US20210170465A1 - Square tube forming method and square tube forming device - Google Patents

Square tube forming method and square tube forming device Download PDF

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Publication number
US20210170465A1
US20210170465A1 US17/046,460 US201917046460A US2021170465A1 US 20210170465 A1 US20210170465 A1 US 20210170465A1 US 201917046460 A US201917046460 A US 201917046460A US 2021170465 A1 US2021170465 A1 US 2021170465A1
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United States
Prior art keywords
roll
forming
roll stand
stand
square tube
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Abandoned
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US17/046,460
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English (en)
Inventor
Jilong Yin
Masato NISHII
Tomoyasu Nakano
Feizhou Wang
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Nakata Manufacturing Co Ltd
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Nakata Manufacturing Co Ltd
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Assigned to NAKATA MANUFACTURING CO., LTD. reassignment NAKATA MANUFACTURING CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NISHII, MASATO, NAKANO, TOMOYASU, WANG, FEIZHOU, YIN, JILONG
Publication of US20210170465A1 publication Critical patent/US20210170465A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/15—Making tubes of special shape; Making tube fittings
    • B21C37/155—Making tubes with non circular section
    • 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
    • B21D15/00—Corrugating tubes
    • B21D15/02—Corrugating tubes longitudinally
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/08—Making tubes with welded or soldered seams
    • B21C37/0803—Making tubes with welded or soldered seams the tubes having a special shape, e.g. polygonal tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/15—Making tubes of special shape; Making tube fittings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/15—Making tubes of special shape; Making tube fittings
    • B21C37/16—Making tubes with varying diameter in longitudinal direction
    • 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
    • B21D5/10—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 for making tubes
    • B21D5/12—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 for making tubes making use of forming-rollers

Definitions

  • the present invention relates to a square tube forming method and a square tube forming device of forming a metallic round tube into a square tube, particularly, to a square tube forming method and a square tube forming device of a forming roll system using forming roll stands in a plurality of states.
  • a square tube means a metallic square tube.
  • a configuration employed as a square tube forming device of forming a round tube having a round cross-sectional shape into a square tube having a rectangular cross-sectional shape uses a forming roll stand array including a plurality of forming roll stands arranged in a forming direction.
  • the most common configuration uses a four-direction forming roll stand for restraining the outer circumference of the same cross section of a round tube from four directions including horizontal directions and vertical directions.
  • there are square tube forming devices not using such a four-direction forming roll stand uses a forming roll stand array in which a horizontal roll stand and a vertical roll stand are arranged alternately in a forming direction, as presented in patent literature 1 and patent literature 2.
  • caliber rolls are used both as a horizontal forming roll and a vertical forming roll.
  • the caliber roll is a forming roll having an outer circumferential surface recessed more deeply in an arc-like shape from opposite end portions toward the center of the outer circumferential surface in a rotary axis direction, and the arc-like recess is a roll caliber.
  • the roll caliber at each stand is basically designed to become shallower gradually from an upstream side toward a downstream side of a material traveling direction. More specifically, the roll caliber is designed in such a manner that the curvature of the roll caliber is reduced stepwise from a value close to the curvature of a round tube as a raw tube to finally become zero, which is equal to that of a linear portion held between a corner portion and a corner portion of a square tube as a product.
  • the roll caliber of the forming roll is divided in a circumferential direction into a corner portion corresponding section, a shoulder portion corresponding section, and a section corresponding to a linear portion other than the shoulder portion, and these corresponding sections are given different curvatures.
  • the roll caliber is designed in such a manner that the caliber bottom of the forming roll limitedly contacts the center of a linear portion of a square tube as a product, thereby allowing forming of tube members of different sizes using the same stand array within a certain range.
  • a range of multi-use of the device is limited, development of a square tube forming device having a wider range of roll multi-usability is expected.
  • Tubes including structural steel tubes have recently been requested to be accurate in curvatures of corner portions at cross sections R conforming to definitions, namely, requested to be free from thickness increase or reduction.
