US20170066031A1 - Method And Apparatus For Forming Profiled Articles - Google Patents
Method And Apparatus For Forming Profiled Articles Download PDFInfo
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- US20170066031A1 US20170066031A1 US15/120,241 US201515120241A US2017066031A1 US 20170066031 A1 US20170066031 A1 US 20170066031A1 US 201515120241 A US201515120241 A US 201515120241A US 2017066031 A1 US2017066031 A1 US 2017066031A1
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- die members
- forming die
- body forming
- pair
- blank
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- 238000000034 method Methods 0.000 title claims abstract description 44
- 239000000463 material Substances 0.000 claims abstract description 53
- 230000000295 complement effect Effects 0.000 claims abstract description 10
- 239000012467 final product Substances 0.000 description 10
- 230000001788 irregular Effects 0.000 description 9
- 239000002184 metal Substances 0.000 description 5
- 238000013461 design Methods 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000012545 processing Methods 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- 238000011161 development Methods 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000004049 embossing Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007717 exclusion Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
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Classifications
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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
- B21D43/00—Feeding, positioning or storing devices combined with, or arranged in, or specially adapted for use in connection with, apparatus for working or processing sheet metal, metal tubes or metal profiles; Associations therewith of cutting devices
- B21D43/02—Advancing work in relation to the stroke of the die or tool
- B21D43/04—Advancing work in relation to the stroke of the die or tool by means in mechanical engagement with the work
- B21D43/06—Advancing work in relation to the stroke of the die or tool by means in mechanical engagement with the work by positive or negative engaging parts co-operating with corresponding parts of the sheet or the like to be processed, e.g. carrier bolts or grooved section in the carriers
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B30—PRESSES
- B30B—PRESSES IN GENERAL
- B30B5/00—Presses characterised by the use of pressing means other than those mentioned in the preceding groups
- B30B5/04—Presses characterised by the use of pressing means other than those mentioned in the preceding groups wherein the pressing means is in the form of an endless band
- B30B5/06—Presses characterised by the use of pressing means other than those mentioned in the preceding groups wherein the pressing means is in the form of an endless band co-operating with another endless band
Definitions
- the present invention relates to a method and apparatus for forming profiled articles, the profiled articles being generally irregular in their body profile.
- the invention relates to a method and apparatus in which at least one body forming die block is employed to form at least part of the profiled article.
- the invention is thought to provide an alternative to current stamping techniques.
- Known systems for forming deformable materials such as sheet metal into a desired profile, particularly a desired uniform profile include roll forming processes. These processes involve passing the sheet metal through a sequence of roll sets, each further deforming the sheet beyond the profile achieved at the previous roll set.
- the disadvantages of roll forming include redundant deformation resulting from non-uniform strain paths as the strip passes each roll set. This in turn leads to high residual stresses which result in product defects such as edge wave, flare, twist, and so on.
- Another disadvantage of roll forming is that the distance between the first roll set and the last roll set is relatively large. Consequently, the space needed to house a roll forming assembly is substantial, particularly when forming complex profiles.
- Chain-die forming has been proposed as an alternative in the production of articles having uniform profiles.
- Chain-die forming may be considered an extension of roll forming that involves forming the product gradually through at least one pass through a plurality of relatively short die blocks that incrementally form a blank into a final uniform profiled article. That is, as the blank moves through each die pair its cross-sectional profile is changed until the final desired cross-sectional profile is achieved.
- the roll radii used in chain-die forming are very large and, therefore, the longitudinal strain imparted to the material being formed is generally very small or negligible. As such, chain-die formed articles may have only a small amount of residual stress resulting from the forming process.
- stamping which is also known as pressing, generally includes a variety of sheet-metal forming manufacturing processes. For example, this may include punching using a machine press or stamping press, blanking, embossing, bending, flanging, and coining. Stamping may involve a single stage operation where every stroke of the press produces the desired form on the sheet metal part, or may alternatively involve a series of stages. The process is usually carried out on sheet metal, but can also be used on other materials, such as polystyrene.
- Stamping is also discontinuous and requires a blank-holder to hold the blank in place during processing.
- the present invention aims to provide an alternative to the aforementioned forming techniques, for the production of articles which may be irregular in profile.
- the present invention relates to a method and apparatus for forming profiled articles, the profiled articles being generally irregular in their body profile.
- the invention relates to a method and apparatus in which at least one body forming die block is employed to form at least part of the profiled article.
- One aspect of the present invention provides an apparatus for forming a profiled article comprising:
- the apparatus may comprise any number of pairs of body forming die members, or a single pair of body forming die members.
