US20040216502A1 - Roll for roll forming and method therefor - Google Patents

Roll for roll forming and method therefor Download PDF

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Publication number
US20040216502A1
US20040216502A1 US10/645,162 US64516203A US2004216502A1 US 20040216502 A1 US20040216502 A1 US 20040216502A1 US 64516203 A US64516203 A US 64516203A US 2004216502 A1 US2004216502 A1 US 2004216502A1
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US
United States
Prior art keywords
roll
sheet material
pressure
rolls
convex
Prior art date
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Abandoned
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US10/645,162
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English (en)
Inventor
Woon Chung
Man Lee
Ik Park
Byung Kim
Jung Kim
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Individual
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Individual
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Assigned to CHUNG, WOON JIN reassignment CHUNG, WOON JIN ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LEE, MAN HYUNG, PARK, IK MIN, KIM, BYUNG MIN, KIM, JUNG KUN
Publication of US20040216502A1 publication Critical patent/US20040216502A1/en
Abandoned legal-status Critical Current

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    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10H—ELECTROPHONIC MUSICAL INSTRUMENTS; INSTRUMENTS IN WHICH THE TONES ARE GENERATED BY ELECTROMECHANICAL MEANS OR ELECTRONIC GENERATORS, OR IN WHICH THE TONES ARE SYNTHESISED FROM A DATA STORE
    • G10H1/00—Details of electrophonic musical instruments
    • G10H1/36—Accompaniment arrangements
    • G10H1/361—Recording/reproducing of accompaniment for use with an external source, e.g. karaoke systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
    • B21D5/06—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles
    • B21D5/08—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles making use of forming-rollers
    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10H—ELECTROPHONIC MUSICAL INSTRUMENTS; INSTRUMENTS IN WHICH THE TONES ARE GENERATED BY ELECTROMECHANICAL MEANS OR ELECTRONIC GENERATORS, OR IN WHICH THE TONES ARE SYNTHESISED FROM A DATA STORE
    • G10H2210/00—Aspects or methods of musical processing having intrinsic musical character, i.e. involving musical theory or musical parameters or relying on musical knowledge, as applied in electrophonic musical tools or instruments
    • G10H2210/031—Musical analysis, i.e. isolation, extraction or identification of musical elements or musical parameters from a raw acoustic signal or from an encoded audio signal
    • G10H2210/091—Musical analysis, i.e. isolation, extraction or identification of musical elements or musical parameters from a raw acoustic signal or from an encoded audio signal for performance evaluation, i.e. judging, grading or scoring the musical qualities or faithfulness of a performance, e.g. with respect to pitch, tempo or other timings of a reference performance
    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10H—ELECTROPHONIC MUSICAL INSTRUMENTS; INSTRUMENTS IN WHICH THE TONES ARE GENERATED BY ELECTROMECHANICAL MEANS OR ELECTRONIC GENERATORS, OR IN WHICH THE TONES ARE SYNTHESISED FROM A DATA STORE
    • G10H2220/00—Input/output interfacing specifically adapted for electrophonic musical tools or instruments
    • G10H2220/135—Musical aspects of games or videogames; Musical instrument-shaped game input interfaces