  • a small-diameter forming roll is employed for the purpose of narrowing a gap between a horizontal roll and a vertical roll adjacent to each other. This disables suppression of springback in a real sense due to the reason of increase in invasion resistance, etc. to make it difficult to respond to the foregoing request.
  • Patent Literature 1 Japanese Patent Application Publication No. 2000-301233
  • Patent Literature 2 Japanese Patent Application Publication No. 2006-150377
  • the present inventors focused on a flat roll stand with a combination of rod-like flat rolls without roll calibers, particularly, on a flat roll stand array in which a horizontal flat roll stand and a vertical flat roll stand are arranged alternately in a tube member forming direction.
  • the flat roll is not recessed in an arc-like shape at an outer circumferential surface. This makes a minimum outer diameter and a maximum outer diameter substantially equal to each other to allow reduction in a gap between the roll stands compared to that in a caliber roll stand.
  • the entire length of the roll stand array is suppressed, and roll multi-usability is enhanced considerably compared to that of a caliber roll stand array.
  • the flat roll stand array was analyzed repeatedly from a variety of viewpoints to find the following issues about forming performance, which is the most significant feature of a square tube forming device.
  • the alternate arrangement of the horizontal roll stand and the vertical roll stand basically achieves bending forming using two-direction rolls to prevent the occurrence of distortion at a corner portion to be caused by constriction forming using four-direction rolls.
  • a forming roll in each roll stand is a flat roll with a controlled maximum diameter, so that a gap between roll stands can actually be reduced. Even if a gap between the roll stands can be reduced, however, it is still impossible to suppress the springback of a tube member occurring between roll stands adjacent to each other.
  • the performance of forming from a round tube into a square tube is affected largely by a ratio of allocation of a rolling amount to each stand in the roll stand array, namely, a rolling amount distribution, rather than the caliber shape of the caliber roll.
  • What is particularly effective is operation of applying an extremely large rolling amount at some of the forming roll stands in the roll stand array and operation of largely changing a rolling amount distribution involving such large change in response to the dimension (outer diameter, thickness) and material of the round tube and the dimension of the square tube.
  • the flat roll stand is considerably effective in performing these operations.
  • the reason for this is as follows.
  • an outer diameter is larger at opposite end portions than at a portion corresponding to a caliber bottom to abut on the tube member, so that a gap between rolls and change in a rolling amount are limited by a portion where the outer diameter is at maximum.
  • a gap between rolls changes in a wide range to allow adjustment of a rolling amount in a wide range, and this works particularly effectively in forming into the square tube.
  • This square tube forming method is a square tube forming method of forming a round tube of any diameter as a forming target raw tube into a square tube of any dimension as a product by passing the round tube through a plurality of roll stands arranged in a raw tube forming direction, comprising:
  • a flat roll stand array in which a first flat roll stand and a second flat roll stand of rolling directions orthogonal to each other are arranged alternately in a forming direction for a tube member and in which a rolling amount at each roll stand is independently settable;
  • the forming rolling amount distribution being determined in advance for the stands from a first-stage stand to a final-stage stand in response to the outer diameter, thickness, and material of the forming target raw tube to be used and an intended dimension of the square tube as a product;
  • the square tube forming device of the present invention is a square tube forming device for implementing the square tube forming method of the present invention comprising:
  • a flat roll stand array in which a first flat roll stand and a second flat roll stand of rolling directions orthogonal to each other are arranged alternately in a forming direction, wherein
  • each roll stand in the flat roll stand array includes roll gap adjusting means by which a rolling amount is independently settable, and at least one of the first flat roll stand and the second flat roll stand adjacent to each other includes roll driving means.
  • a roll stand array means a flat roll stand array and a forming raw member means a forming target raw tube.
  • each rolling direction may be at any angle relative to a vertical line or a horizontal line.
