WO2007044327A2 - Continuous process of roll-forming stamped sheet - Google Patents
Continuous process of roll-forming stamped sheet Download PDFInfo
- Publication number
- WO2007044327A2 WO2007044327A2 PCT/US2006/038609 US2006038609W WO2007044327A2 WO 2007044327 A2 WO2007044327 A2 WO 2007044327A2 US 2006038609 W US2006038609 W US 2006038609W WO 2007044327 A2 WO2007044327 A2 WO 2007044327A2
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- WO
- WIPO (PCT)
- Prior art keywords
- strip
- roll
- forming
- press
- dies
- Prior art date
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- 238000010924 continuous production Methods 0.000 title description 8
- 239000000463 material Substances 0.000 claims abstract description 124
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- 238000012986 modification Methods 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 229910000797 Ultra-high-strength steel Inorganic materials 0.000 description 2
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- 239000002184 metal Substances 0.000 description 2
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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
- 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
-
- 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
- B21C37/08—Making tubes with welded or soldered seams
- B21C37/0815—Making tubes with welded or soldered seams without continuous longitudinal movement of the sheet during the bending operation
-
- 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
- B21C37/083—Supply, or operations combined with supply, of strip material
-
- 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
- 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
- B21C37/18—Making tubes with varying diameter in longitudinal direction conical tubes
- B21C37/185—Making tubes with varying diameter in longitudinal direction conical tubes starting from sheet material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
- B21D5/06—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles
- B21D5/08—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles making use of forming-rollers
- B21D5/086—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles making use of forming-rollers for obtaining closed hollow profiles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
- B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
- B60R19/18—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by the cross-section; Means within the bumper to absorb impact
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C3/06—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal with substantially solid, i.e. unapertured, web
- E04C3/07—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal with substantially solid, i.e. unapertured, web at least partly of bent or otherwise deformed strip- or sheet-like material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
- B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
- B60R19/18—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by the cross-section; Means within the bumper to absorb impact
- B60R2019/1806—Structural beams therefor, e.g. shock-absorbing
- B60R2019/1813—Structural beams therefor, e.g. shock-absorbing made of metal
- B60R2019/1826—Structural beams therefor, e.g. shock-absorbing made of metal of high-tension steel
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C2003/0404—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects
- E04C2003/0426—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by material distribution in cross section
- E04C2003/0439—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal beams, girders, or joists characterised by cross-sectional aspects characterised by material distribution in cross section the cross-section comprising open parts and hollow parts
Definitions
- the present invention relates to a continuous process of roll-forming pre-stamped varying shapes, and more particularly relates to a process combining a stamping/deforming process with a roll-forming apparatus to obtain advantages of both in a continuous process.
- the roll-forming process has many benefits that make it a cost-effective method of manufacturing tubular beams.
- Some advantages of roll-forming include the abilities to form high strength steels and Ultra High Strength Steels (UHSS).
- Pre-pierce, mid- pierce, and/or post-pierce operations can be used on flat sections of the sheet material oerore ron-iorming.
- AISO, operations can oe uone in-line wiin me ron-rormmg process, such as in-line welding and cutoff.
- roll-forming has limitations, such as the inability to change material properties within the part and the inability to change the cross section along the length of the part.
- the inability to change the cross section along the length of the part typically results in excessive material being used in areas where it is not needed to meet performance requirements in other areas where it is needed.
- the excessive material also adds to the weight of the part and to material cost.
- testing and computer analysis shows that a tubular beam that is constrained at its ends and loaded in the center will exhibit a free body diagram where greater section depth, (i.e., moment of inertia) at the beam's center produces a stiffer beam.
- the inability to change the cross section of a roll-formed tubular beam along its length results in a tubular beam with a constant moment of inertia.
- the constant moment inertia results in excess material and geometry in areas along the length of the tubular beam that do not contribute to the overall bending stiffness of the beam.
- stamping processes have an advantage over roll-forming in that beams with nonuniform cross sections can be made.
- stamping operations are limited and generally less efficient than roll-forming since individual sheet blanks must be laterally moved and accurately positioned after each die stroke.
- dies cannot make tubular beams without significant difficulty or complexity, or with secondary operations.
- high strength and ultra high strength sheet material is very wearing on dies depending on the amount of shape deformation being imparted onto the sheet material and depending on a strength of the material.
- Typical (most) stamping press methods for forming metals can be referred to as cold stamping.
- cold stamping the material is formed between dies, with the material and dies being kept generally at room temperature.
- hot stamping Another type of forming.
- hot stamping processes the metal is heated to its austenite temperature (Ac3) and then cooled rapidly after forming is completed in the die. The required austenite temperature and time required to quench the material are dependent on the cnei ⁇ isiry oi me inaienai, aim me ⁇ nai properties ⁇ esireu.
