second forming surface enables, when used, to form into the sheet metal material a signature that is a visual indicator of alignment between the tool and another tool with which the tool interacts.

18. The tool of any one of claims 13 to 17, wherein the configuration of the second forming surface allows, in use, to form into the sheet metal material a brand name that is distorted if the tool's alignment is misaligned with another tool with which the tool interacts.

19. The tool according to any one of claims 13-18, in which the brand name is machine readable.

20. The tool according to any one of claims 13-19, in which the pattern contains a matrix of protrusions, and the brand name contains an identifier.

21. A tool according to any one of claims 13 to 20, wherein the second forming surface is recessed relative to at least a portion of the first forming surface.

22. The tool according to any one of claims 13 to 21, wherein the locking means comprises a locking projection that engages the locking recess.

23. The tool of claim 22, wherein the locking protrusion is movable between an operative or locked position or condition and a non-operational or retracted or unlocked position or condition.

24. The tool of claim 23, wherein the locking protrusion is moved to an operating or locked position or condition.

25. The tool according to any one of claims 22 to 24, wherein the locking protrusion includes a locking pin movably installed in the forming tool, and the liner includes a locking recess.

26. The tool according to any one of claims 13 to 25, further comprising a drive means located at or offset towards its first end, while the other end of the tool does not include a drive means.

27. A tool according to claim 18, having a substantially cylindrical shape, the first forming surface comprising a plurality of teeth, the tips of which define a nominal tooth tip diameter, d _VZ , in a circumferential direction, the drive means comprising a spur gear having an outer diameter d _N , and the ratio of the nominal diameter of the tooth tips, d _VZ , to the outer diameter d _N is in the range from 0.5 to 1.5.

28. The tool according to claim 27, in which the ratio of the nominal diameter of the tooth tips, d _VZ , to the outer diameter d _H is in the range between 0.8 and 1.2.

29. A pair of forming tools for forming sheet metal material therebetween, comprising a first forming tool according to any one of claims 13 to 28 and a second forming tool comprising a first forming surface for interacting with a first forming surface of the first tool for forming a pattern in or on the sheet metal material being formed therebetween, and a flat surface for engaging with a second forming surface of the first forming tool for forming a brand name on the sheet metal material being formed therebetween.

30. A pair of forming tools according to claim 29, wherein the configuration of the first forming surfaces of the forming tools provides interaction - when used - for cold working of sheet metal material between them, and the configuration of the second forming surfaces of the forming tools provides interaction for embossing a relief of the sheet metal material between them.

31. A pair of forming tools for forming sheet metal material therebetween, each forming tool comprising a corresponding first forming surface and a corresponding second forming surface, wherein the first forming surfaces, in use, cooperate to form a pattern of projections in or on the sheet metal material being formed therebetween. and the second forming surfaces cooperate to simultaneously mold the indicia into discontinuities in the pattern of protrusions in or on the sheet metal material being formed therebetween, the configuration of the second forming surfaces being such that the insignia is distorted in the event of tool alignment misalignment.

32. A pair of tools according to any one of claims 29 to 31, wherein the second surfaces comprise cooperating forming edges separated by a predetermined distance in use when the sheet metal material is formed between the tools and the tools are properly aligned.

33. A pair of tools according to any one of claims 29 to 31, wherein one of the second forming surfaces comprises a male forming surface or a male projection, and the other of the second forming surfaces comprises a corresponding female forming surface or a corresponding female projection or a corresponding female recess.

34. A pair of tools according to any one of claims 29 to 33, wherein the first forming surfaces, in use, cooperate to form a matrix of projections and recesses distributed such that lines drawn on the surface of the molded sheet material between adjacent rows of projections and recesses are not straight.

35. A pair of tools according to any one of claims 29 to 34, wherein the second forming surface of each tool is surrounded or limited by its first forming surface.

36. A pair of tools according to any one of claims 29 to 35, each of which includes drive means located at or offset towards its first end, while the other end of each tool does not include drive means.

37. A pair of tools as set forth in claim 36, wherein each tool has a substantially cylindrical shape, the first forming surface of each tool comprising a plurality of teeth, the tips of which define a nominal tooth tip diameter, d _VZ , in a circumferential direction, wherein each means The drive contains a spur gear having an outer diameter d _H , and the ratio of the nominal diameter of the tooth tips, d _VZ , to the outer diameter d _H is in the range from 0.5 to 1.5.