- the apparatus comprises a plurality of pairs of body forming die members, each pair of body forming die members being adapted to act on a respective blank of deformable material independently to form a desired profile on each respective blank.
- neighbouring body forming die members of the plurality of pairs of body forming die members are generally hingedly connected to one another.
- neighbouring body forming die members are hingedly connected with minimal clearance therebetween. This ensures a relatively strong structure and a simplified structure compared with, for example, chain-die forming.
- the apparatus comprises locating elements mounted between adjacent body forming die members, the locating elements being adapted to locate the blanks prior to engagement of the blanks with the body forming die members.
- adjacent blanks may be connected to one another with a web and the locating elements may be disposed between adjacent body forming die members on a lower section of the forming path and, in use, locate on one or both sides of respective webs.
- an upper section of the forming path comprises gaps between adjacent body forming die members, the gaps cooperating with and receiving respective locating elements in use.
- the locating elements may be of any suitable form, provided they serve to substantially restrict movement of the blanks relative to the die members when the locating elements are engaged with the blanks.
- the locating elements may comprise blocks, cylinders, hooks, bolts or pins.
- the locating elements comprise pins.
- the pair of body forming die members, or each of the pair of body forming die members is adapted to form the blank of deformable material into the profiled article in a single pass along the forming path. Depending on the complexity of the profile, two or more passes may be required.
- the pair of body forming die members, or each of the pair of body forming die members is adapted to form the blank of deformable material into a profiled intermediate in a single pass along the forming path
- the apparatus comprising at least one additional pair of body forming die members adapted to independently act on the profiled intermediate in at least one additional pass along the forming path, or along an additional forming path of the apparatus, to form the profiled article. If the forming path is that used in the initial forming process, the additional pair of body forming die members is inserted into the forming path, thereby replacing the initial pair of body forming die members.
- the apparatus will comprise at least one additional forming path along which a respective pair of the at least one additional pair of body forming die members travels.
- the pair of body forming die members is of a length substantially equivalent to that of the blank of deformable material and acts along the length of the blank. That is, the body forming die members effectively “stamp” the length of the blank with the desired profile.
- a forming surface of the die member with which the blank comes into contact may be configured with at least a portion of the desired profile.
- the apparatus preferably comprises first and second mounts that define the forming path therebetween and which mount first and second body forming die members of the pair of body forming die members.
- the first and second mounts may comprise drive cogs that engage the first and second body forming die members and that are driven by the drive.
- the first and second mounts define first and second endless paths along which a first set of first body forming die members and a second set of second body forming die members respectively travel.
- the first and second mounts define a limited path along which the pair of body forming die members travel in forward, forming, motion and reverse, resetting, motion.
- the form of the first and second mounts is not particularly limited.
- at least one of the first and second mounts may comprise a large radial surface through the forming path.
- Each of the first and second mounts may comprise a large radius surface through the forming path.
- the respective radii of the large radius surfaces may be substantially equal, or are different.
- the curvature centres of radii may be on respective opposite sides of the forming path, or may be on the same side of the forming path.
- One of the first and second mounts may comprise a large radius surface through the forming path and the other of the first and second mounts may comprise a substantially flat surface through the forming path.
- the blanks for deformable material may be of any suitable dimensions, dictated by the article to be formed. Generally, it is envisaged that the apparatus will primarily be suitable for use on blanks having a length of from about 100 mm to 3,000 mm, although the invention is not bound to these dimensions.
- the forming path may comprise a plurality of pairs of body forming die members, in which case the method preferably comprises passing a plurality of blanks of deformable material through the forming path and engaging a respective blank with a respective pair of body forming die members to independently to form a desired profile on each respective blank.
- the method preferably comprises locating the blanks prior to engagement of the blanks with the body forming die members, the locating being achieved with locating elements mounted between adjacent body forming die members.
- the locating elements preferably comprise locating pins, although the above option and others may also be appropriate.
- the pair of body forming die members forms the blank of deformable material into the profiled article in a single pass along the forming path.
- the pair of body forming die members forms the blank of deformable material into a profiled intermediate in a single pass along the forming path, the method further comprising:
- the pair of body forming die members is of a length substantially equivalent to that of the blank of deformable material and acts along the length of the blank.
- blanks having a length of from about 100 mm to 3,000 mm will be suitable for use in the method, although the invention is not bound to these dimensions.
- a length of deformable material for use with an apparatus as described above, specifically an apparatus that comprises locating elements mounted between adjacent body forming die members, the locating elements being adapted to locate the blanks prior to engagement of the blanks with the body forming die members.