- the above-described hot stamping technique tends to be an intermittent "stop-and-go" process which historically is not considered to be well-suited for use in a continuous processes operating at relatively high line speeds (i.e. not well-suited for being used in-line with rollforming equipment). Further, I, the present inventor, am not aware of anyone combining stamping with rollforming, for the reasons discussed above.
- an apparatus adapted to form a reinforcement beam includes a press having dies configured to deform a flat strip of heated metal material into a deformed strip with a three-dimensional shape by drawing and moving material, and a cooling system associated with the press and configured to cool the heated metal material of the deformed strip.
- a roll-former is located downstream of the press and cooling system and has rolls configured to shape edge portions of the deformed strip into a continuous beam.
- an apparatus adapted to form a reinforcement beam includes a heater configured to heat steel material to a temperature of at least about 85O 0 C.
- a press includes dies configured to deform a continuous strip of hot steel material.
- a cooling system is associated with the press for quenching and hardening the hot steel material.
- a roll-former is positioned in-line with the press and downstream of the cooling system and has rolls configured and arranged to receive the strip in the feed direction and shape edge portions of the deformed strip into a reinforcement beam. Luuxv j xii tujujuj.wj.
- the method further includes quenching the stamped sheet to cause the material to have a higher tensile strength.
- the method still further includes roll-forming portions of the stamped sheet by use of a roll-forming mill into a beam.
- a method of forming a reinforcement beam comprises steps of providing a heater, providing a press including forming dies at a location downstream of the heater and also a cooling system associated with the press, and providing a roll-former having rolls in-line and downstream of the press.
- the method includes heating a strip of material, operating the dies to deform the strip of material by drawing the hot material and thereafter quickly cooling the material, and operating rolls of a roll-forming mill to receive the strip in a feed direction and shape edge portions of the deformed strip into a reinforcement beam.
- Fig. 1 is a flow chart showing a process embodying the present invention.
- Fig. IA is a side view of an apparatus incorporating a roll-forming mill, a stamping station, a welding station, and a sweeping station for the process of Fig. 1.
- FIG. 2 is a side view of a vehicle bumper beam embodying the present invention.
- Figs. 3-6 are cross sections taken through Fig. 2.
- Fig. 7 is a side view of the vehicle bumper beam after being roll-formed but prior to being longitudinally swept.
- Fig. 8 is an end view of the beam of Fig. 7 moving through an exemplary roll- forming station, the view showing the beam, the rolls, and a weld joint.
- FIGs. 9-9A are a flow chart and side view of a corresponding machine similar to
- Figs. 1 and IA but adapted for hot stamping steel sheet material prior to the roll forming portion of the machine.
- the current invention defines a way to produce roll-formed tubular beams with varying cross sections from high-strength sheet material, such as materials of over 80 ksi tensile strength and even ultra-high-strength steel of over 140 ksi tensile strength (sometimes called "UHSS” or "AUHSS" material).
- a DP980 (DF140) material has successfully been used.
- the ability to change cross sections along the length of the beam is achieved by combining a pre-forming process via stamping with the roll-forming. The stamping process and roll-forming operations are done in-line and sequentially.
- the stamping press is used to preform material as well as pre-pierce the sheet material and add features before it travels through the roll-forming tooling.
- the stamping of the material while it is in the flat produces a shape with varying depth and geometry across the length of the part.
- the formed shape could represent the rearward section of a tubular bumper section.
- the stamping press that combines the stamping of features and forming of varying shapes would have a greater tonnage than a typical pre-pierce press that stamps features into the material.
- the present stamping press would also have to include stamping dies beyond the required punches and buttons necessary for the stamping of features.
- UHSS shape when formed by UHSS material is formed primarily by moving material and not stretching or extruding the material.
- Materials such as UHSS have high yield and tensile bucuguis auu. HI iuiii a l ⁇ w ei ⁇ iigau ⁇ u. me l ⁇ w ciuugauuii translates ⁇ irecuy iu low ductility which prohibits the forming through material thinning, i.e., extrusion/drawing.
- the material that is used to form the shape during the stamping process draws from the width of the coil and not down the length of the coil.
- the width of the coil that feeds the stamping press will be oversized to allow for shape forming via stamping and still provide sufficient blank width for the roll-forming operation which is used to finish the shape into a tubular geometry.
- relief slots will need to be introduced at the ends of the formed shape. These slots will assist in forcing material from the edges of the blank width and not down the length of the formed shape. The relief slots also will maintain blank flatness of the unstamped non- deformed areas of the blank before and after the shape is stamped into each part.