  • one of the first flat roll stand and the second flat roll stand is preferably a horizontal roll stand and the other is preferably a vertical roll stand.
  • both the first flat roll stand and the second flat roll stand adjacent to each other may be driven, namely, all the rolls may be driven.
  • Driving both the horizontal roll and the vertical roll allows forming into a square tube of different rectangular ratios. While both of these rolls can be driven only at some of the stands, driving only one of the rolls in each of all the stands is rational and desirable in terms of giving rationality to a device configuration and reducing cost of manufacturing the device.
  • the flat roll at each roll stand has an outer diameter constant along its entire length in a rotary axis direction.
  • shallow arc-like recesses having larger curvatures than an outer surface R of a roll contact surface of the tube member to pass through the one or plurality of roll stands may be formed at both of the rolls in each roll stand, regardless of whether the rolls are to be driven or not to be driven. This is also within the range of the present invention.
  • a gap adjusting motor of a roll gap adjusting mechanism for the roll stand array is preferably shared in the roll stand array. More specifically, while gap adjusting motors in a pair intended for the first flat roll stand and the second flat roll stand in a pair adjacent to each other are movable along the roll stand array, these gap adjusting motors are preferably shared between the first flat roll stands and the second flat roll stands in a plurality of pairs. This simplifies the configuration of the device and reduces the weight of the device, thereby reducing cost of manufacturing the device.
  • these inventions basically relate to a technique of square tube forming using the caliber roll stand array, namely, a technique of roll forming of a round tube as a raw tube gradually into a square tube as a product by reducing the curvature of the roll caliber stepwise at the stands.
  • a total forming amount is allocated substantially uniformly to all the stages in response to the number of stands to be used.
  • a caliber curvature at each stand is designed.
  • a rolling amount at each stand is also determined by allocating a total rolling amount uniformly to the stands in response to a caliber curvature distribution.
  • the square tube forming method and the square tube forming device of the present invention use the roll stand array in which the first flat roll stand and the second flat roll stand of rolling directions orthogonal to each other are arranged alternately in the forming direction to remove limitation on forming dimensions imposed by the roll caliber, thereby achieving considerably high roll multi-usability.
  • a need for a sizing stand (four-direction roll stand) conventionally indispensable for ensuring thrust is eliminated, thereby facilitating incorporation into a current tube manufacturing line.
  • a rolling amount at each stand in the stand array is independently settable to allow a rolling amount to be allocated freely, and suppressing the entire length of the roll stand array allows increase in the number of stages of the roll stands.
  • a forming amount at one stage of roll stand is still suppressed, thereby reducing the occurrence of winding around a roll to reduce an invasion resistance.
  • bending forming is performed using two-direction rolls unlike constriction forming using four rolls, and at least one of the first flat roll stand and the second flat roll stand adjacent to each other is driven to allow application of stable thrust to a tube member to pass through the stand array.
  • the square tube forming method and the square tube forming device of the present invention achieve manufacture of high-quality square tubes economically.
  • FIG. 1 is a perspective view of a square tube forming device showing an embodiment of the present invention
  • FIG. 2 is a perspective view of the square tube forming device taken from a different angle from which a roll driving mechanism is omitted;
  • FIG. 3 is a perspective view of a horizontal roll stand in the square tube forming device
  • FIG. 4 is a perspective view of a vertical roll stand in the square tube forming device
  • FIG. 5 is a perspective view showing one example of a square tube forming method of the present invention and showing a square tube forming process continuously and entirely according to this example;
  • FIG. 6 is an explanatory view showing the square tube forming process of forming a raw round tube into a square tube as a product in stages according to the one example by illustrating cross-sectional shapes of the tube at respective stands;
  • FIG. 7 is a perspective view showing a different example of the square tube forming method of the present invention and showing a square tube forming process continuously and entirely according to this example;
  • FIG. 8 is an explanatory view showing the square tube forming process of forming a raw round tube into a square tube as a product in stages according to the different example by illustrating cross-sectional shapes of the tube at respective stands.