- the length of material of this aspect of the invention comprises a plurality of blanks of the deformable material, wherein consecutive blanks of the length of deformable material are connected to one another by a web of material, the web and the consecutive blanks defining recesses adapted to engage the locating elements of the apparatus.
- the blanks and webs may be formed from the same material or different materials and may be connected or joined together by ay suitable means.
- the blanks and the webs are integral with one another.
- the length of deformable material may take the form of a sheet or strip, or may take any other form.
- the length of deformable material is in the form of a roll that can be fed to the forming path of the apparatus.
- the blanks have a length of from about 100 mm to 3,000 mm, although the invention is not bound to these dimensions.
- FIG. 1 illustrates the method of an embodiment of the invention in which a number of body forming die blocks are used to form an irregular profiled article.
- FIG. 2 illustrates a blank used in the method illustrated in FIG. 1 .
- FIG. 3 illustrates the profiled article produced by the method illustrated in FIG. 1 .
- FIG. 4 illustrates an apparatus according to an embodiment of the invention including a number of body forming die blocks.
- FIG. 5 illustrates a pair of irregular body forming die blocks.
- FIG. 6 illustrates an alternative arrangement for an apparatus and method of an embodiment of the invention.
- FIGS. 7 and 8 illustrate an embodiment of the apparatus of the invention showing locating pins for locating a run of blanks.
- FIGS. 9 a -9 c illustrate drive arrangements for the apparatus of embodiments of the invention.
- FIGS. 10 a -10 c illustrate profiles for forming surfaces of apparatuses according to embodiments of the invention, along which body forming die blocks travel.
- the present invention relates to a method and apparatus for forming profiled articles, the profiled articles being generally irregular in their body profile.
- the invention relates to a method and apparatus in which at least one body forming die block is employed to form at least part of the profiled article.
- FIG. 1 a simplified diagram of a forming method 10 from a blank 11 (as shown in FIG. 2 ) to a final product 12 (shown in FIG. 3 ) is illustrated.
- the blank 11 experiences ‘n’ forming passes through body forming die block pairs 13 to gradually achieve the final product 12 .
- the proposed method 10 differs to conventional stamping, which can form the final product in a single stroke, as the proposed method 10 involved rolling of the blank 11 between the die block pairs 13 . This does not require a blank-holder, as is the case with stamping, and does not result in the need to trim off earring.
- each of the die block pairs 13 imparts a desired profile to the blank 11 .
- Each die block pair 13 acts on the blank 11 to facilitate production of a final product 12 having an irregular profile.
- the proposed method 10 employs whole body forming die blocks 13 instead of discrete die-blocks seen in chain-die forming. It is considered that the use of whole body forming die blocks 13 in the proposed method 10 advantageously ensures that the forming dies have higher strengths than those used in chain-die forming and are free of gaps between the dies. As such, it is envisaged that the surface finish of the final product 12 will be improved. Also, from the mechanical implementation stand point, the structure of the apparatus, discussed below, is simpler and much more robust compared with chain-die forming.
- the apparatus 40 includes a forming path 41 disposed between a first mount 42 and a second mount 43 . Additional mounts may be provided, although this will not be described here in any detail.
- the first and second mounts 42 , 43 include drive gears 44 , 44 ′ that engage cooperating first die members 45 and second die members 45 ′ respectively.
- the first and second mounts 42 , 43 may form endless paths (e.g. these may be large radii elliptical mounts) or large radii semi-elliptical mounts. Blanks of deformable material travel along the forming path 41 between the cooperating first and second die members 45 , 45 ′ to form final products 46 .
- Each pair of cooperating first and second die members 45 , 45 ′ acts on a respective blank to impart the characteristics of the pairs of die members 45 , 45 ′ to the blank.
- each pair of die members 45 , 45 ′ acts as a whole body die block that acts on the length of a respective blank independent of any subsequent processing with further die pairs. Therefore, the pairs of die members 45 , 45 ′ do not act in a similar way to die pairs in chain-die forming, in which a length of deformable material is sequentially deformed to a desired cross-sectional profile. Rather, the pairs of die members 45 , 45 ′ effectively act in a similar way to a conventional stamping mechanism. As illustrated, the profiles of the pairs of die members 45 , 45 ′ act independently on a respective blank to form this into the desired profile of the final product 46 , which may be generally irregular or may be uniform.
- the die members 45 , 45 ′ are provided in FIG. 5 .
