US3187539A

US3187539A - Roll forming of sheet material

Info

Publication number: US3187539A
Application number: US29671A
Authority: US
Inventors: Richard H Shultz; Ruhl T Schenck
Original assignee: Continental Can Co Inc
Current assignee: Continental Can Co Inc
Priority date: 1960-05-17
Filing date: 1960-05-17
Publication date: 1965-06-08
Anticipated expiration: 1982-06-08

Description

J1me 1965 R. H. SHULTZ ETAL 3,187,539

ROLL FORMING OF SHEET MATERIAL Filed May 17. 1960 2 Sheets-Sheet 1 RIC/MRO H SHUL rz Rum. 7. SCHENCK mmvroxs ATTORNEYS June 8, 1965 R. H. SHULTZ ETAL 3,187,539

ROLL FORMING OF SHEET MATERIAL Filed May 17, 1960 2 Sheets-Sheet 2 RICHARD H Sam 72 s, Rum. 7. 5CHENCK 30 INVENTORS ATTORNEYS ROLL FORMING OF SHEET MATERIAL Richard H. Shultz, La Grange, and Ruhl T. Schenck,

Chicago, Ill.,.assignors to Continental Can Company, Inc., New York, N.Y., a corporation of New York Filed May 17, 1960, Ser. No. 29,671 8 Claims. (Cl. 72-180) This invention relates in general to new and useful improvements in the art of forming cylindrical members of sheet material, and more particularly relates to a novel method of roll forming sheet material in the forming of can bodies.

In the operation of a conventional can body maker, the sheet metal blank is moved'longitudinally until it is in transverse alignment with a set of roll-s, at which time it must be stopped. The direction of movement of the body blank is then changed 90 degrees to put it through the set of rolls, after which it is again stopped. The curved blank then has its direction of movement again changed 90 degrees so that it may continue in its original direction through the remainder of the canwbody maker. It is, of course, apparent that it i undesirable to change directions of and to start and stop the movement of materials in a forming operation wherein the forming operation is carried out at high speeds.

In view of the foregoing, it is an object of the inven- .tion to provide a novel set of rolls wherein a can body blank or a similar blank may be moved longitudinally through the rolls ina continuous operation and the material of the body blank is so stressed that as it exits from the rolls, it begins to assume a generally cylindrical shape with the axis thereof disposed in the general direction of movement.

Another object of the invention is to provide a novel set of rolls through which a blank may be passed in a longitudinal direction, and which rolls are so configurated to result in the plastic deformation of areas of the blank in the manner that as the blank exits from the set of rolls, the plastic deformation of the areas of the blank Will result in the blank assuming a generally cylindrical shape having an axis extending longitudinally of the direction of movement of the blank through the rolls.

Another object of the invention is to provide a novel method of roll forming sheet material, such as can body blanks, wherein the sheet blank material is passed between two rolls and while within the rolls, alternating areas thereof are subjected to plastic deformation andlelastic deformation so that the stresses within the metal of the fiat blank will result in the blank assuming a circular cross-section as it is progressively released by the rolls.

Another object of the invention is to provide a novel can body or other type of tubular member which is selfretaining in its tubular shape due to the existence of areas of plastic deformation.

A further object of the invention is to provide a novel tubular member, such as a can body, wherein the tubular member has been formedfrom a flat sheetblank and the circular cross-section thereof is accomplished by subjecting areas of the blank to plastic deformation, the areas of plastic deformation being in the form of two sets eX- tending spirally about the tubular member and disposed in crossing relation, the areas of plastic deformation both effecting the shaping of the metal and functioning as a decoration thereto. 7 p

Still another object of the invention i to provide a novel method of forming can bodies wherein a can body blank is first passed between a pair of rolls and areas thereof are subjected to plastic deformation so that as the blank passes through the rolls, the blank will be shaped through the formation of the plastic deformed areas into a partial circular cross-section with theaxis thereof exblank through the, rolls.

Patented June 8, 1965 the can .body will have a true circular cross-section.

With the above, and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following de tailed description, the appended claims, and the several views illustrated in the accompanying drawings:

In the drawings: l

FIGURE 1 is a schematic perspective view showing a flat sheet blank passing between rolls of a set of rolls formed in accordance with the invention, withthe blank having areas thereof deformed, alternating ones of the areas being subjected to plastic deformation and the others being subjected to elastic deformation wherein as the sheet material passes out from between the rolls, it assumes a' generally cylindrical shape.

