SE517435C2 - Manufacturing method for the production of profiled products that are deformed into final shape by pressure against the wall of the blank and the blank - Google Patents

Abstract

The invention relates to a method of manufacturing products, wherein a blank is produced in the shape of a closed profile and having an at least partially profiled wall and is then deformed to its final shape by applying pressure to the wall of the blank. In accordance with the invention a piece of material (M1) is provided with longitudinal indentations (8) through roll-forming, the profile piece of material is formed to a substantially closed generally tubular profile in a pipe mill and the profile is closed by firmly connecting adjacent side edges thereof, whereupon the profile is deformed by applying pressure to the wall of the closed profile in a manner that is known in itself. The invention also relates to a blank for use in hydroforming operations.

Description

15 20 Nås 517 435 o: | U.S. Pat. No. 2,707,820 discloses a method of making tubular members, and more particularly a method of making metal tanks of larger dimensions.

According to this document, this refers to the extrusion of tank blanks. The cost of the extrusion method increases dramatically with increasing pipe diameter, partly due to the cost of the press tools themselves, but above all through the size of the press that must be used to generate the required press pressure. In the above-mentioned U.S. patent, it is proposed to reduce the cost of manufacturing a specific tank size by extruding the tubular member with a substantially smaller outer diameter than that of the finished tank, but with a corrugated wall. By applying internal hydraulic pressure to the tubular element, this is expanded to the final diameter, whereby the expansion takes place by the corrugations "unfolding". As a result, the material is also subjected to minimal elongation during the final forming.

Although extrusion can today, under certain conditions, be used for the production of pipes or other closed steel profiles, this method is usually limited to the production of non-ferrous metal profiles. In addition, a change of tool is required, ie both the dome and the matrix, as soon as the slightest change takes place in the profile, ie when changing both the outer diameter and the shape, size and / or mutual placement of the corrugations.

In summary, it can thus be stated that the conventional manufacturing methods traditionally used for the purposes discussed above entailed a relatively cumbersome and expensive re-rigging and conversion work for the production of various products. In other words, there is an obvious need to find a manufacturing method that offers a solution to these problems and allows quick and easy conversion between different processes.

DESCRIPTION OF THE INVENTION The invention eliminates the above problems in an efficient and effective manner.

A general purpose of the invention is to provide a solution to the problem of being able to quickly and conveniently manufacture generally tubular products such as the blank or semi-finished products for a final molding of products with different dimensions and shapes. 10 15 43: obtained 517 435 3 A basic object of the invention is consequently to provide a simple and expedient method of producing generally tubular starting materials or blanks, adapted to form, after a final deformation of these profiles or blanks, end products of different dimensions and with different cross-sectional profiles.

According to the invention, there is thus provided a process for the manufacture of products by producing a blank with a closed profile and at least partially profiled wall and by deforming this substance into the final shape of the product. According to the invention, the blank is produced by roll-forming a generally sheet-shaped piece of material, partly for achieving a profiling of the blank and partly for closing the profile of the blank, and subsequently fixed connection of the sides of the blank. The final form of the product is then formed by deformation of the end known per se.

This results in a relatively simple adjustment for the production of the substance with different proliferations, adapted to the actual end product and / or to its final formation by deformation. This in turn entails significantly reduced working hours and costs compared to the conventional methods.

According to embodiments of the invention, the blank is provided at the roll forming with uniformly or alternatively non-uniformly distributed proliferations around its circumferential surface. By utilizing the roller formation, a conversion between a production of blanks suitable for symmetrical and asymmetric deformation can be achieved relatively quickly and easily.

According to other embodiments of the invention, a blank is provided in the roll forming with proliferations with the same or alternatively different depths. This offers a further opportunity to achieve the conversion between blanks suitable for symmetrical and asymmetrical deformation in a relatively fast, simple and smooth manner.

According to further embodiments of the invention, the deformation of the unit is carried out by applying a mechanical or alternative hydraulic pressure to the entire interior of the blank. outer surface or alternatively only towards parts of this inner resp. outer surface. With such designs, a very large vad flexibility is achieved with simple means with regard to the final shape of the products that can be manufactured according to the invention. Another embodiment of the invention specifically relates to a manufacture of products which are finalized by hydroforming, more particularly "internal" hydroforming, and consists in the end being formed by roll forming with different material contents, in the form of different depths and / or widths. proliferations, but with the same outer diameter. This means that production can be further rationalized by the fact that only one outer diameter for the profiles needs to be produced in the pipeline, even if they are to be formed into end products with different shapes and sizes.

