US20110179842A1 - System for cold roll forming profiles having variable cross-sections - Google Patents

System for cold roll forming profiles having variable cross-sections Download PDF

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Publication number
US20110179842A1
US20110179842A1 US13/122,412 US200913122412A US2011179842A1 US 20110179842 A1 US20110179842 A1 US 20110179842A1 US 200913122412 A US200913122412 A US 200913122412A US 2011179842 A1 US2011179842 A1 US 2011179842A1
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United States
Prior art keywords
sheet
metal strip
forming
roll
rollers
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Abandoned
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US13/122,412
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English (en)
Inventor
Stefan Freitag
Albert Sedlmaier
Andre Abee
Bernard Poks
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Data M Sheet Metal Solutions GmbH
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Data M Sheet Metal Solutions GmbH
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Assigned to DATA M SHEET METAL SOLUTIONS GMBH reassignment DATA M SHEET METAL SOLUTIONS GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ABEE, ANDRE, FREITAG, STEFAN, POKS, BERNARD, SEDLMAIER, ALBERT
Publication of US20110179842A1 publication Critical patent/US20110179842A1/en
Abandoned legal-status Critical Current

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    • 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
    • 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
    • B21D5/083—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 for obtaining profiles with changing cross-sectional configuration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/08—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling structural sections, i.e. work of special cross-section, e.g. angle steel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/38—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling sheets of limited length, e.g. folded sheets, superimposed sheets, pack rolling