- the first die member 45 includes a first profile 55 and the second die member 45 ′ includes a second profile 55 ′.
- the first and second profiles 55 , 55 ′ are complementary and impart a desired profile to the final product as the blank or intermediate passes between the pair of die members 45 , 45 ′.
- the pair of die members 45 , 45 ′ draws a blank 61 into the apparatus 60 and moves the blank 61 forward 62 to facilitate forming. Once the process is complete, the final product 63 is produced and the apparatus 60 reverses and moves the die members 45 , 45 ′ backwards 64 and returns to the start position.
- FIGS. 7 and 8 A preferred embodiment of the apparatus of the invention is illustrated in FIGS. 7 and 8 .
- the apparatus 70 is substantially as described above in that a blank 71 of deformable material is passed between sets of die members 45 , 45 ′ to form a final product 73 .
- the apparatus 70 includes locating pins 75 on one side or on opposing sides of the die members 45 , 45 ′, generally located in lower gaps between the die members 45 , 45 ′ and in cooperation with upper gaps 77 between the die members 45 , 45 ′.
- the locating pins 75 engage recesses 76 between blanks 71 , the blanks 71 in this embodiment being joined by webs 78 . This advantageously ensures that the blanks 71 are correctly positioned between respective die members 45 , 45 ′ as they pass through the apparatus 70 .
- die members 45 , 45 ′ act independently on a respective blank 71 passing through the apparatus 70 .
- FIGS. 9 a to 9 c show some exemplary ways in which the apparatus 90 can operate.
- the system is provided with driving gears 91 which drive the two sets of die elements 45 , 45 ′ in phase so as to draw a section through the forming portion.
- a separate set of driving rolls 92 is provided to propel this section through the forming portion.
- FIG. 9 c shows a similar configuration in which a separate set of driving rolls 93 are used to push a section through the forming portion.
- FIGS. 10 a to 10 c show some of the possible configurations of the forming path in the forming portion of the apparatus.
- each of the opposed forming portions has a large radius and the centres of the radii are respectively on the opposite sides of the forming space.
- FIG. 10 b shows a configuration in which one of the forming portions has a large radius and another has an infinite radius or in other words is flat.
- FIG. 10 c shows a configuration in which the centres of the radii are both on one side of the forming space and large radii are used for the respective forming portions to provide converging paths between the opposed dies. It is also considered that a configuration may be provided in which the radii of the forming portion are not constant, for example to provide a converging track between the opposed dies.
Abstract
Description
- The present invention relates to a method and apparatus for forming profiled articles, the profiled articles being generally irregular in their body profile. In particular, the invention relates to a method and apparatus in which at least one body forming die block is employed to form at least part of the profiled article. The invention is thought to provide an alternative to current stamping techniques.
- Known systems for forming deformable materials such as sheet metal into a desired profile, particularly a desired uniform profile, include roll forming processes. These processes involve passing the sheet metal through a sequence of roll sets, each further deforming the sheet beyond the profile achieved at the previous roll set. The disadvantages of roll forming include redundant deformation resulting from non-uniform strain paths as the strip passes each roll set. This in turn leads to high residual stresses which result in product defects such as edge wave, flare, twist, and so on. Another disadvantage of roll forming is that the distance between the first roll set and the last roll set is relatively large. Consequently, the space needed to house a roll forming assembly is substantial, particularly when forming complex profiles.
- Known systems using multiple roll sets also suffer from significant difficulties associated with initial alignment. A further disadvantage of roll forming is that tooling design is related to the designer's experience. “Trial and error” plays a dominant role in tooling design and alignment and for a new complex profile tooling design, this means the development time is less predictable. Additionally a large amount of material can be wasted during the period of tooling design and alignment, which contributes to the cost of tooling development.
- In more recent times, chain-die forming has been proposed as an alternative in the production of articles having uniform profiles. Chain-die forming may be considered an extension of roll forming that involves forming the product gradually through at least one pass through a plurality of relatively short die blocks that incrementally form a blank into a final uniform profiled article. That is, as the blank moves through each die pair its cross-sectional profile is changed until the final desired cross-sectional profile is achieved. The roll radii used in chain-die forming are very large and, therefore, the longitudinal strain imparted to the material being formed is generally very small or negligible. As such, chain-die formed articles may have only a small amount of residual stress resulting from the forming process.