  • a square tube forming device of the embodiment is a device of forming a round tube as a forming raw member continuously into a square tube by passing the round tube through a plurality of forming roll stands sequentially.
  • the square tube forming device is arranged in a round tube manufacturing line and used for forming a part of a manufactured round tube into a square tube to allow manufacture of both the round tube and the square tube.
  • this square tube forming device includes a roll stand array 10 of a square tubular shape extending long in a tube member forming direction.
  • the square tubular roll stand array 10 has a configuration in which a horizontal roll stand 20 A of a square frame-like shape having a small thickness in the tube member forming direction and a vertical roll stand 20 B of a square frame-like shape also having a small thickness in the tube member forming direction are arranged alternately on a stand base 30 in the tube member forming direction.
  • a round tube as a forming raw member passes through the roll stand array 10 from a front side toward a back side of FIG. 1 .
  • the front side of FIG. 1 is an upstream side of the roll stand array 10
  • the back side of FIG. 1 is a downstream side of the roll stand array 10 .
  • the horizontal roll stand 20 A includes: upper and lower horizontal fixed bases 22 A, 22 A coupled by a total of four vertical rods 21 A arranged two on the right and two on the left; upper and lower horizontal movable bases 23 A, 23 A supported to be vertically movable by the right and left vertical rods 21 A between the upper and lower horizontal fixed bases 22 A, 22 A; and upper and lower horizontal rolls 24 A, 24 A attached to respective surfaces of the movable bases 23 A, 23 A facing each other.
  • Each of the upper and lower horizontal rolls 24 A is a flat roll having an outer diameter substantially constant along its entire length in a center axis direction.
  • a horizontal support shaft supporting the horizontal roll 24 A is rotatably supported by brackets 25 A, 25 A provided in bearings on the opposite sides of the horizontal roll 24 A.
  • One end portion of this support shaft projects as an input shaft 24 A′ toward one side of the roll stand array 10 and is coupled to a roll driving mechanism 40 as roll driving means arranged on the one side, thereby driving the horizontal roll 24 A to rotate (see FIG. 1 ).
  • a roll gap between the upper and lower horizontal rolls 24 A, 24 A in a pair is adjusted by a mechanical upper jack 26 A attached in a downward-pointing position to the upper surface of the upper horizontal fixed base 22 A at the center and by a mechanical lower jack 26 A attached in an upward-pointing position to the lower surface of the lower horizontal fixed base 22 A at the center.
  • the downward-pointing upper jack 26 A has a tip portion coupled to the upper surface of the upper movable base 23 A while penetrating the upper horizontal fixed base 22 A, and is driven by a horizontal roll gap adjusting motor 50 A (see FIGS. 1 and 2 ) arranged on the one side of the roll stand array 10 through a horizontal input shaft 27 A.
  • the upward-pointing lower jack 26 A has a tip portion coupled to the lower surface of the lower movable base 23 A while penetrating the lower horizontal fixed base 22 A, and is driven symmetrically to and synchronously with the upper jack 26 A as driving force of the horizontal roll gap adjusting motor 50 A (see FIGS.
  • the symmetric and synchronous driving using the upper and lower jacks 26 A, 26 A described above drives the upper and lower movable bases 23 A, 23 A to move up and down symmetrically, thereby adjusting a roll gap between the upper and lower horizontal rolls 24 A, 24 A.
  • a gap adjusting mechanism for the upper and lower horizontal rolls 24 A, 24 A is configured using the upper and lower jacks 26 A, 26 A, the horizontal roll gap adjusting motor 50 A, and a power transmission mechanism including the input shaft 27 A, the upper and lower gear boxes 28 A, 28 A, and the power transmission shaft 29 A.