FIGURE 2 is an enlarged fragmentary vertical seetional view taken through the mating portions only of the rolls, and shows the specific configuration thereof, and the shaping of the sheet material while within the rolls, intermediate portions of the rolls and sheet material being omitted.

FIGURE 3 is a perspective view of a cemented can body formed in accordance with the invention.

FIGURE 4 is a transverse sectional view taken through ;-the can body of FIGURE 3 and shows the cross-section thereof, r 1

FIGURE 5 is an enlarged transverse sectional view showing-a modified shaping of the blank wherein the tubular cross-section is-incomplete.

FIGURE 6 is an enlarged view similar to FIGURE 5, and shows a form of shaping wherein the edges of the blank abut one another in the forming of a complete circle.

FIGURE 7 is an enlarged perspective view of a modified form ofcan body similar to that of FIGURE 3, but

wherein the areas of plastic deformation are arranged in two sets extending spirally about the can body in crossing relation, and the areas of plastic deformation defining an ornamental pattern to enhance the appearance of the can body. V

FIGURE 8 is a fragmentary developed view of a roll which may be used in the forming of the can body of FIGURE 7.

It is well known to pass a flat blank through a pair of rolls to effect a curving of the flat blank and with the longitudinal axis of the resultant curved article being disposed at right angles to the direction of movement of the However, when this arrangement is used in a can body maker, for example, it isnec- .essary that the blank be stopped and started twice, and -that ,it changes direction ofmo-vement degrees twice.

This,i of course, is undesirable in that it is highly desirable to eliminate all stopping and starting of movement of can body blanks to thus eliminatereciprocating forces and increase the speed of movement of the blank through the can body maker; It is to this end that the present cular shape having an aXis disposed longitudinally .of the I direction of movementof the blank.

Reference is made to FIGURE 1, wherein a conventional can body blank B or a similar blank is illustrated. The blank is provided in a flat state and is normally 9 formed of sheet metal. The blank B is passed between a 1 pair of rolls 10 and 1 1, and asit passes between the rolls structure.

10, 11, the material of the blank B is stressed in a manner to effect the movement of the material of the blank into a generally cylindrical shape as it exits from between the rolls and 1 1. It is-t-o be understood thatv the configurations of the rolls 10, 1.1 are only schematically illustratecl in 'FIGURE -l, and the true section of each rolling surface of the two rolls is best illustrated in FIG- URE/2. I

The roll 11 is formed of a nonyielding material and 'is very rigid, The roll 1-1 is provided with annular ribs 12 which are disposedat spaced intervals along the length of the roll 11. Each rib 12 is relatively narrow and has generally semi-circular cross-section. Thus, each rib 12 presents an arcuate sheet engaging surface. The roll 11 is substantially flatbetween adjacent ones of the ribs 12.

The roll 10, which roll is disposed uppermost, has a surface defined by a plurality of closely spaced, relatively wide ribs 13. V The ribs..13 are also of a partially circular cross-section so as to present an arcuate sheet engaging surface; The radius of curvature'of each of the ribs 13 is much greater than that of each of the ribs 12, It

is to be noted that the intersection between adjacent ribs 13 defines generally recessed V-areas 14. i

The ribs 12 and Bare disposed in opposed staggered relation. The ribs 12 generally seat within the V-areas 14,.and the ribs 13 generally seat in the flattened areas between the ribs 12. i

As the blank B passes between the

rolls

10, 11, the

"material thereof 'is shaped over the

ribs

12 and 13;; The

ribs12 being relatively sharp as compared to the ribs 13,

as the blank B is shaped over the ribs 12, there is set up in the blank B localized areas having plastic deformation. On the other hand, the curvature of the ribs 13 is relatively fiat, with the result that the portions-0f the blank B shaped over the ribs 16 are subject only to elastic deformation. It is to be understood that the deformations of the blank B are greatly exaggerated in FIGURE 2,

and that actually the numerous deformations are so minute that in most instances, even the areas of formation are not readily ascertainable.