- The formation of articles having irregular profiles requires other considerations. Conventionally, such articles are produced by stamping. Stamping, which is also known as pressing, generally includes a variety of sheet-metal forming manufacturing processes. For example, this may include punching using a machine press or stamping press, blanking, embossing, bending, flanging, and coining. Stamping may involve a single stage operation where every stroke of the press produces the desired form on the sheet metal part, or may alternatively involve a series of stages. The process is usually carried out on sheet metal, but can also be used on other materials, such as polystyrene.
- Articles produced by stamping generally have earring that needs to be trimmed off after the stamping process, resulting in wasted material and additional processing time. Stamping is also discontinuous and requires a blank-holder to hold the blank in place during processing.
- The present invention aims to provide an alternative to the aforementioned forming techniques, for the production of articles which may be irregular in profile.
- The subject matter claimed herein is not limited to embodiments that solve any disadvantages or that operate only in environments such as those described above. Rather, this background is only provided to illustrate one exemplary technology area where some embodiments described herein may be practice.
- The present invention relates to a method and apparatus for forming profiled articles, the profiled articles being generally irregular in their body profile. In particular, the invention relates to a method and apparatus in which at least one body forming die block is employed to form at least part of the profiled article.
- One aspect of the present invention provides an apparatus for forming a profiled article comprising:
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- a forming path through which a blank of deformable material to be formed into the profiled article passes;
- a pair of complementary and opposing body forming die members adapted to travel along the forming path; and
- a drive that facilitates travel of the body forming die members along the forming path,
- wherein the pair of body forming die members is adapted to act on the blank of deformable material independently to form a desired profile on the blank.
- The apparatus may comprise any number of pairs of body forming die members, or a single pair of body forming die members. In one embodiment, the apparatus comprises a plurality of pairs of body forming die members, each pair of body forming die members being adapted to act on a respective blank of deformable material independently to form a desired profile on each respective blank. According to this embodiment neighbouring body forming die members of the plurality of pairs of body forming die members are generally hingedly connected to one another. Preferably, neighbouring body forming die members are hingedly connected with minimal clearance therebetween. This ensures a relatively strong structure and a simplified structure compared with, for example, chain-die forming.
- In preferred embodiments, the apparatus comprises locating elements mounted between adjacent body forming die members, the locating elements being adapted to locate the blanks prior to engagement of the blanks with the body forming die members. In that regard, adjacent blanks may be connected to one another with a web and the locating elements may be disposed between adjacent body forming die members on a lower section of the forming path and, in use, locate on one or both sides of respective webs. Preferably, an upper section of the forming path comprises gaps between adjacent body forming die members, the gaps cooperating with and receiving respective locating elements in use.
- The locating elements may be of any suitable form, provided they serve to substantially restrict movement of the blanks relative to the die members when the locating elements are engaged with the blanks. For example, the locating elements may comprise blocks, cylinders, hooks, bolts or pins. In a preferred embodiment, the locating elements comprise pins.
- In certain embodiments, the pair of body forming die members, or each of the pair of body forming die members, is adapted to form the blank of deformable material into the profiled article in a single pass along the forming path. Depending on the complexity of the profile, two or more passes may be required.
- In other embodiments, the pair of body forming die members, or each of the pair of body forming die members, is adapted to form the blank of deformable material into a profiled intermediate in a single pass along the forming path, the apparatus comprising at least one additional pair of body forming die members adapted to independently act on the profiled intermediate in at least one additional pass along the forming path, or along an additional forming path of the apparatus, to form the profiled article. If the forming path is that used in the initial forming process, the additional pair of body forming die members is inserted into the forming path, thereby replacing the initial pair of body forming die members. Generally, though, the apparatus will comprise at least one additional forming path along which a respective pair of the at least one additional pair of body forming die members travels.
- Generally, although not essentially, the pair of body forming die members, or each of the pair of body forming die members, is of a length substantially equivalent to that of the blank of deformable material and acts along the length of the blank. That is, the body forming die members effectively “stamp” the length of the blank with the desired profile. In particular, a forming surface of the die member with which the blank comes into contact may be configured with at least a portion of the desired profile.
- The apparatus preferably comprises first and second mounts that define the forming path therebetween and which mount first and second body forming die members of the pair of body forming die members. The first and second mounts may comprise drive cogs that engage the first and second body forming die members and that are driven by the drive.
- In certain embodiments, the first and second mounts define first and second endless paths along which a first set of first body forming die members and a second set of second body forming die members respectively travel.
- In other embodiments, the first and second mounts define a limited path along which the pair of body forming die members travel in forward, forming, motion and reverse, resetting, motion.