By, according to another form of drying, also providing the objects with proliferations of varying numbers and with different mutual positions depending on the deformed end shape for each sleeve, the production can be further rationalized and cold stretching can be avoided at the same time.

Additional embodiments of this first aspect of the invention are set forth in the corresponding dependent claims.

Another object of the invention is to provide a blank for hydroforming which has a profiled surface, whereby the material of the sleeve during hydroforming is subjected to minimal elongation.

These and other objects of the invention are achieved by the invention as defined in the appended claims.

In short, the present invention entails the following advantages: - Relatively quick and easy adjustment for the manufacture of the article adapted for different end products; The shape of the substance can be relatively easily "tailored" to the purpose of the intended end product; - The shape of the blank can be adjusted with less adjustment work so that minimal stretching of the material occurs during the deformation, for example by hydroforming; 10 15 20 ï- "ào 517 435 c n v u o | oO 5 - For hydroforming, the sleeve can be manufactured with a uniform outer diameter in a pipe, but with different material contents, whereby blanks with the same outer diameter can be used for deformation into end products with a large dimensional difference.

In the case of hydroforming, tubular blanks of high-strength materials can also be used, without risk of changing the material properties by cold-drawing. Additional objects, features and advantages of the invention, as well as further embodiments thereof, appear from the dependent claims and the following description of exemplary embodiments.

DESCRIPTION OF THE DRAWINGS The invention is described in more detail below, in connection with the accompanying drawings, in which: Figs. 1A Pig. 1ß Pig. zA-B Pig. aA-B Pig. 4A-B Pig. sA-B is a partial schematic end view of a station in a roll forming arrangement, seen in the forming direction; is a partial schematic end view of a station in a pipework, showing the principles for closing a subject profile; shows an example of an embodiment of a substance according to the invention in three different stages of the preparation; shows an example of an alternative embodiment of a substance profile according to the invention in three different stages of the preparation; shows ärmu an example of an alternative embodiment of a substance profile according to the invention in three different stages of the preparation; shows an alternative design resp. an alternative distribution of the longitudinal projections of the article, and Figs. 6A-C show examples of further embodiments of an end product according to the invention.

DESCRIPTION OF EMBODIMENTS Referring primarily to Figures 1-2A, the basic principles of the invention will now be described by means of a first embodiment shown in these figures, and at the same time the differences from previously known methods will be clarified.

For the manufacture of an end product 9 (see 2 g 2B), it is basically proposed according to the invention that in a first step a piece of material M1 is provided in the form of a disc or sheet of a suitable material with longitudinal parallel proliferations 8. A distinguishing feature of the invention is that the proliferations or the corrugations are formed by roll forming. Drawing 1A shows very schematically an example of a roller forming plant 1 of conventional construction.

Such a plant conventionally consists of a number of stations 2 located in the direction of the flow or of each other, of which only one is shown in Figure 1A. Each station contains a pair of upper and lower axes 3 resp. 4 on which upper and lower forming rollers 5 and 5, respectively, cooperating. 6 are stored to form projections 8 between them in the piece of material M1. Usually, some of the rollers simultaneously have the task of advancing the piece of material M1. The proliferations 8 in the piece of material M1 are gradually deepened in the successive stations 2 and reach their final shape in the last station. For further details of the general construction of a conventional roll forming plant, reference may be made, for example, to Swedish patent 348 955. However, the invention is in no way limited to the embodiment of the roll forming plant shown in principle here or described in said patent, but any expedient roll forming plant may be used. when practicing the invention.

The same applies to the pipe structure 7 illustrated in Fig. 1B, in which the piece of material M1 propelled in the forming stations 2 in a second step is formed into a substantially closed profile P1 (see Fig. 2A) with a general pipe shape. The pipework 7 is included as a terminus in or connects to the roll forming plant 1 and consists of a number of substations 7A, of which only one is shown in fi g. 1B, each containing a lower roller 7B and an upper roller 7C. This shape is obtained in such a way that the profiled piece of material M1 in the pipework 7 is gradually closed to the desired profile shape via the successively arranged roller sets with rollers 7B, 7C which have a shape which is gradually changed to form a profile with an ever smaller radius forward. to that its 10 15 20 fl és nrsn »I now. 3: 0 n n ap »517 435 7 final form is achieved. This is schematically illustrated in Figure 1B by the dashed lines M1 ', M1 "drawn for the piece of material. The general construction of such pipelines belongs to the state of the art and does not in itself form part of the invention. The main difference from the conventional pipelines is that the gap between the upper and lower rollers must be increased corresponding to the height or depth of the profiles in the piece of material, so that the profiles are not defined at this stage.