Definitions

  • the present invention relates to a roll for roll forming and a roll forming method using the same, and more particularly, to a roll for roll forming and a roll forming method therefor, by which a strip of sheet material is continuously fed and passed between roll stands that are arranged continuously, and is sequentially formed so that the sectional shape of the sheet material becomes circular, and by welding both ends of the sheet material, a pipe is finally produced.
  • FIGS. 1 a through 1 c are sectional views of a break down roll, a cluster roll, and a pin pass roll, respectively, used in a roll forming process.
  • the break down roll 10 comprises a pair of an upper convex roll 12 and a lower concave roll 14 .
  • the convex roll 12 has a circumference surface which is convex
  • the concave roll 14 has a circumference surface which is concave in a shape corresponding to the convex surface of the convex roll 12 . If a sheet of material is passed between these convex roll 12 and concave roll 14 , the contour of the sheet material is changed into the same as the circumference surfaces of the convex roll 12 and concave roll 14 .
  • Many pairs of the break down rolls 10 are used in the roll forming process, and as the process is proceeding, the width and curvature of a break down roll being used become smaller.
  • the present invention relates to this break down roll and a method using the same.
  • the cluster roll comprises two parts, each having one side with a concave part.
  • the two parts are arranged in the left and in the right of a sheet of material so that the two parts face and pressure the sheet material passing out of the break down roll 10 , from respective sides in order to change the shape of the sheet material.
  • many pairs of these cluster rolls 20 are used and as the process is proceeding, the side recess of a cluster roll being used becomes more circular.
  • Each of these cluster rolls 20 are arranged between break down rolls 10 .
  • the pin pass roll 30 shown in FIG. 1 c makes the shape of the sheet material close to a circle and makes the interval between both ends of the sheet material even so that the ends can be welded well.
  • the pin pass roll 30 comprises an upper roll 32 having a protruding pin and a lower part 34 having no pin. These rolls 30 are used in the post process after the break down roll 10 and cluster roll 20 processes.
  • FIGS. 2 a through 2 d are sectional views of examples of break down rolls.
  • the break down rolls 10 as shown in FIGS. 2 a through 2 d , are used.
  • the upper convex roll 12 a which is divided into a left part and a right part, and the lower concave roll 12 a having a W-shaped circumference surface are used, as shown in FIG. 2 a .
  • the rolling forming process does not necessarily use the break down roll 10 as shown in FIG. 2 a.
  • FIG. 3 is a diagram showing a roll forming process in which a sheet of material is being formed. That is, the sheet material 40 is in a flat plate state in the initial stage but after passing the break down rolls 10 , cluster rolls 20 , and pin pass rolls 30 several times, the sectional shape of the sheet material is gradually changed to a circular one.
  • the sheet material 40 in a flat plate state is formed to have a circular sectional shape through total 14 steps from F1 to FS7.
  • FIG. 4 is a sectional view of a pipe produced by roll forming.
  • the strip of the sheet material 40 is changed to have a circular sectional shape, and then the both ends of the sheet material 40 facing each other are welded such that a pipe 50 having a welding seam 52 as shown in FIG. 4 is produced.
  • This pipe 50 is made to have a desired diameter by a drawing process, or is reprocessed and made to have a complex shape by a hydroforming process, in which a tube preliminary formed is mounted inside a mould, and fluid is filled in the inside to press fully so that a desired shape is produced.
  • the bottom center part 54 is continuously pressured by the upper rolls and lower rolls of many break down rolls 10 and is plastic deformed by compression such that the part suffers more serious work hardening than other parts.
  • the length of the bottom center part 54 suffering serious work hardening is about 10 ⁇ 15 percent of the circumference of the pipe 50 , that is, the entire width of the sheet material ( 40 ). Also, in other parts, the degree of work hardening occurs differently with respect to location.
  • the part suffering serious work hardening has inferior material properties and workability of the part is greatly degraded.
  • the degree of work hardening is not even, the material properties and workability are degraded.
  • the work hardening of the bottom center part 54 of the pipe is one of the factors degrading the quality of finished products after processing.
  • the present invention provides a roll for roll forming which prevents work hardening of a predetermined part of roll formed sheet material that degrades the material properties and reprocessing properties of products.
  • the present invention also provides a roll forming method which prevents work hardening of a predetermined part of roll formed sheet material that degrades the material properties and reprocessing properties of products.
  • a roll for roll forming which has an axis coupling part for coupling with a rotation axis, and a circular sectional shape, and pressures and deforms a sheet of material passing between two rolls for roll forming, the roll comprising a plurality of pressure parts which are formed along the circumference of the circumference surface of the roll, are disposed with intervals in the width direction, and divide and pressure the sheet material passing by; and a non-pressure part which is disposed between the pressure parts and is to not pressure partially the sheet material passing by, wherein the pressure parts and non-pressure part are disposed symmetrically on the left side and right side.
  • the non-pressure part is formed in the form of a groove, the non-contact length of the roll and the sheet material is less than 60% of the effective length of the roll, and equal to or more than 10% of the width of the sheet material.
  • the plurality of the pressure parts and non-pressure part may be formed alternately in the width direction.