  • the vertical roll stand 20 B includes: right and left vertical fixed bases 21 B, 21 B in a pair; two upper and lower horizontal rods 22 B, 22 B coupling the right and left vertical fixed bases 21 B, 21 B; right and left movable bases 23 B, 23 B supported to be horizontally movable by the two upper and lower horizontal rods 22 B, 22 B between the right and left vertical fixed bases 21 B, 21 B; and right and left vertical rolls 24 B, 24 B rotatably supported by the right and left movable bases 23 B, 23 B respectively.
  • the right and left vertical fixed bases 21 B, 21 B are provided in standing positions symmetrically to each other on opposite end portions of the lower horizontal fixed base 22 A of the horizontal roll stand 20 A described above (see FIG. 3 ). Namely, the foregoing lower horizontal fixed base 22 A of the horizontal roll stand 20 A extends toward the downstream side of the roll stand array 10 , and the vertical fixed bases 21 B, 21 B are attached to this extending portion. In this way, the horizontal roll stand 20 A and the vertical roll stand 20 B in a pair adjacent to each other form a horizontal and vertical stand pair 20 integrated by the common horizontal fixed base 22 A.
  • Each of the right and left movable bases 23 B includes upper and lower sliders slidably supported by the upper and lower horizontal rods 22 B, 22 B, and a roll support frame 25 B attached between the upper and lower sides.
  • the roll support frame 25 B which further functions as a coupling member between the upper and lower sliders, has a configuration opened inwardly formed by a combination of upper and lower horizontal members and an outer vertical member.
  • the foregoing right and left vertical rolls 24 B, 24 B are rotatably supported between these upper and lower horizontal members.
  • a roll gap between the right and left vertical rolls 24 B, 24 B is adjusted by right and left jacks 26 B, 26 B attached to outer side surfaces of the right and left vertical fixed bases 22 B, 22 B respectively with the inner sides thereof pointing toward the respective outer side surfaces.
  • the jack 26 B on the one side has a tip portion coupled to the outer side surface of the outer vertical member of the movable base 23 B on the one side while penetrating the vertical fixed base 22 B on the one side, and is driven by a vertical roll gap adjusting motor 50 B (see FIGS. 1 and 2 ) arranged on the one side of the roll stand array 10 through a vertical input shaft 27 B.
  • the jack 26 B on the other side has a tip portion coupled to the outer side surface of the outer vertical member of the movable base 24 B on the other side while penetrating the vertical fixed base 22 B on the other side, and is driven symmetrically to and synchronously with the jack 26 B on the one side as driving force of the vertical roll gap adjusting motor 50 B (see FIGS. 1 and 2 ) is transmitted to the jack 26 B on the other side through a gear box 28 B attached to a lateral portion of the stand base 30 on the one side, a horizontal power transmission shaft 29 B, and a gear box 28 B attached to a lateral portion of the stand base 30 on the other side.
  • a gap adjusting mechanism for the right and left vertical rolls 24 B, 24 B is configured using the right and left jacks 26 B, 26 B, the vertical roll gap adjusting motor 50 B, and a power transmission mechanism including the input shaft 27 B, the right and left gear boxes 28 B, 28 B, and the power transmission shaft 29 B.
  • the roll stand array 10 is composed of 11 stand pairs 20 (23 roll stands in total including the horizontal roll stand 20 A in a final stage).
  • a gap between the horizontal rolls 24 A, 24 A in the horizontal roll stand 20 A is adjusted by the horizontal roll gap adjusting motor 50 A
  • a gap between the vertical rolls 24 B, 24 B in the vertical roll stand 20 B is adjusted by the vertical roll gap adjusting motor 50 B.
  • the horizontal roll gap adjusting motor 50 A and the vertical roll gap adjusting motor 50 B are provided only in one pair for one horizontal and vertical stand pair 20 , and the horizontal roll gap adjusting motor 50 A and the vertical roll gap adjusting motor 50 B in one pair moves along the roll stand array 10 (here, in a self-propelled manner) to adjust gaps between the horizontal rolls 24 A, 24 A and gaps between the vertical rolls 24 B, 24 B of the 12 horizontal and vertical stand pairs 20 sequentially.