Thus, according to the first embodiment of the present invention shown in Figs. 1 and 2A-B, the piece of material M1 is formed in the roll forming bearing ring 1 with generally longitudinal profiles 8 of the same depth and pitch, and in this first step obtains the shape shown in Figs. 2A. The proliferations 8 in this example have a general trapezoidal shape and are evenly distributed over the piece of material M1.

In the second step, the piece of material M1 in the flue 7, i.e. the end station of the roll forming plant, is formed into a generally cylindrical, profiled pipe form P1 shown in solid line in 2 g 2B. In a third step, not shown, the facing edges of the piece of material are then connected to each other by conventional methods, such as welding or cold rolling in the case of metals and turning or welding in the case of other materials. Thus, the blank is ready for the final formation by deformation. Figure 2B shows the former of the final product 9 with a dotted line, and in this case it is a question of an expansion of all available material in the profiles 8, so that the final product 9 takes the form of a smooth cylinder. The expansion of the pro1 P1 to the form of the final product can take place mechanically, for example by means of a mandrel, but in a currently dry application the expansion takes place by means of an under uid under high pressure, ie by hydroforming. In the hydroforming known per se, the expansion generally takes place so that by applying high hydraulic internal pressure, the blank P1 is formed against the inner surface of a tool (not shown here) which has the intended final shape.

As stated at the outset, the basic aim of the invention is to provide a method which obviates the disadvantages of conventional technology, and more particularly to achieve this by providing a highly flexible manufacturing method which allows for quick and easy adaptation to the actual end product. An example of this large fl flexibility will now be described with reference in particular to fi g. 3A-B and 4A-B. 10 15 20 Jäs n nn n n -, n30 I n n ny »517 435 n | n n o o u o »8 Fig. 3A shows an embodiment in which a piece of material M2 in a roll-forming arrangement is provided with the same number of longitudinal projections 18 as the piece of material M1 according to fi g. 2A. In this case, however, the propellers 18 are made with a much greater depth than the propellers 8 according to fi g. 2A. Despite this, the piece of material M2 in the same end station can be formed into a sleeve sleeve P2 with the same outer diameters as the profile P1. This means that much more material is available to perform an expansion without cold stretching to the shape of the final product 19, which has a significantly larger diameter than the final product 9 according to fi g. 2B.

Such a solution consequently provides an opportunity to achieve a very rational production since the same piping can be used to make blank profiles for end products with very varying dimensions. This is very useful, for example, for the hydroforming process. In order to achieve the same outer shape for blanks intended for different end products, it is possible to vary different parameters such as the depth, width, shape, distribution and / or mutual distance of the proliferations, and thereby cover a very large area of final shapes after deformation.

Figs. 4A-B show a further example of a variation which can be achieved in a relatively simple manner by the roll forming. This variant can also be made with one and the same pipe, ie in the form of a blank 3 P3 with the same outer diameter as those in the previous embodiments. This variant is particularly suitable for expansion by hydroforming other end shapes 29 than purely cylindrical by concentrating different amounts of material for the expansion without cold stretching in different parts of the profile P3. As can be seen most clearly from fi g. 4A, this is achieved by forming different deep proliferations 28, 28 'in different parts of the plate M3 which correspond to the different parts of the circumference of the final product 29.

In Figures 2A-B, 3A-B and 4A-B, all projections have been shown performed with a general trapezoidal shape and with mutual distances. However, the invention is not limited to such designs. As an example of this is shown in fi g. 5A and SB embodiments with generally sinusoidal projections 38 and 38, respectively. 38 'som i fi g. 5A are uniformly distributed over the piece of material M4 and as in fi g. 5B are unevenly distributed in the piece of material M5, corresponding to the intended end shape (not shown) after deformation. It is obvious that both the shape and also the distribution of the proliferations 38, 38 'can be varied freely within the scope of the invention. 10 15 20 5 517 435 9 I fi g. 6A-C finally show an example of other end products 39, 49, 50 which can be manufactured within the scope of the invention, and which in the embodiments shown for the sake of simplicity are all based on the internal profile P1 shown in fi g. 6A and corresponding to it according to fi g. 2A.