  • a roll forming method by which while sheet material is sequentially passed between a plurality of convex rolls and a plurality of concave rolls, the sheet material is pressured so that the sectional shape of the sheet material is formed as desired, wherein the plurality of convex rolls are arranged with intervals, and have convex circumference surfaces, and the curvatures of the convex rolls are sequentially diminishing, and the plurality of concave rolls are arranged neighboring the convex rolls to make respective roll pairs with corresponding convex rolls, and have concave circumference surfaces corresponding to the circumference surface of the convex rolls, respectively, the roll forming method comprising dividing and disposing a pressure part for pressuring the sheet material passing by, and a groove-shaped non-pressure part for not pressuring the sheet material passing by, on the circumference surface of the convex roll or the concave roll, so that the frequency of pressure applied to at least one part of the sheet material, which passes through
  • the pressure part formed on one roll pair is disposed so that the pressure part does not overlap the pressure part of another roll pair equal to or more than (the number of roll pairs —2) times and by doing so, the frequency of pressure applied to each part of the sheet material passed through is less than the number of the roll pairs.
  • the pressure part formed on one roll pair except the parts corresponding to both ends of the sheet material is disposed so that the pressure part overlaps the pressure part of another roll pair at a roughly identical frequency, and by doing so, the frequency of pressure applied to each part of the sheet material except both ends of the sheet material has a roughly identical distribution in the width direction of the sheet material.
  • a roll forming method by which while sheet material is sequentially passed between a plurality of convex rolls and a plurality of concave rolls, the sheet material is pressured so that the sectional shape of the sheet material is formed to a circle and parts of the sheet material facing each other are welded to produce a pipe, wherein the plurality of convex rolls are arranged with intervals, and have convex circumference surfaces, and the curvatures of the convex rolls are sequentially diminishing, and the plurality of concave rolls are arranged neighboring the convex rolls to make respective roll pairs with corresponding convex rolls, and have concave circumference surfaces corresponding to the circumference surface of the convex rolls, respectively, the roll forming method comprising dividing and disposing a pressure part for pressuring the sheet material passing by, and a groove-shaped non-pressure part for not pressuring the sheet material passing by, on the circumference surface of the convex roll or the concave roll,
  • the pressure part formed on one roll pair may be disposed so that the pressure part does not overlap the pressure part of another roll pair equal to or more than (the number of roll pairs —2) times and by doing so, the frequency of pressure applied to each part of the sheet material passed through is less than the number of the roll pairs.
  • the pressure part formed on one roll pair except the parts corresponding to both ends of the sheet material is disposed so that the pressure part overlaps the pressure part of another roll pair at a roughly identical frequency, and by doing so, the frequency of pressure applied to each part of the sheet material except both ends of the sheet material has a roughly identical distribution in the width direction of the sheet material.
  • FIGS. 1 a through 1 c are sectional views of a break down roll, a cluster roll, and a pin pass roll, respectively, used in a roll forming process;
  • FIGS. 2 a through 2 d are sectional views of examples of break down rolls
  • FIG. 3 is a diagram showing a roll forming process in which a sheet of material is being formed
  • FIG. 4 is a sectional view of a pipe produced by roll forming
  • FIG. 5 is a perspective view of an embodiment of a roll for roll forming according to the present invention.
  • FIG. 6 is a perspective view of another embodiment of a roll for roll forming according to the present invention.
  • FIG. 7 is a section view of a modified embodiment of a convex roll of FIG. 5;
  • FIG. 8 is a sectional view of a modified embodiment of a concave roll of FIG. 6;
  • FIG. 9 is a sectional view of a state where a sheet of material passes between the convex roll of FIG. 5 and the concave roll of FIG. 6;
  • FIGS. 10 a through 10 d are sectional views of combinations of modified embodiments, respectively, of rolls for roll forming according to the present invention.
  • FIG. 11 is a conceptual diagram for explaining a roll forming method according to the present invention.
  • FIG. 5 is a perspective view of an embodiment of a roll for roll forming according to the present invention.
  • the roll shown in FIG. 5 is a convex roll 110 used as one of upper rolls of a break down roll.
  • An axis coupling part 111 for coupling with a rotation axis is formed at the rotation center of the roll 110 and the circumference surface of the roll 110 is divided into pressure part 113 and non-pressure part 115 .
  • Pressure part 113 is disposed along the circumference of the circumference surface of the convex roll 110 and is a part to pressure corresponding part of passing sheet material. It is preferable that edge part of this pressure part 113 is round-processed so that no scratch is made on the sheet material being pressured. A plurality of this pressure parts 113 are formed with intervals and are symmetrically disposed on the left side and right side. The width, number, position, and the like of this pressure part 113 can be adjusted in line with those of pressure parts and non-pressure parts of other rolls arranged in the same roll forming apparatus.
  • the non-pressure part 115 is formed.
  • the non-pressure part 115 is also disposed along the circumference of the circumference surface of the convex roll 110 and in parallel with the pressure part 113 .
  • This non-pressure part 115 is for not pressuring corresponding part of passing sheet material.
  • the non-pressure parts 115 are also symmetrically disposed on the left side and right side and are formed in the form of a groove. The width, number, position, and the like of this non-pressure part 115 can be adjusted in line with those of pressure parts and non-pressure parts of other rolls arranged in the same roll forming apparatus. The width, number, position, and the like of pressure parts and non-pressure parts formed on other rolls will be explained in detail later.