- The form of the first and second mounts is not particularly limited. For example, at least one of the first and second mounts may comprise a large radial surface through the forming path. Each of the first and second mounts may comprise a large radius surface through the forming path. The respective radii of the large radius surfaces may be substantially equal, or are different. The curvature centres of radii may be on respective opposite sides of the forming path, or may be on the same side of the forming path. One of the first and second mounts may comprise a large radius surface through the forming path and the other of the first and second mounts may comprise a substantially flat surface through the forming path.
- The blanks for deformable material may be of any suitable dimensions, dictated by the article to be formed. Generally, it is envisaged that the apparatus will primarily be suitable for use on blanks having a length of from about 100 mm to 3,000 mm, although the invention is not bound to these dimensions.
- According to another aspect of the invention there is provided a method of forming a profiled article comprising:
-
- passing a blank of deformable material to be formed into the profiled article through a forming path comprising a pair of complementary and opposing body forming die members adapted to travel along the forming path; and
- progressively engaging the blank with the pair of complementary and opposing body forming die members;
- wherein the pair of body forming die members is adapted to act on the blank of deformable material independently to form a desired profile on the blank.
- As will be appreciated by the above discussion, the forming path may comprise a plurality of pairs of body forming die members, in which case the method preferably comprises passing a plurality of blanks of deformable material through the forming path and engaging a respective blank with a respective pair of body forming die members to independently to form a desired profile on each respective blank. In this embodiment, the method preferably comprises locating the blanks prior to engagement of the blanks with the body forming die members, the locating being achieved with locating elements mounted between adjacent body forming die members. Again, the locating elements preferably comprise locating pins, although the above option and others may also be appropriate.
- In certain embodiments, the pair of body forming die members forms the blank of deformable material into the profiled article in a single pass along the forming path.
- In other embodiments, the pair of body forming die members forms the blank of deformable material into a profiled intermediate in a single pass along the forming path, the method further comprising:
-
- passing the profiled intermediate through at least one additional forming path comprising a respective at least one additional pair of complementary and opposing body forming die members adapted to travel along the a respective at least one additional forming path; and
- progressively engaging the profiled intermediate with the at least one additional pair of body forming die members,
- wherein the at least one additional pair of body forming die members independently acts on the profiled intermediate in at least one additional pass along the at least one additional forming path to form the profiled article.
- Again, in certain embodiments the pair of body forming die members is of a length substantially equivalent to that of the blank of deformable material and acts along the length of the blank. Likewise, blanks having a length of from about 100 mm to 3,000 mm will be suitable for use in the method, although the invention is not bound to these dimensions.
- According to another aspect of the invention there is provided a length of deformable material for use with an apparatus as described above, specifically an apparatus that comprises locating elements mounted between adjacent body forming die members, the locating elements being adapted to locate the blanks prior to engagement of the blanks with the body forming die members. The length of material of this aspect of the invention comprises a plurality of blanks of the deformable material, wherein consecutive blanks of the length of deformable material are connected to one another by a web of material, the web and the consecutive blanks defining recesses adapted to engage the locating elements of the apparatus.
- In certain embodiments the blanks and webs may be formed from the same material or different materials and may be connected or joined together by ay suitable means. Preferably, though, the blanks and the webs are integral with one another.
- The length of deformable material may take the form of a sheet or strip, or may take any other form. In certain embodiments, the length of deformable material is in the form of a roll that can be fed to the forming path of the apparatus.
- Preferably, the blanks have a length of from about 100 mm to 3,000 mm, although the invention is not bound to these dimensions.
- In a further aspect of the invention there is provided a profiled article formed using the apparatus or method of the invention.
- The present invention consists of features and a combination of parts hereinafter fully described and illustrated in the accompanying drawings, it being understood that various changes in the details may be made without departing from the scope of the invention or sacrificing any of the advantages of the present invention.
- To further clarify various embodiments of the present invention, a more detailed description of the invention follows with reference to specific embodiments thereof, which are illustrated in the accompanying drawings. It should be appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting on its scope. The invention will be described and explained with additional specificity and detail through the accompanying drawings in which:
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FIG. 1 illustrates the method of an embodiment of the invention in which a number of body forming die blocks are used to form an irregular profiled article. -
FIG. 2 illustrates a blank used in the method illustrated inFIG. 1 . -
FIG. 3 illustrates the profiled article produced by the method illustrated inFIG. 1 . -
FIG. 4 illustrates an apparatus according to an embodiment of the invention including a number of body forming die blocks. -
FIG. 5 illustrates a pair of irregular body forming die blocks. -
FIG. 6 illustrates an alternative arrangement for an apparatus and method of an embodiment of the invention. -
FIGS. 7 and 8 illustrate an embodiment of the apparatus of the invention showing locating pins for locating a run of blanks. -
FIGS. 9a-9c illustrate drive arrangements for the apparatus of embodiments of the invention. -
FIGS. 10a-10c illustrate profiles for forming surfaces of apparatuses according to embodiments of the invention, along which body forming die blocks travel. - The present invention relates to a method and apparatus for forming profiled articles, the profiled articles being generally irregular in their body profile. In particular, the invention relates to a method and apparatus in which at least one body forming die block is employed to form at least part of the profiled article.