  • a support table 51 is provided on the one side of the roll stand array 10 , particularly at the top thereof while extending along the entire length of the roll stand array 10 .
  • the support table 51 is supported horizontally by a stay 52 , etc. extending from the top of the stand pair 20 toward the one side.
  • the horizontal roll gap adjusting motor 50 A and the vertical roll gap adjusting motor 50 B in a pair are coupled to each other and in this state, are movable on the support table 51 along the roll stand array 10 .
  • the horizontal roll gap adjusting motor 50 A and the vertical roll gap adjusting motor 50 B in a pair stop at positions corresponding to the 12 horizontal and vertical stand pairs 20 and are coupled to the horizontal input shaft 27 A in the horizontal roll stand 20 A and to the vertical input shaft 27 A in the vertical roll stand 20 B at each of the stopping positions, thereby adjusting a gap between the horizontal rolls 24 A, 24 A in the horizontal roll stand 20 A and a gap between the vertical rolls 24 B, 24 B in the vertical roll stand 20 B.
  • This operation is performed on each of all the horizontal and vertical stand pairs 20 to adjust the gaps between the horizontal rolls 24 A, 24 A and the gaps between the vertical rolls 24 B, 24 B in all the respective horizontal and vertical stand pairs 20 independently of each other.
  • 53 is a flexible cable for feeding electricity to the movable horizontal roll gap adjusting motor 50 A and vertical roll gap adjusting motor 50 B.
  • the horizontal rolls 24 A, 24 A in the horizontal roll stand 20 A are driven to rotate by the roll driving mechanism 40 arranged on the one side of the roll stand array 10 .
  • the roll driving mechanism 40 mentioned herein is divided into three driving units 41 .
  • Each of the driving units 41 is coupled to four horizontal roll stands 20 A in four stand pairs 20 adjacent to each other in the roll stand array 10 , thereby driving the upper and lower horizontal rolls 24 A, 24 A in each of the four horizontal roll stands 20 A to rotate.
  • the roll driving mechanism 40 includes a driving motor 42 for driving each driving unit 41 , and includes upper and lower output shafts 43 , 43 corresponding to each of the four horizontal roll stands 20 A and coupled to the input shafts 24 A′, 24 A′ of the upper and lower horizontal rolls 24 A, 24 A in each of the four horizontal roll stands 20 A.
  • the upper and lower horizontal rolls 24 A, 24 A in each of the horizontal roll stands 20 A are driven to rotate.
  • a method of forming a round tube into a square tube using the square tube forming device of the embodiment will be described next as a square tube forming method of the embodiment.
  • a gap between the upper and lower horizontal rolls 24 A, 24 A in the horizontal roll stand 20 A and a gap between the right and left vertical rolls 24 B, 24 B in the vertical roll stand 20 B are adjusted for each stand pair 20 in order from the upstream side toward the downstream side of the roll stand array 10 , for example.
  • this adjustment is made using the movable horizontal roll gap adjusting motor 50 A and vertical roll gap adjusting motor 50 B in combination.
  • the roll driving mechanism 40 drives only the horizontal rolls 24 A, 24 A in the horizontal roll stand 20 A in each of all the stand pairs 20 to rotate.
  • the round tube as a forming raw member is passed through the roll stand array 10 .
  • This tube member is passed through the stand pairs 20 in the roll stand array 10 (namely, combinations of the horizontal roll stands 20 A and the vertical roll stands 20 B) sequentially to be formed from the round tube into the square tube.