  • FIG. 6 is a perspective view of another embodiment of a roll for roll forming according to the present invention.
  • the roll shown in FIG. 6 is a concave roll 120 used as one of lower rolls of a break down roll. Also, an axis coupling part 121 for coupling with a rotation axis is formed at the rotation center of the roll 120 and the circumference surface of the roll 120 is divided into pressure part 123 and non-pressure part 125 .
  • the pressure part 123 and non-pressure part 125 are also formed on the concave circumference surface of the concave roll 120 , and except this, other things are the same as explained referring to FIG. 5.
  • FIG. 7 is a section view of a modified embodiment of a convex roll of FIG. 5.
  • the convex roll 110 a shown in FIG. 7 is installed in a back-end process after the convex roll 110 of FIG. 5, and is also to pressure sheet material for plastic deformation. Compared to the convex roll 110 of FIG. 5, the convex roll 110 a has a short width and a smaller curvature. Here, when the same number of pressure parts 113 and non-pressure parts 115 as in FIG. 5 are disposed, the widths of the pressure part 113 and non-pressure part 115 are also shorter than those of the convex roll 110 of FIG. 5.
  • FIG. 8 is a sectional view of a modified embodiment of a concave roll of FIG. 6.
  • the concave roll 120 a shown in FIG. 8 is installed in a back-end process after the concave roll 120 of FIG. 6, and compared to the concave roll 120 of FIG. 6, has a short width and a smaller curvature. Other things are the same as explained in FIG. 6.
  • FIG. 9 is a sectional view of a state where a sheet of material passes between the convex roll of FIG. 5 and the concave roll of FIG. 6.
  • the forming load is expressed as the following equation 1:
  • the contact length 2 b between the sheet material 40 and rolls 110 or 120 when the pressure applied to the sheet material should be equal to or greater than 53.65(mm) so that the pressure ( ⁇ y ) applied to the sheet material 40 does not exceed the yield strength ( ⁇ a ) of the material.
  • the length should be 40 percent or more of the contact length (hereinafter, referred to as the effective length (L) of a roll) when there is no non-pressure part 115 and 125 , which means that the maximum contact length that can be formed by the non-pressure part 115 and 125 should be less than 60 percent.
  • FIGS. 10 a through 10 d are sectional views of combinations of modified embodiments, respectively, of rolls for roll forming according to the present invention.
  • the pressure parts 113 and 123 and non-pressure parts 115 and 125 of the upper convex roll 110 b and the lower concave roll 120 b may be formed alternately and more densely than the roll of FIG. 9.
  • the non-pressure part 115 and 125 may be formed on only one of the convex roll 110 b and the concave roll 120 b and not formed on the other.
  • the non-pressure part is not formed and the prior art roll is used as is, and only at the center of the convex roll 110 c , the non-pressure part 115 is formed and pressure parts 113 are formed at both sides of the non-pressure part 115 , and then the upper convex roll 110 c can be arranged at a desired position of the roll forming apparatus.
  • the non-pressure part is not formed on the lower concave roll 14 , and three non-pressure parts 115 are formed around the center of the upper convex roll 110 d and pressure parts 113 are formed between the non-pressure parts 115 and at both sides of the non-pressure parts 115 . Then, the upper convex roll 100 d can be arranged at a desired position of the roll forming apparatus.
  • the non-pressure part is not formed on the upper convex roll 12 , and the prior art roll is used as is, and only at the center of the concave roll 120 c , the non-pressure part 125 is formed and pressure parts 123 are formed at both sides of the non-pressure part 125 , and then the lower concave roll 120 c can be arranged at a desired position of the roll forming apparatus.
  • FIG. 11 is a conceptual diagram for explaining a roll forming method according to the present invention.
  • FIG. 11 there are four line diagrams and one graph in an orderly manner.
  • the sheet material 40 passes along the first break down roll described above, the sheet material 40 is divided into and expressed as a pressure area 43 and a non-pressure area 45 in the first line diagram 131 on the top.
  • the pressure area 43 corresponds to the pressure part 113 and 123 of the first roll and the non-pressure area 44 corresponds to the non-pressure part 115 and 125 of the first roll.
  • the second line diagram 132 divides and expresses the pressure area 43 and non-pressure area 45 when the sheet material passes along the second break down roll. This is the same state as the circumference surface of part of the convex roll or the concave roll of the second break down roll.
  • the pressure area 43 corresponds to the pressure part 113 and 123 of the second roll and the non-pressure area 44 corresponds to the non-pressure part 115 and 125 of the second roll. This is the same in the third and fourth line diagrams 133 and 134 .
  • the graph 135 at the bottom shows the distribution in the width direction of frequencies of pressures applied to the sheet material 40 when the sheet material 40 passes all pairs of rolls. This is the same as the distribution in the width direction of cumulative pressure applied to each part of the sheet material 40 .
  • the forming positions and width of the pressure parts 113 and 123 and the non-pressure parts 115 and 125 formed on each roll need to be adjusted considering the frequency of contacts of the pressure parts in connection with neighboring rolls. That is, by appropriately combining and disposing the pressure parts and non-pressure parts formed on each roll, a variety of modifications different from that in FIG. 11 can be implemented.
  • rolls for roll forming and the roll forming methods according to the present invention reduces work hardening in pipe material in the roll forming process.
  • the rolls for roll forming and the roll forming methods according to the present invention makes work hardening occur evenly on the entire surface of a pipe.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Multimedia (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
US10/645,162 2003-04-30 2003-08-21 Roll for roll forming and method therefor Abandoned US20040216502A1 (en)