- Hereinafter, this specification will describe the present invention according to the preferred embodiments. It is to be understood that the following description of the preferred embodiments of the invention is provided to facilitate discussion of the present invention and it is envisioned that without departing from the scope of the appended claims.
- Referring to
FIG. 1 , a simplified diagram of a formingmethod 10 from a blank 11 (as shown inFIG. 2 ) to a final product 12 (shown inFIG. 3 ) is illustrated. In the illustratedmethod 10, the blank 11 experiences ‘n’ forming passes through body forming die block pairs 13 to gradually achieve thefinal product 12. The proposedmethod 10 differs to conventional stamping, which can form the final product in a single stroke, as the proposedmethod 10 involved rolling of the blank 11 between the die block pairs 13. This does not require a blank-holder, as is the case with stamping, and does not result in the need to trim off earring. Importantly, each of the die block pairs 13 imparts a desired profile to the blank 11. Each dieblock pair 13 acts on the blank 11 to facilitate production of afinal product 12 having an irregular profile. To compare with chain-die forming, the proposedmethod 10 employs whole body forming die blocks 13 instead of discrete die-blocks seen in chain-die forming. It is considered that the use of whole body forming die blocks 13 in the proposedmethod 10 advantageously ensures that the forming dies have higher strengths than those used in chain-die forming and are free of gaps between the dies. As such, it is envisaged that the surface finish of thefinal product 12 will be improved. Also, from the mechanical implementation stand point, the structure of the apparatus, discussed below, is simpler and much more robust compared with chain-die forming. - Referring to
FIG. 4 , anapparatus 40 according to an embodiment of the invention is illustrated. Theapparatus 40 includes a formingpath 41 disposed between afirst mount 42 and asecond mount 43. Additional mounts may be provided, although this will not be described here in any detail. The first andsecond mounts members 45 and second diemembers 45′ respectively. According to this embodiment, the first andsecond mounts path 41 between the cooperating first and second diemembers final products 46. - Each pair of cooperating first and second die
members die members die members die members die members die members final product 46, which may be generally irregular or may be uniform. - There is very
little gap 47 between consecutive pairs ofdie members joints 48. This ensures that thedie members final product 46. - Examples of the
die members FIG. 5 . Referring to this figure, thefirst die member 45 includes afirst profile 55 and thesecond die member 45′ includes asecond profile 55′. The first andsecond profiles die members - In an alternative embodiment of the
apparatus 60, as illustrated inFIG. 6 , the pair ofdie members apparatus 60 and moves the blank 61 forward 62 to facilitate forming. Once the process is complete, thefinal product 63 is produced and theapparatus 60 reverses and moves thedie members - A preferred embodiment of the apparatus of the invention is illustrated in
FIGS. 7 and 8 . Referring to these figures, theapparatus 70 is substantially as described above in that a blank 71 of deformable material is passed between sets ofdie members final product 73. However, in this embodiment theapparatus 70 includes locating pins 75 on one side or on opposing sides of thedie members die members upper gaps 77 between thedie members recesses 76 betweenblanks 71, theblanks 71 in this embodiment being joined bywebs 78. This advantageously ensures that theblanks 71 are correctly positioned betweenrespective die members apparatus 70. Hence, diemembers apparatus 70. -
FIGS. 9a to 9c show some exemplary ways in which theapparatus 90 can operate. InFIG. 9a the system is provided with drivinggears 91 which drive the two sets ofdie elements FIG. 9b a separate set of driving rolls 92 is provided to propel this section through the forming portion.FIG. 9c shows a similar configuration in which a separate set of driving rolls 93 are used to push a section through the forming portion. -
FIGS. 10a to 10c show some of the possible configurations of the forming path in the forming portion of the apparatus. InFIG. 10a each of the opposed forming portions has a large radius and the centres of the radii are respectively on the opposite sides of the forming space.FIG. 10b shows a configuration in which one of the forming portions has a large radius and another has an infinite radius or in other words is flat.FIG. 10c shows a configuration in which the centres of the radii are both on one side of the forming space and large radii are used for the respective forming portions to provide converging paths between the opposed dies. It is also considered that a configuration may be provided in which the radii of the forming portion are not constant, for example to provide a converging track between the opposed dies. - Unless the context requires otherwise or specifically stated to the contrary, integers, steps or elements of the invention recited herein as singular integers, steps or elements clearly encompass both singular and plural forms of the recited integers, steps or elements.