- the forming operation in the press will produce an irregular width blank since material moves across the coil width and will need to be resized before the material can pass through the roll-former.
- Roll-forming uses the edges of the material to guide the material from pass to pass and to trap the material while bending is being performed at each of the passes.
- the resizing of the blank width can be done at one or more locations along the manufacturing process. It is contemplated that the irregular blank will be slit immediately after the material leaves the stamping press. The slitting operation may have to be offset where one edge is slit and then used as a reference edge to slit the other edge.
- the material can also be slit after one or more of the early passes of the roll- former operation. It is contemplated that there may be some advantages to begin some initial forming in the roll-form mill before the irregular blank is resized with a slitting operation and before the roll-forming process is finalized.
- An additional option is to resize the irregular blank in a station of a multiple station stamping operation.
- One option would be to have the bed of the stamping press be at least twice the length of a typical part, or the other option would be to use two presses in-line. It is envisioned that the first station of the stamping press or the first press would stamp the relief slots needed at the ends of the part length and form the complete shape. The second station of the press or the second press would stamp features (holes, slots, etc..) into the formed shape and trim the irregular blank to a size appropriate for the roll-forming process which will finish the part into a tubular beam section with varying cross-sectional geometries along the length of the part.
- the die is configured to travel with the material, (i.e., flying pre-pierce die).
- the forming die would be configured to stamp while moving longitudinally along with the moving material, i.e., flying die configuration.
- the shape-forming die is too heavy to move with the material, it may become necessary to accumulate the material after the press and before the roll-forming process.
- stop-start process Another option for excessively heavy dies would be to forgo the accumulation of material after the press and use a stop-start process with the roll-forming operation.
- Roll-form mills can be run successfully and efficiently using a stop-start repetitive motion, but stop-start motion is not a very complimentary process if in-line high frequency induction welding is used.
- a stop-start process may be more suited for either laser welding or contact welding.
- the formed shape and either the untrimmed blank or the trimmed blank can now be fed into the roll-forming process.
- the roll-form tooling would be designed to provide clearance for the formed shape. It is envisioned that only upper roll tooling be used to complete constant part geometry via roll forming, with the stamp formed perimeter of the part would be supported while the rest of the perimeter is roll formed. It is envisioned that the depth of the formed shape and the shape itself would change along the length of the part.
- the width at some given location and most preferably a location near the transition between the stamped formed section and the roll-formed section would remain constant along the length of the part. This common width is important because it provides a location where the material can be constrained as the remaining material is formed in the roll-forming process.
- the individual legs of the part are brought to a point of contact via the roll- forming process and at this point, the two individual legs are welded to form a one-piece tubular part with varying cross sections along the length of the part.
- Welding can be done in various ways where the type of the welding process used is based on numerous l ⁇ u ⁇ ia, i.e. , gcumcuy, ucsucu vyvic LUUC, CU;. . . . upnons ior wei ⁇ ing may inciu ⁇ e high frequency induction welding, contact welding, or laser for tubular section.
- Other welding options such as impulse seam welding (rotary spot), plasma arc welding, or laser may be more suitable for irregular shaped geometries. All of these welding methods are widely used today to produce commercially available tubular and irregular shapes of constant cross section.
- An automotive bumper beam typically requires some degree of curvature which is complimentary to vehicle styling. As styling changes and becomes more aggressive, a bumper beam with multiple radii becomes easier to package in the available envelope. Imparting of multiple radii in a bumper beam is referred to as a compound swept bumper. This ability to produce compound swept bumper beams in-line and during the manufacturing process can be accomplished with an apparatus that uses servos, is driven, and is computer controlled. This type of apparatus allows for real time adjustment of a bending roller which is used to impart curvature into the beam. Because of the real time adjustment of the bending roller, multiple radii can be imparted at given locations along the length of the beam. The last in-line operation is to cut the beam section to length.
- the cutoff operation can be done in various ways.
- the most common method of cutting bumper beams to length is to use a flying cutoff apparatus.
- a flying cutoff will travel with the part and perform the cut-off operation as the part is moving at line speed.
- a typical flying cut-off apparatus would include part clamping steel forms, air or hydraulic cylinders, and shearing blade.
- the uniqueness of the present invention is the ability to produce a one-piece roll- formed structural beam or an open section roll-formed structural beam that has varying cross section along the length of the part.
- the ability to change the cross section along the length of the beam is achieved by the use of a forming die and a stamping press positioned upstream and in-line with the roll-forming process.
- the innovative design of the roll tooling allows the stamped pre-formed shape to move its coplanar flat edge sections through the individual roll-forming passes freely without distortion or shape change of its now-stamp-formed center section. Each pass of the roll-forming process continues to form the material of the edge sections into a final shape that incorporates the stamped form.