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KR1020030027843A KR20040092990A (ko) 2003-04-30 2003-04-30 롤 포밍용 롤 및 롤 포밍 방법
KR10-2003-0027843 2003-04-30

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8795571B2 (en) 2011-03-01 2014-08-05 Xerox Corporation Dual operation de-curler
CN104647927A (zh) * 2015-02-15 2015-05-27 杨永国 板材表面几何形状滚压装置
CN108895213A (zh) * 2018-05-30 2018-11-27 浙江康盛股份有限公司 一种超薄壁管及其加工方法
US20220297038A1 (en) * 2019-08-21 2022-09-22 Munters Euroform Gmbh Mist eliminator profile and associated method of production

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR100851779B1 (ko) * 2006-11-27 2008-08-13 주식회사 성우하이텍 롤 포밍 성형빔의 교정장치

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US297291A (en) * 1884-04-22 Portable lightning-rod machine
US1814594A (en) * 1926-06-21 1931-07-14 Harvey M Gersman Apparatus for widening rolled metal products
US2159290A (en) * 1937-01-26 1939-05-23 Metal Trim Ltd Rollers for use in producing profiled sections from sheet metal
US3059685A (en) * 1957-09-09 1962-10-23 Walter D Behlen Corrugated panel making machine and method
US3145758A (en) * 1961-01-23 1964-08-25 Mobile Pipe Corp Apparatus for continuous forming of metal shapes
US3187539A (en) * 1960-05-17 1965-06-08 Continental Can Co Roll forming of sheet material
US6041632A (en) * 1997-09-10 2000-03-28 Kawasaki Steel Corporation Pipe forming roll apparatus and method
US6119498A (en) * 1998-06-05 2000-09-19 Knudson; Gary A. Node roller combination

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US297291A (en) * 1884-04-22 Portable lightning-rod machine
US1814594A (en) * 1926-06-21 1931-07-14 Harvey M Gersman Apparatus for widening rolled metal products
US2159290A (en) * 1937-01-26 1939-05-23 Metal Trim Ltd Rollers for use in producing profiled sections from sheet metal
US3059685A (en) * 1957-09-09 1962-10-23 Walter D Behlen Corrugated panel making machine and method
US3187539A (en) * 1960-05-17 1965-06-08 Continental Can Co Roll forming of sheet material
US3145758A (en) * 1961-01-23 1964-08-25 Mobile Pipe Corp Apparatus for continuous forming of metal shapes
US6041632A (en) * 1997-09-10 2000-03-28 Kawasaki Steel Corporation Pipe forming roll apparatus and method
US6119498A (en) * 1998-06-05 2000-09-19 Knudson; Gary A. Node roller combination

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8795571B2 (en) 2011-03-01 2014-08-05 Xerox Corporation Dual operation de-curler
CN104647927A (zh) * 2015-02-15 2015-05-27 杨永国 板材表面几何形状滚压装置
CN108895213A (zh) * 2018-05-30 2018-11-27 浙江康盛股份有限公司 一种超薄壁管及其加工方法
US20220297038A1 (en) * 2019-08-21 2022-09-22 Munters Euroform Gmbh Mist eliminator profile and associated method of production

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