  • the roll stand array 10 is configured using the horizontal roll stand 20 A and the vertical roll stand 20 B arranged alternately. Further, the horizontal rolls 24 A, 24 A in the horizontal roll stand 20 A and the vertical rolls 24 B, 24 B in the vertical roll stand 20 B are both flat rolls having outer diameters substantially constant along their entire lengths in the center axis direction. These realize not only reduction in a distance between adjacent stands but also ease of avoidance of interference between rolls in the adjacent stands. This makes a roll gap in each stand independently adjustable in a wide range. Moreover, even with a reduced gap between the adjacent stands, it is still possible to use a flat roll of a relatively large diameter to avoid winding of the tube member around the roll and avoid increase in invasion resistance to be cause by such winding.
  • a rolling amount distribution oriented to forming performance can be set in consideration of a springback amount to be changed by the outer diameter, material, or thickness of a forming raw member, for example.
  • a tube member invasion resistance is inherently controlled low in the roll stand array 10 , and the horizontal rolls 24 A, 24 A are driven to rotate in each of all the horizontal roll stands 20 A to apply thrust to the entire length of a tube member to pass through the roll stand array 10 .
  • the tube member is still passed smoothly through the roll stand array 10 .
  • the extremely shallow arc-like recesses having larger curvatures than the roll contact surface R of the tube member to pass through between rolls are formed at the outer circumferential surfaces of the horizontal rolls 24 A, 24 A in each horizontal roll stand 20 A and at the outer circumferential surfaces of the vertical rolls 24 B, 24 B in each vertical roll stand 20 B.
  • particularly large thrust is applied to the tube member while the tube member passes through the stands.
  • the tube member to pass through the roll stand array 10 is subjected to bending forming applied from two directions using the flat horizontal rolls 24 A, 24 A and the flat vertical rolls 24 B, 24 B to form a corner portion.
  • This functions, in addition to the smooth passage of the tube member, to enhance forming performance, thereby manufacturing a high-quality square tube.
  • the square tube having a predetermined sectional curvature is manufactured in the absence of a thickness reduction at the corner portion.
  • the absence of thickness reduction at the corner portion eliminates a need to assume the occurrence of thickness reduction in the dimension of a forming raw tube, thereby achieving the effect of reducing the diameter of a base tube or the effect of giving substantially equal thicknesses to a round tube and a square tube to be manufactured.
  • the horizontal roll stand 20 A and the vertical roll stand 20 B are arranged alternately to suppress interference between rolls in adjacent stands. Further, only the horizontal rolls 24 A, 24 A in the horizontal roll stand 20 A are driven to rotate while the vertical rolls 24 B, 24 B in the vertical roll stand 20 B are free rollers. Thus, interference between members in the adjacent stands is suppressed to a greater extent. As a result, the entire length of the roll stand array 10 is controlled to a short length to facilitate retention of space for arrangement of the device in a tube manufacturing factory. Moreover, the weight of the device is reduced to encourage reduction in manufacturing cost.
  • a gap between rolls in the horizontal roll stand 20 A and a gap between rolls in the vertical roll stand 20 B are adjusted for each horizontal and vertical stand pair 20 using a pair of the movable horizontal roll gap adjusting motor 50 A and vertical roll gap adjusting motor 50 B in combination.
  • the horizontal roll gap adjusting motor 50 A and the vertical roll gap adjusting motor 50 B are shared between a plurality of the horizontal and vertical stand pairs 20 . This simplifies the configuration of the square tube forming device, resulting in reduction in the weight of the device and further reduction in cost of manufacturing the device.
  • analysis result about two square tube forming examples will be described in detail as examples of the present invention.
  • Analysis software used for obtaining the analysis result is 3D elastic-plastic deformation finite analysis software developed by the present inventors having accuracy sufficient for reproducing actual forming.
  • These drawings are schematic drawings generated on the basis of result output from this software.
  • FIG. 5 continuously and entirely shows a square tube forming process implemented in the flat roll stand array according to the square tube forming example 1
  • FIG. 6 shows change in a tube cross-sectional shape from a round tube as a forming raw member to a square tube as a product in stages of respective stands according to the square tube forming example 1.