Definitions

  • the invention relates to a system for cold roll forming profiles having variable cross-sections according to the preambles of Claims 1 and 11 .
  • Such systems are disclosed in the German patent application DE 10 2007 059 439.0, the content of which is incorporated herein by reference, DE 100 11 755 A1, DE 2004 040 257 A1 and U.S. Pat. No. 3,051,214 A.
  • profiles with cross-sections which are variable over the length are produced by not only moving the roller stands, or the adjustment stands carrying them, respectively, transversely to the longitudinal profile extension during profiling, but by also positioning the roller tools of each adjustment stand tangentially to the desired bending edge course of a profile over the entire profile length.
  • the adjustment stand is enabled to perform a rotation about an axis vertical to the sheet-metal feeding plane, additionally to the possibility of adjustment transversely to the longitudinal profile extension.
  • an additional shape element is present on a leg of the profile, such as the folded rim of top-hat and C-profiles, which are used as passenger car door sills or parts of the floor assembly of a vehicle and have a relatively large cross-section in relation to the metal sheet thickness, such undesired deviations in shape can be observed to an even greater extent.
  • the additional shape element is also vertical or nearly vertical to the forming axis, this shape element represents a stiffener and must not only be bent, but also stretched or upset (compressed), respectively.
  • the aim of the invention is to counteract the deviations in shape, caused by upsetting, stretching, backspringing and evasions, in a rational manner during cold roll forming of profiles with variable cross-sections.
  • FIG. 1A shows a perspective view of a C-profile with variable width
  • FIG. 1B shows a top view of the C-profile of FIG. 1A ;
  • FIG. 1C shows five superimposed cross-sectional views of a C-profile similar to the one in FIGS. 1A and 1B along the drawn in section lines in FIG. 1B ;
  • FIG. 2 shows an illustrative drawing of the operating method of a re-forming device
  • FIG. 3 shows a perspective view of a re-forming device having three working rollers and a supporting roller
  • FIG. 4 shows a schematic perspective view of a re-forming device having a small movable press
  • FIG. 5 shows a schematic diagram of a re-forming device with clamping shoes.
  • the forming unit comprises in a known manner a series of adjustment stands, each having a roller stand containing a pair of rollers between which a sheet-metal strip is guided lengthwise.
  • the roller stands are displaced or moved translationally transversely to the length of the sheet-metal strip and rotationally about an axis of the roller stand so as to form the sheet-metal strip to a profile having a variable cross-section.
  • the axes of the rollers of a roller stand are frequently parallel to each other; however, the axes of rollers having diameters which are variable in longitudinal direction can also be slightly inclined with respect to each other.
  • a profile with variable width is for instance a top-hat profile or the C-profile shown in FIGS. 1A through 1C .
  • the principles described herein, however, can also be applied to the cold roll forming of profiles with variable height and constant width or of profiles with variable width and height.
  • FIGS. 1A and 1B show an intermediate state in the transition to a C-profile which is supposed to a have a first portion with a constant width from A-A to B-B, a portion with constantly increasing width from B-B to D-D and a second portion with constant width from D-D to E-E.
  • This structure is already suggested, but not yet fully developed in FIGS. 1A and 1B .
  • From the material structure lines drawn in in FIGS. 1A and 1B it can be seen that in portions with convex curvatures, for instance at a transition from a portion with constant width to a portion which becomes continually broader, the profile edge must be stretched. Also, in this area, a depression is frequently formed in the profile bottom (section B-B).
  • the strip edge In portions of the profile with convex curvature, for instance at a transition from a portion becoming continually broader to a portion with constant width, the strip edge must be upset (compressed), and the profile bottom frequently forms a bump (section D-D).
  • the discontinuities at the transitions between the various profile portions with different width along the length X of the sheet-metal strip prevent the desired forming process in the discontinuous roll forming of cross-sections.
  • an additional shape element is present on a lateral leg of the profile, this disadvantageous effect is even more marked.
  • the additional shape element is also present on a plane vertical or nearly vertical to the forming axis, such as the narrow edge sections on the top of the C--profile in FIGS. 1A through 1C , it forms a significant stiffener which must additionally be stretched or upset during forming.
  • upsetting or stretching the sheet-metal material is difficult since the material is not deformed as desired but the entire cross-section may yield.
  • a re-forming unit is arranged behind at least one of the roller stands, which has at least one drive for producing a movement of the re-forming unit on a plane transverse to the length X of the sheet-metal strip, which drive is controlled, on the basis of data calculated from data concerning the material and thickness of the sheet-metal strip, the configuration and control data of the roller stands and the CAD data of the profiles to be formed, in such a way that the re-forming unit autonomously undoes any deviations in shape of the sheet-metal strip leaving the at least one roller stand due to upsetting, stretching and/or backspringing in the course of system operation.
  • FIG. 2 A principle by means of which such shape deviations are eliminated is shown in FIG. 2 .
  • This figure shows a portion of a sheet-metal strip 2 between two roller stands (not shown) or in the process of leaving the last roller stand, which is again re-formed between two rollers 4 and 6 .
  • the difference between the rollers 4 and 6 of the re-forming unit of FIG. 2 and the rollers of the roller stands is that the rollers of the roller stands are normally exactly opposed to, each other on both sides of the sheet-metal strip 2 , whereas the rollers 4 and 6 are mutually offset in the longitudinal direction X of the sheet-metal strip 2 .
  • FIG. 3 A particularly advantageous re-forming unit is shown in FIG. 3 . It works according to the three-roller method, where bending takes place around three touching lines, and contains three working rollers embodied as a forming roller 8 and two smaller rollers 10 which contact a portion of the sheet-metal strip 2 to be re-formed, and a supporting roller 12 for the two smaller rollers 10 .
  • the two small rollers 10 are advanced only for the re-forming period.
  • Each axis of the two small rollers 10 is either advanced by a separate drive, where these drives can be supported, for instance, on the roller stand arranged before them, or the advance is performed by only one drive, where the two small rollers 10 are simply made to approach each other by reduction of the angle between the brackets 14 which retain the small rollers 10 on the circumference of the supporting roller 12 . Stoppers for these movements are useful, but not mandatory.
  • the small rollers can be installed with a fixed distance, and the large roller is advanced by a suitable drive and suitable bearing.
  • rollers 4 , 6 of FIG. 2 or the rollers 8 , 10 and 12 of FIG. 3 can also be positioned on a separate guide and are moved by suitable drives, such as a threaded-spindle drive, servo-hydraulic cylinders or pneumatic cylinders.
  • suitable drives such as a threaded-spindle drive, servo-hydraulic cylinders or pneumatic cylinders.
  • the guide of the rollers is advantageously mounted perpendicular to the profiling direction X. A numerical control is recommended, but point-to-point control is also possible. Fixed stops are possible as well.
  • stretching of the material is easier to achieve than upsetting; however, in a discontinuous roll forming process, stretching is always connected to a certain amount of upsetting in adjacent areas which is difficult to perform by the roll forming process itself, but easy to perform by means of the re-forming unit described herein.
  • Another solution is to introduce an additional deformation, such as a bend or a radius, in the profile contour and/or its legs.
  • This is not a deformation in the classical sense, but rather a change in geometry which creates space for the material and yielding possibilities for the material volume.