- Throughout this specification, unless the context requires otherwise, the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated step or element or integer or group of steps or elements or integers, but not the exclusion of any other step or element or integer or group of steps, elements or integers. Thus, in the context of this specification, the term “comprising” is used in an inclusive sense and thus should be understood as meaning “including principally, but not necessarily solely”.
- It will be appreciated that the foregoing description has been given by way of illustrative example of the invention and that all such modifications and variations thereto as would be apparent to persons of skill in the art are deemed to fall within the broad scope and ambit of the invention as herein set forth.
Claims (32)
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2014900602A AU2014900602A0 (en) | 2014-02-25 | Method and apparatus for forming profiled articles | |
AU2014900602 | 2014-02-25 | ||
PCT/AU2015/050071 WO2015127509A1 (en) | 2014-02-25 | 2015-02-24 | Method and apparatus for forming profiled articles |
Publications (1)
Publication Number | Publication Date |
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US20170066031A1 true US20170066031A1 (en) | 2017-03-09 |
Family
ID=54008058
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US15/120,241 Abandoned US20170066031A1 (en) | 2014-02-25 | 2015-02-24 | Method And Apparatus For Forming Profiled Articles |
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Country | Link |
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US (1) | US20170066031A1 (en) |
EP (1) | EP3110619B1 (en) |
JP (1) | JP6502391B2 (en) |
CN (1) | CN106103071B (en) |
AU (1) | AU2015222693B2 (en) |
WO (1) | WO2015127509A1 (en) |
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JP4859524B2 (en) * | 2006-05-10 | 2012-01-25 | 株式会社オオタ | Press forming method of metal part having shaft portion and spring hook |
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JP5057467B2 (en) * | 2008-03-03 | 2012-10-24 | 株式会社中田製作所 | Molding apparatus, shoe thereof and molding method |
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JP5565168B2 (en) * | 2010-07-26 | 2014-08-06 | 住友電装株式会社 | Atypical corrugated tube manufacturing apparatus and atypical corrugated tube manufacturing method |
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2015
- 2015-02-24 EP EP15755660.6A patent/EP3110619B1/en active Active
- 2015-02-24 WO PCT/AU2015/050071 patent/WO2015127509A1/en active Application Filing
- 2015-02-24 JP JP2016570146A patent/JP6502391B2/en active Active
- 2015-02-24 AU AU2015222693A patent/AU2015222693B2/en active Active
- 2015-02-24 US US15/120,241 patent/US20170066031A1/en not_active Abandoned
- 2015-02-24 CN CN201580009939.7A patent/CN106103071B/en active Active
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US2407253A (en) * | 1943-10-28 | 1946-09-10 | Guy O Conner | Forming machine |
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US4597278A (en) * | 1979-08-24 | 1986-07-01 | Sumitomo Metal Industries, Ltd. | Method for producing I-beam having centrally corrugated web |
US4543054A (en) * | 1984-05-25 | 1985-09-24 | Hitek Limited | Thermoforming machine |
US5088209A (en) * | 1988-08-19 | 1992-02-18 | Renishaw Plc | Metrological scale |
US5115660A (en) * | 1989-09-04 | 1992-05-26 | Nisshin Steel Co., Ltd. | Method for making band plates deformed in section |
US5460771A (en) * | 1992-10-16 | 1995-10-24 | Itt Corporation | Process for producing corrugated multi-layer tubing having layers of differing plastic characteristics |
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Also Published As
Publication number | Publication date |
---|---|
CN106103071A (en) | 2016-11-09 |
JP2017506161A (en) | 2017-03-02 |
JP6502391B2 (en) | 2019-04-17 |
AU2015222693A1 (en) | 2016-08-18 |
EP3110619A1 (en) | 2017-01-04 |
EP3110619A4 (en) | 2017-10-18 |
WO2015127509A1 (en) | 2015-09-03 |
CN106103071B (en) | 2018-08-24 |
AU2015222693B2 (en) | 2019-12-05 |
EP3110619B1 (en) | 2019-04-10 |
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