As the metal of the blank B passes from between the 7

rolls

10, 11, it'progressively stress relieves itself and forms into a cylindrical shape. Thefinal shape of the originalblank B maybe cylindrical having abutting of the edges of the original blank, cylindrical with overlapped edges, or that of only a partial cylinder, the edges of the blank being spaced apart. These three alternatives are illustratedin FIGURES 6, 4 and 5, respectively;

The shaping of the blank B by passing it between the rolls 1t), 11 may function equally as well-in a can body having a hooked and lapped seam, one having a lapped seam, or one having a welded seam. In the case of the lapped seam, the lapped edge portions of the original plastic de- 7 for bumping, in the case of a can body having a lapped and locked seam, cementing inthe case of a lapped seam, and welding in the case of either a lapped or butt seam. When the blank B initially assumes its tubular shape, it has visual surface irregularities along the lines of plastic deformation. However, the stressing of the partially formed blank .of FIGURE 5 in a'conventional can body maker will result in the disappearance of the visual surface irregularities, and the .can body'will have a true circular cross-section.

Inthe blank shaping operation herein described, the

i ribs

12,13 extend annularly about the

rolls

10, 11, respectively, with the result that the-areas of plastic deformation and elastic deformation extend longitudinally of the can body. However, it is not necessary that the areas of deformation extend longitudinally of the can body. If desired, the areas of deformation may extend spirally about the can body, and it is preferred that two sets of spirals be disposed in crossing relation, as is best illustrated in FIGURE 7. Such an arrangement provides a can body which is not subject'to' paneling, as is the case of the can body formed with the rolls 1%, 11.

Further, the particular spiral crossing arrangement of the areas of plastic deformation provides a highly ornamental design on the exterior surface of the can body so as to enhance the appearance of the can body. The

numerous lines on the surface of the can body 17 indicate can body in FIGURE 7 is referred to, by the numeral 18 and is shown as having a lapped seam 19. However, the seam could be butt or lapped and locked, if desired. The

' lines or areas of plastic deformations, the lines being referred to by the numeral 20. I

In. FIGURE 8, there is illustrated a fragmentary developed view of a roll which corresponds to the roll 11,

but is specifically designed for effecting the deformation of the material from which the-can body 18 is formed.

This latter roll is referred to in general by the numeral 21 and differs from the roll 11' in that it is provided with two sets of ribs 22 which are'spirally arranged and which are disposed in crossing relations. The roll '21 may be used in conjunctionwith either another rigid' roll corresponding to the roll 10, butconfigurated to match the roll blank may be secured together either by cementing or Welding, as desired. A typical lapped seam can body is illustrated in FIGURE 3 and is referred to by C. The "details of the lapped edges are clearly shown in the sectional view of FIGURE 4. The can body C may be shaped entirely by the use of

therolls

10,11, with the shape being maintained only during the cementing operation by a suitable holding means in a conventional manner, or the shaping and cementing of the can body C may be atleast partially accomplished in a conventionallcan body maker. i

Reference is now made to FIGURE 6 wherein a sectional viewtaken through a modified. formofcan body C isillustrated. The edges of the'sheet material are,

abutted together as at 15 and may be secured togetherby a welding operation or by other securing. means.- The abutting together of the edges of the sheet material may either be accomplished byprimarily utilizingthe set of rolls 1t 11 and suitable guide means, or by utilizing the set ofrolls together with a conventional canbody maker 21, or it may be used in conjunction with a resilient roll,

such as one having a hard rubber facing layer. Further,

it is to be understood that the roll 11 could be used with a plain roll having a hard rubber facing layer in lieu of the roll 10. However, the roll 10 assists in the deforming of the material of the blank B.-

From the foregoing, it will be seen that novel and advantageous provision has been made for carrying out the desired end. However, attention is again directed to the fact that variations may be made in the example ,rnethod and apparatus disclosed herein without departing from the spirit and scope of theinvention, as defined in i the appended claims.

We claim:

1. A method of shaping a fiat sheet blank into a tubular shape comprising the steps of longitudinally feeding. the blank, progressively subjecting spaced areas of the'blank while inaflat state to forming forces normal to the direction of feedto plastically deform the blank and effective to cause the blank to tend toassume a generally circular cross section with the axis thereof normal to the forming forces and parallel to the directionof feed, and

. releasing the stressed portion of the blank to permit the In FIGURE 5, the blankB has been any partially shaped and. the cross-section thereof is a partial circle,

,blank to assume a generally circular cross section.

2. A method of rolling a flat sheet blank into a tubular.

shape comprising the steps 'o-f longitudinally feeding the blank .between opposed .rolls, progressively subjecting spaced areas of the blank while in a flat state to plastic deformation within the rolls effective to cause the blank to tend to assume a generally circular cross section with the axis thereof normal to the axes of the opposed rolls, and releasing the stressed portion of the blank to permit the blank to assumea generally circular cross section.