  • Such a deformation can be introduced in the profile, for instance, with a small co-moving press 16 such as is schematically shown on a portion of the sheet-metal strip 2 in FIG. 4 .
  • the existing stands can be used and the plant supplemented with small auxiliary means. It is also useful to support and hold the profile so that the re-forming can take place.
  • re-forming can take place at the beginning, in the middle or at the end of roll forming.
  • these operations should be performed at the end of roll forming to prevent deformed areas in the (possibly already existing) additional shape elements from being crushed during further roll forming.
  • some of these operations or final corrections can be performed in a downstream process outside the roll forming unit.
  • a certain degree of deformation should already have been achieved since undesired deviations in shape increase in the course of the profiling. The following criteria are to be taken into account:
  • a re-forming unit can also have two guide shoes.
  • the guide shoes are advanced at the same time as the rollers in the previously described embodiments.
  • driving takes place electrically, hydraulically or pneumatically.
  • the guide shoes work like the rollers, but with sliding surface contact.
  • Such a guide shoe unit can be installed in a fixed position before or behind a roller stand. In this case, a controlled movement transversely to the sheet-metal conveying direction or vertically to the surface of the profile cross-section segment to be deformed is necessary.
  • such a guide shoe unit can also move together with the sheet-metal feed, and therefore it does not necessarily require a controlled freedom of movement along the sheet-metal feed direction.
  • the direction of movement is advantageously parallel to the position of the strip edge in this forming stage.
  • the path curve of the sheet-metal strip can be corrected.
  • a roller stand is not only moved tangentially to the predefined contour, but the path curve is traveled with an offset. This, however, is possible only with certain cross-sections, possibly with a non-deformed element (buffer element) between the individual profile segments (bottom, transition element and side wall).
  • material can be added.
  • the cut blank is adjusted such that a certain amount of material is upset at the cross-section at the opposite bending.
  • the additional material is accumulated at certain portions of the roller and causes a force leading to the desired bending or upsetting.
  • FIG. 5 shows an embodiment in which movable clamping shoes 18 , 20 clamp a portion of a sheet-metal strip 2 leaving the rollers 22 , 24 of a roller stand between them, thus preventing a yielding of the entire profile.
  • the clamping shoes 18 , 20 are movable or forcibly guided, respectively, in the feed direction X of the sheet-metal strip 2 , possibly also inclined to it, i. e. with a component in the vertical direction Z to the plane of the sheet-metal strip.
  • the clamping shoes 18 , 20 After clamping of a specific portion of the sheet-metal strip 2 , the clamping shoes 18 , 20 are passively entrained over a certain distance by the advance movement of the sheet-metal strip 2 .
  • the clamping is then released, and the clamping shoes 18 , 20 are actively returned to their starting position.
  • clamping shoes 18 , 20 supporting rollers or guide shoes can also be used. These must be positioned before and behind a roller stand.
  • the clamping shoes, supporting rollers or guide shoes are arranged so that the profile cross-section cannot yield at the time of forming the transition between different profile sections.
  • Holding elements for the clamping shoes, supporting rollers or guide shoes must be movable in the vertical direction Z to the sheet-metal strip plane and must be moved and controlled according to the profile contour. Such holding elements are used only at the discontinuities of the profile, i. e. at the transition points between different profile sections or in the forming of variable radii, respectively. Thus, the necessary upsetting or stretching, respectively, can be performed.
  • the working direction of the press is vertical to the surface of the profile with the contour to be applied.
  • the stamp embosses the desired shape into the profile cross-section, and if necessary, adjacent profile segments are upset in the required manner.
  • the press operates vertically to the surface of an additional shape element, a crease can be pressed into the additional shape element so as to provide the excess material with a new geometry.
  • it is to be ensured that only the geometry of the sheet-metal strip is changed and the sheet-metal strip is not stretched. It is recommended to use large radii in the pressing tool and to avoid clamping in the edge areas of the tool. Of course, the material is deformed, i. e. upset and stretched, in these areas as well. The aim, however, is to change the geometry.
  • Another solution consists in making the inner and outer rollers of a roller stand adjustable independently of one another. Normally, the two forming rollers of a roller stand are tangentially contacting the profile contour, the connecting line of the roller centers always extending vertically to the clamped section of the sheet-metal strip. If, however, the two rollers are movable independently of one another, a controlled lateral offset of the two rollers is possible. This results in a lever, and thus a bending moment can be exercised on the profile contour, with the same operating principle as is used with the re-forming unit of FIG. 2 by means of dedicated rollers.
  • the constructive implementation can be such that only one roller is driven and the second roller can be moved in a swiveled manner.
  • Slewing gears with high transmission ratios spindle drives with levers or hydraulic or pneumatic cylinders are suitable as drives for this slewing movement.
  • the drive of the slewing movement can be controlled numerically for precise control of the deformation; however, a binary axis can also be provided since in this case, movement against a stopping point takes place and the deformation can be controlled by the movement of the entire roller stand.
  • Another solution consists in excising undesired portions of material already before cold roll forming, i. e. from the flat strip.
  • Slots are introduced in portions of the sheet-metal strip which are stretched during the roll forming process, in order to facilitate deformation. In this way, the sheet-metal material itself needs only, very minor stretching in the slot areas.
  • Notches or wedge-shaped cutouts are introduced in portions of the sheet-metal strip which have to be upset (compressed) during roll forming. Only very minor residual upsetting is then required, so as to greatly facilitate roll forming.
  • the number, position and size of the slots and notches is selected according to the requirements. Other conditions to be taken into account are the degree of deformation, the bending radius and the material strength.
  • the introduced slots, notches or cutouts remain within the sheet metal. This method is particularly suited if no optical or static impairments result. Otherwise, the slots, notches or cutouts can be welded and, if necessary, dressed.
  • Another solution consists in punctual heating of the sheet-metal strip so as to facilitate flowing of the material. If the sheet-metal strip is sufficiently heated in the points to be upset or stretched, deformation or flowing of the material, respectively, are greatly facilitated. Suitable methods are local heating with the gas-flame, laser or by induction.
  • the order of the deformation and re-forming steps can be of critical importance. For instance, if the folded rim of a top-hat or C-profile or the like is formed first, the profile is much stiffer in the transverse direction, thus impairing forming of the transition between different profile sections. This stiffening, however, can also have positive effects on the deformation.
  • the decisive factor in single cases is the cross-section of the finished component. Predictions can be made on the basis of a finite element analysis. The different manufacturing strategies are to be simulated individually, compared and evaluated.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)
  • Control Of Metal Rolling (AREA)
US13/122,412 2008-10-02 2009-09-29 System for cold roll forming profiles having variable cross-sections Abandoned US20110179842A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102008050366.5 2008-10-02
DE102008050366A DE102008050366B4 (de) 2008-10-02 2008-10-02 System zum Kaltwalzprofilieren von Profilen mit veränderlichem Querschnitt
PCT/EP2009/062580 WO2010037731A2 (de) 2008-10-02 2009-09-29 System zum kaltwalzprofilieren von profilen mit veränderlichem querschnitt