Fig. 6B shows an embodiment where the internal profile P1 according to fi g. 6A has been expanded into a conical end product 39 by gradually expanding more and more towards one end 39A, while at the other end 39B it is lent in its original shape. In this way the conical shape is obtained at the same time as the propellers become shallower and shallower in the direction of the expanded end 39A. Alternatively, the end 39A can be expanded to a cylindrical shape in cases where the proliferations for a particular application need not be continuous.

I fi g. 6C and 6D show a further variant in which the internal profile P1 according to fi g. 6A is expanded, so to speak, linearly. This is done by applying internal pressure, preferably mechanically, for example along two diarnetrally opposite lines at the inner surface of the blank P1. If this internal pressure is supplemented by external pressure which strives to flatten the sleeve, a product 49 is formed according to fi g. 6C which has inner and outer channels. As in the working example according to fi g. 6B, the sleeve here has been gradually expanded more and more towards one end 49A while the proliferations at the other end 49B have largely retained their original shape.

I fi g. 6D shows a further variant in which the product 49 is divided so as to obtain two generally fan-shaped halves 50, of which only one is shown in the fi clock, which here constitute the final product.

The end products shown in the figures have not been shown with a view to any particular use or application, but for the purpose of demonstrating the possibilities offered by utilizing the principles of the invention. Furthermore, it should be emphasized that although all the examples shown and described herein refer to a deformation to the shape of the final product mainly through expansion of the substance, the recovery should not be limited thereby. Thus, the invention also comprises a deformation of substances by applying a pressure to their outer surface, i.e. an indentation of the entire outer surface or parts thereof or a combination of expansion and indentation.

As mentioned, the invention is currently considered to have one of its most important applications in hydroforming technology. By utilizing the invention, in particular, tubular blanks of high-strength materials can also be used, and this without risk of the change in the material properties which, when utilizing conventional technology, arises due to the cold elongation which occurs during deformation of a cylindrical tube blank. In this context, according to the invention, it is further proposed that the sheet be heated in connection with the roll forming of the profiles. More specifically, the sheet is heated locally in the area of the profiles or (in the case of profiling with sharp corners) or very locally, only in the area of the corners or edges of the profiles. Such a local heating can advantageously take place, for example, with the aid of a laser and has the purpose of eliminating cold stretching of the material as much as possible even during the roll forming.

In particular when using high-strength materials, they are currently assessed in fi g. 5A-B showed, in general, sinusoidal probes - or other probes with correspondingly rounded corners - to be most advantageous for the same reason.

According to a further embodiment of the invention, a blank as above can be arranged in a tubular shape, second product, not shown, and then expanded into contact with the second tubular product. This method can, for example, be used to repair a broken pipeline. In a variant thereof, the blank may be formed of a material whose properties differ from those of the material of the other tubular product, in order to obtain a composite product with different internal and external material properties. This design can, for example, be used to line an existing pipe with a nobler metal.

According to the invention, the present invention is normally based on a piece of material in the form of a metal plate, but the invention also comprises a manufacture of blanks and products of other materials with similar material properties, ie materials which are possible and suitable for rolling and deforming to their final shape. , for example synthetic materials. The starting material is preferably a mainly flat board or sheet of the material in question, but of course other boards or sheets can also be used, for example those with a certain deformed structure. By utilizing the roll forming to form the closed pro-roll, many different material qualities can also be considered, even those that do not learn at all for, for example, extrusion.

In the same way, the wall thickness of the blank can thereby be varied in a way that is not possible with extrusion. but. The person skilled in the art will appreciate that various modifications and alterations may be made to the present invention without departing from the scope of the invention as defined by the appended claims.

Claims (26)