3. A method of shaping a fiat sheet blank into a tubular shape comprising the steps of longitudinally feeding the blank, progressively subjecting spaced diagonally extending and crossed areas of the blank while in a fiat state to forming forces normal to the direction of feed to plastically deform the blank and effective to cause the blank to tend to assume a generally circular cross section with the axis thereof normal to the forming forces and parallel to the direction of feed, and releasing the stressed portion of the blank to permit the blank to assume a generally circular cross section.

4. A method of rolling a flat sheet blank into a tubular shape comprising the steps of longitudinally feeding I the blank between opposed rolls, progressively subjecting spaced diagonally extending, and crossed areas of the blank while in a flat state to plastic deformation within the rolls efiective to cause the blank to tend to assume a generally circular cross section with the axis thereof normal to the axes of the opposed rolls, and releasing the stressed portion of the blank to permit the blank to assume a generally circular cross section.

5. A method of rolling a flat sheet blank into a tubular shape comprising the steps of longitudinally feeding the blank between opposed rolls, progressively subjecting longitudinally extending alternating areas of the blank while in a flat state to plastic deformation effective to cause the blank to tend to assume a generally circular cross section with the axis thereof normal to the axes of the opposed rolls, and releasing the stressed portion of the blank to permit the stressed portion to stress relieve itself and assume a generally circular cross section.

6. A method of forming a can body from a fiat sheet blank comprising the steps of longitudinally feeding the blank between opposed rolls, progressively subjecting spaced areas of the blank to plastic deformation within the rolls effective to cause the blank to tend to assume a generally circular cross section, releasing the stressed pertion of the blank to permit the blank to assume an open.

partially circular cross section, and then stressing the blank to its finished circular form through a conventional can body making operation in a conventional can body maker thereby eliminating visual evidence of the areas of plastic deformation.

7. A cylinder-forming roll assembly comprising a set of opposing rolls, a path normal to and from the axis of each roll of the set of opposing rolls whereby a flat sheet blank may be'transported to, between and from the rolls along said path, one roll of said set of opposing rolls being provided with first means cooperative with complementary second means on another roll of said set of rolls, said first means and said complementary second means being constructed and arranged to progressively plastically deform-a flat sheet blank along linearly extending areas thereof for curling lateral edges of the blank toward each other about an axis parallel to said path whereby said fiat sheet blank is formed into a cylinder along the path extending from and normal to the axes of said rolls, said first means comprising a plurality of widely spaced projecting narrow ribs for plastically deforming the flat sheet blank from one side, and the complementary second means comprising a plurality of closely spaced wide ribs in staggered mating relation with said narrow ribs.

8. The cylinder-forming roll assembly of claim 7 wherein said narrow ribs and said wide ribs having arcuate sheet engaging surfaces.

References Cited by the Examiner UNITED STATES PATENTS 2,006,827 7/35 Feller 220-83 2,075,286 3/37 Jackes.

2,277,725 3/42 Smith et al. 153-77 2,352,675 7/44 Yoder 153-28 2,391,766 12/45 Barnhart 29-534 2,438,844 3/48 Pale 220-83 2,471,490 5/49 Mercer 153-28 2,702,429 2/55 Peters et a1 29-534 2,986,193 5/61 Howell 155-77 CHARLES W. LANHAM, Primary Examiner.

NEDWIN BERGER, Examiner.

Claims

1. A METHOD OF SHAPING A FLAT SHEET BLANK INTO A TUBULAR SHAPE COMPRISING THE STEPS OF LONGITUDINALLY FEEDING THE BLANK, PROGRESSIVELY SUBJECTING SPACED AREAS OF THE BLANK WHILE IN A FLAT STATE TO FORMING FORCES NORMAL TO THE DIRECTION OF FEED TO PLASTICALLY DEFORM THE BLANK AND EFFECTIVE TO CAUSE THE BLANK TO TEND TO ASSUME A GENERALLY CIRCULAR CROSS SECTION WITH THE AXIS THEREOF NORMAL TO THE FORMING FORCES AND PARALLEL TO THE DIRECTION OF FEED, AND RELEASING THE STRESSED PORTION OF THE BLANK TO PERMIT THE BLANK TO ASSUME A GENERALLY CIRCULAR CROSS SECTION.