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US (1) US20110179842A1 (zh)
EP (1) EP2342029A2 (zh)
KR (1) KR20110061620A (zh)
CN (1) CN102170979A (zh)
BR (1) BRPI0920724A2 (zh)
DE (1) DE102008050366B4 (zh)
MX (1) MX2011003554A (zh)
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US20150027189A1 (en) * 2013-07-25 2015-01-29 Sungwoo Hitech Co., Ltd. Flexible roll forming method
US9573318B2 (en) 2013-07-25 2017-02-21 Sungwoo Hitech Co., Ltd. Flexible roll forming device
US9878357B2 (en) 2013-07-25 2018-01-30 Sungwoo Hitech Co., Ltd. Flexible roll forming device, blank guide device, blank feeding device, and flexible roll forming system having the same
US11623729B2 (en) * 2018-06-29 2023-04-11 Airbus Operations Gmbh Method for producing a crossmember for a vehicle and a crossmember for a vehicle
US11745242B2 (en) 2018-09-21 2023-09-05 The Bradbury Co., Inc. Machines to roll-form variable component geometries

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CN103639251B (zh) * 2013-11-23 2016-04-20 华中科技大学 一种用于船舶双向曲率板的冷热一体成型方法
DE102014104222A1 (de) * 2014-03-26 2015-10-01 Data M Sheet Metal Solutions Gmbh Z-Walzprofil mit variierender Höhe und Verfahren zur Herstellung
DE102017009311A1 (de) * 2017-10-07 2019-04-11 Hacanoka Gmbh Verfahren zum Ausbreiten und Formatieren von profiliertem metallischem Bandmaterial zu einer netzartigen Mattenstruktur und Vorrichtung zur Durchführung des Verfahrens
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WO2010037731A2 (de) 2010-04-08
DE102008050366A1 (de) 2010-04-08
DE102008050366B4 (de) 2010-06-17
MX2011003554A (es) 2011-05-25
BRPI0920724A2 (pt) 2016-01-12
KR20110061620A (ko) 2011-06-09
WO2010037731A3 (de) 2010-06-24
CN102170979A (zh) 2011-08-31

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