10 15 20 25 30 517 435/2 -. - o o n u. ~ co PATENTKRAV A method for manufacturing products (9; 19; 29; 39; 49; 50), wherein a substance is manufactured in the form of a closed profile (P1; P2; P3) and with at least a partially profiled wall and wherein this profile is deformed to its final shape by applying pressure to the wall of the unit, characterized in that in a first step a piece of material (M 1; M2: M3; M4; M5) is provided by roll forming with longitudinal profiles (8; 18; 28; 28 '; 38; 38 '), that in a second step the perforated piece of material is also formed by roll forming in a pipe (7), into a substantially closed, generally tubular profile (P1; P2; P3) and that in a third step it is closed the profile by firmly connecting adjacent side edges thereof, after which the profile is deformed by applying pressure in a manner known per se to the wall of the closed profile. Method according to Claim 1, characterized in that the piece of material (M1; M2; M4) is provided by the roll forming with uniformly distributed longitudinal profiles (8; 18; 38) distributed over its surface or parts of its surface. Method according to Claim 1, characterized in that the piece of material (M3; M5) is provided by the roll forming with longitudinal proliferations (28, 28 '; 38') distributed uniformly over its surface or parts of its surface. Method according to Claim 1, 2 or 3, characterized in that the longitudinal profiles (8; 18; 38; 38 ') in one and the same piece of material (M1; M2; M4; M5) are formed with substantially the same depth. Method according to Claim 1, 2 or 3, characterized in that the longitudinal projections (28, 28 ') in one and the same piece of material (M3) are formed with mutually different depths. Method according to one or more of Claims 1 to 5, characterized in that in the event of deformation of the blank (P1), a pressure is applied locally against parts of the wall of the closed profile (P1) to change the general tubular shape. 10 15 20 25 30 Å 517 435 A3 Method according to one or more of Claims 1 to 5, characterized in that in the event of deformation of the blank (P1; P2; P3), a pressure is applied locally against the entire wall of the closed profile (P1; P2; P3) to change the general tubular shape. . Method according to one or more of Claims 1 to 7, characterized in that a mechanical pressure is applied to the wall of the closed profile (P1; P2; P3). Method according to one or more of Claims 1 to 7, characterized in that a hydraulic pressure is applied to the wall of the closed profile (P1; P2; P3). Method according to claim 9 for the manufacture of products (9; 19; 29; 39; 49; 50) by hydroforming, characterized in that blanks (P1; P2; P3) are provided by the roll forming with different material contents, in the form of different depths and / or wide longitudinal profiles (8; 18; 28; 28 '; 38; 38') and / or different numbers and distribution of profiles, and in one and the same piping are formed with a definite, common outer diameter. Method according to claim 10, characterized in that the depth of the proliferations (8; 18; 28; 28 '; 38; 38') in the blanks (P1; P2; P3) is determined on the basis of the magnitude of the deformation of the respective closed profile to be produced by the hydroforming. Method according to Claim 10 or 11, characterized in that the depth, width, number and / or their location around the circumference of the blanks (P1; P2; P3) are determined from the outside (8; 18; 28; 28 '; 38; 38'). the deformed final mold (9; 19; 29; 39; 49; 50) for the respective blank to be produced by the hydroforming. Method according to one or more of Claims 1 to 12, characterized in that the blanks (P1; P2; P3) are formed from metal. Method according to one or more of Claims 1 to 13, characterized in that the mandrels (P1; P2; P3) are formed from high-strength material. l0 15 20 25 30 "517 435 uu so: / 4 Method according to one or more of Claims 1 to 14, characterized in that the piece of material (M1g M2; M3) is heated in the area thereof in connection with the roll formation of the proliferations (8; 18; 28; 28 '; 38; 38'). Method according to one or more of Claims 1 to 15, characterized in that the proliferations (38; 38 ') are formed with a general sinusoidal shape. Method according to one or more of Claims 1 to 15, characterized in that the proliferations (8; 18; 28; 28 ') are formed with a general trapezoidal shape. Method according to one or more of Claims 1 to 17, characterized in that the blank (P1; P2; P3) is arranged in a tubular second product and then expanded into contact with the second tubular product. Process according to Claim 18, characterized in that the core (P1; P2; P3) is formed from a material whose properties differ from those of the other tubular product, in order to obtain a composite product with different internal and external material properties. Blank (P1; P2; P3) for hydroforming consisting of a closed profile with a general tubular shape and having a profiled circumferential surface with longitudinal profiles (8; 18; 28; 28 '; 38; 38'), characterized in that the longitudinal profiles (28; 28 ') have mutually different depths seen in the radial direction of the generally tubular profile (P1; P2). A blank (P1; P2; P3) according to claim 20, characterized in that the longitudinal profiles (8; 18; 28, 28 '; 38) are uniformly distributed over its circumferential surface or over parts of its circumferential surface. Blank according to Claim 20, characterized in that the longitudinal profiles (38 ') are distributed unevenly over its circumferential surface or over parts of its circumferential surface. Substance according to one or more of Claims 20 to 22, characterized in that the longitudinal profiles (38; 38 ') have a general sine shape. 10 "517 435 n o o a nu a / 5 Blank (P1; P2; P3) according to one or more of Claims 20 to 23, characterized in that the longitudinal projections (8; 18; 28; 28 ') have a general trapezoidal shape. Substance (P1; P2; P3) according to one or more of Claims 20 to 24, characterized in that it consists of metal. Substance (P1; P2; P3) according to one or more of Claims 20 to 25, characterized in that it consists of high-strength material.