38. A pair of tools according to claim 36, in which the ratio of the nominal diameter of the tooth tips, d _VZ , to the outer diameter d _H is in the range between 0.8 and 1.2.

39. A device for forming sheet material, comprising a pair of opposing tools according to any one of claims 29 to 38, mounted for movement relative to each other.

40. The device according to claim 39, in which the first forming surfaces contain projections or teeth, and the geometry and position of the projections or teeth and the spacing of the tools are such that the projections or teeth on one tool - when used - are exposed and/or extend into the gaps between ridges or teeth on another tool.

41. A profile or beam or product with a shaped cross section, wherein the profile or beam or product has a shaped cross section containing sheet metal material according to any one of claims 6 to 12.

42. A profile formed from sheet material, comprising a first portion having peaks and valleys formed by cold working the sheet material, and a second portion in discontinuities of peaks and valleys containing one or more raised or recessed regions with grooves, and in the second portion preferably a brand name is provided.

43. A quality control method of using a pair of tools to form a pattern on or in a first portion of a sheet metal material, using the tools to form a brand mark in a second portion of the sheet metal material, and determining by the mark whether the tools are aligned.

Claims (19)

1. A molded sheet metal material comprising a ridge and recess pattern formed on both major surfaces of the shaped sheet metal material in a first portion of the shaped sheet metal material, and a brand name formed on a second portion of the shaped sheet metal material at a break in said ridge and recess pattern, characterized in that at least the branding portion provides a visual and/or machine-readable indication of the alignment of the tools used to form said sheet metal material. 2. The molded sheet metal material of claim 1, wherein said second portion is defined by the first portion. 3. The molded sheet metal material of claim 1 or 2, wherein one or more or each of the depressions formed on the major surfaces of the molded sheet metal material has a corresponding projection on the other major surface of the molded sheet metal material, or vice versa. 4. The molded sheet metal material of any one of the preceding claims, wherein at least the trademark portion is microscopic. 5. A molded sheet metal material as claimed in any one of the preceding claims, wherein the logo is formed on a flat, particularly unmolded, surface of the molded sheet metal material. 6. The molded sheet metal material of any one of the preceding claims, wherein the brand name is embossed such that the brand name projects from a plane of the molded sheet metal material. 7. The formed sheet metal material of any one of the preceding claims, wherein the degree of mark distortion corresponds to the degree of tool alignment mismatch. 8. The molded sheet metal material of any one of the preceding claims, wherein said pattern of projections and recesses is configured and/or distributed such that lines drawn on the surface of the molded sheet metal material between adjacent rows of projections and recesses are not straight. 9. The molded sheet metal material of any one of the preceding claims, wherein said pattern of projections and recesses is arranged in a matrix. 10. The molded sheet metal material of any one of the preceding claims, wherein said pattern of projections and recesses comprises a plurality of rows and/or columns. 11. The molded sheet metal material of any one of the preceding claims, wherein the sheet metal material comprises steel. 12. The molded sheet metal material according to any one of the preceding claims, wherein the pattern of projections and recesses is formed on the first portion of the molded sheet metal material by cold working. 13. The molded sheet metal material of any one of the preceding claims, wherein the trademark comprises a predetermined pattern configured specifically to provide rapid and/or simplified detection of alignment mismatch between tools. 14. The formed sheet metal material of any one of the preceding claims, wherein the formed sheet metal material has a central or neutral plane. 15. The formed sheet metal material of claim 14, wherein one or more or each of the projections formed on the first major surface of the formed sheet metal material is formed on the first side of the central or neutral plane. 16. The molded sheet metal material of claim 14 or 15, wherein one or more or each of the projections formed on a second major surface of the molded sheet metal material opposite the first major surface is formed on a second side of a central or neutral plane opposite said first side. 17. A profile containing a molded sheet metal material according to any one of paragraphs. 1-16. 18. A beam containing a molded sheet metal material according to any one of claims. 1-16. 19. A product with a shaped cross section, comprising a molded sheet metal material according to any one of paragraphs. 1-16.

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