  • FIG. 7 continuously and entirely shows a square tube forming process implemented in the flat roll stand array according to the square tube forming example 2
  • FIG. 8 shows change in a tube cross-sectional shape from a round tube as a forming raw member to a square tube as a product in stages of respective stands according to the square tube forming example 2.
  • the roll outer diameters are shown at the same ratio in FIGS. 5 and 7 to facilitate comparison between the sizes of the outer diameters of the raw tubes.
  • the flat roll stand array used in the square tube forming examples 1 and 2 has a configuration conforming to the square tube forming device shown in FIGS. 1 to 4 .
  • this roll stand array includes 24 rolls with 12 pairs of vertical roll stands and horizontal roll stands in total arranged alternately.
  • a roll diameter in each roll stand is 150 mm, and the roll stand array has an entire length of 4660 mm.
  • the 12 pairs of roll stands each including a vertical roll stand and a horizontal roll stand in one pair were divided into three groups with one group including four pairs, and an individual rolling amount was set for each of these groups.
  • a shallow arc-like recess having a larger curvature than an outer surface R of a roll contact surface of a tube member to pass through each roll stand is formed at each roll.
  • a ratio of 9:3:1 was set for the first group, for the second group, and for the third group respectively.
  • the rolling amount distribution was determined in such a manner as to perform forming of a rolling amount of 9/13 (about 69.3%) in the first group, to perform forming of a rolling amount of 3/13 (about 23%) in the second group, and to perform forming of a rolling amount of 1/13 (about 7.7%) in the third group.
  • the same rolling amount is set for a vertical roll and a horizontal roll in a pair, and as a result of planarization of side sections, four corners of the regular square cross section are formed.
  • a rolling amount distribution was also set to provide a ratio of 9:3:1 for the first group, for the second group, and for the third group respectively.
  • a position to become a corner can be set by determining a rolling amount for a vertical roll and a horizontal roll in a pair in such a manner as to be larger on the vertical side and to be smaller on the horizontal side.
  • a position to become a corner can be set by determining a rolling amount for a vertical roll and a horizontal roll in a pair in such a manner as to be larger on the vertical side and to be smaller on the horizontal side.
  • a rolling amount is distributed in the foregoing manner for reason of employing a forming process of performing planarization of side sections readily in the first group on the upstream side for corner forming, continuously performing the planarization of the side sections gently in the second group on the midstream side for the corner forming, and obtaining intended dimensions in the third group on the downstream side.
  • such a rolling amount distribution is employed by giving consideration to intended dimensions of a product. Allowing employment of a forming process responsive to such product specifications according to circumstances forms the characteristic of the present invention.
  • a range of roll multi-use defined by a model for analysis is such that an outer diameter ratio is up to three times and an aspect ratio is up to three times. Result obtained from the analysis shows that manufacturing an actual machine and actually operating the machine produces the same effect.
  • While roll stands in a flat roll stand array are divided into three groups with one group including one pair ⁇ 4 (eight stands), these roll stands may alternatively be divided into four groups with one group including one pair ⁇ 3 (six stands), into six groups with one group including one pair ⁇ 2 (four stands), or into 12 groups with one group including one pair ⁇ 1 (two stands).

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)
US17/046,460 2018-04-13 2019-04-12 Square tube forming method and square tube forming device Abandoned US20210170465A1 (en)

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JP2018-077349 2018-04-13
JP2018077349 2018-04-13
PCT/JP2019/015917 WO2019198805A1 (ja) 2018-04-13 2019-04-12 角管成形方法及び装置

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JPH0634810U (ja) * 1992-10-09 1994-05-10 住友重機械工業株式会社 角管曲り矯正装置
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JP2004243367A (ja) * 2003-02-13 2004-09-02 Aisin Seiki Co Ltd ロール成形装置の調整方法，ロール成形装置の調整装置
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JP6839786B2 (ja) 2021-03-10
WO2019198805A1 (ja) 2019-10-17

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