- the same concept can be applied to open sections where the stamping operation imparts an irregular shape across the length of the part and the roll-forming operations process the rest of the part shape.
- the varying of cross sections along the length of the part provides the opportunity to efficiently use material and geometry to achieve performance requirements.
- the result is a weight and performance optimized structural member that is produced in a continuous cost-effective manufacturing process.
- FIG. 1 is a flow chart showing a process embodying the present invention.
- Fig. IA shows a corresponding apparatus.
- the process starts with a step 30 (Fig. 1) where a coiled sheet 31 (Fig. IA) is unrolled and the uncoiled strip/sheet 32 is fed forward.
- the process proceeds to a step 33 to pre-pierce and shape form the sheet 32 through the use of a stamping press 34 that actuates dies 35 and 36 together against the sheet 32.
- the press 34 and/or dies 35 and 36 preferably are movable laterally along with the sheet 32 during the stamping process and also are relatively fast-acting.
- the roll-forming operation can be slowed or stopped during the stamping operation.
- the dies 35 and 36 are configured and designed to stamp the sheet material, primarily pulling and moving material from a width direction and not from a longitudinal direction of the sheet 32.
- a preferred material is ultra high strength steel (UHSS), which can be bent but basically not drawn or stretched. Accordingly, pulling and moving material laterally (rather than longitudinally) is a significant concept when USHH material is used. Slits in the sheet at each end of a (future) bumper section can be used to reduce longitudinal movement of sheet material during the three-dimensional deformation process of step 33.
- the process proceeds in a step 38 through slitter 39 that slits/cuts edges of the formed sheet 32 to a particular known width dimension, with edge portions of the sheet 32 still in a coplanar flat condition.
- the particular illustrated roll mill 42 has rolls constructed to form the sheet into a tubular shape (see Fig. 7) which is welded in process step 50 at abutting edges 51, 52 (Fig.
- an internal mandrel can be positioned upstream or downstream to help maintain cross sectional shape or to provide support for bending or forming through the roll forming operation.
- the internal mandrel can be anchored at location 54 and an anchoring tie-bar or cord can extend downstream (or upstream) to provide mandrel support. Due to the stamping operation, the middle or lower portion of the cross section changes shape longitudinally and laterally, causing the final cross section of the final beam 72 to vary in a depth dimension and shape along its length (see Figs. 3-6).
- step 60 the continuous welded tubular beam 61 is longitudinally swept as it moves through stabilizing/motivating rolls 49 and a sweep station 62 with adjustable external mandrels 63 and with (if needed) internal mandrels 64. Thereafter, the continuous beam 61 is cut to length in step 70 by a cut-off apparatus 71 into individual beams 72 useful as impact reinforcement bumper beams on a vehicle. The entire process is controlled by a controller for optimal, coordinated, and simultaneous operation.
- Fig. 2 is a side view of a vehicle bumper beam embodying the present invention as it comes off the cut-off apparatus 71.
- Figs. 3-6 are cross sections taken through Fig. 2. Notably, these cross sections are similar to cross sections taken through similar locations in the continuous beam 61 (see Fig. 7) prior to the step of sweeping the beam 61.
- UU35J Jr 1 Ig. 7 is a side view or tne venicie Dumper Deam a ⁇ er oeing ron-rorme ⁇ out prior to being longitudinally swept.
- the top "half" section of the beam is linear and constant in cross section (compare the upper portion of Figs. 3-6 and also see Fig. 8), while the bottom "half" section of the beam is deformed into different three- dimensional changing longitudinal shapes (compare the Figs. 3-6).
- the angled surfaces 73 (Fig. 2) become coplanar and aligned mounting surfaces 74 when the beam 61 is swept to become individual beams 72.
- the coplanar mounting surfaces 74 are adapted to be attached to a front of vehicle frame rails, such as by attachment bolts or fasteners, and can include pre-pierced holes for the attachment bolts and fasteners.
- Fig. 8 is an end view of the beam of Fig. 7 moving through an exemplary roll- forming station, the view showing the beam 61 engaged by bottom forming roll 80 and side containment rolls 81.
- a weld joint 82 found at station 53 is shown at abutting edges 51 and 52.
- Sequential formation of the top "wings" or side flanges 84 of the sheet are illustrated by the positions 85-88.
- the bottom forming roll 80 and/or side constraint roll 81 can also be fully or partially replaced with stationary guide blocks and/or roll(s).
- the present process can be used to manufacture sophisticated beams with non-uniform cross section along their length, allowing the beams to be "customized” and optimized for various applications, such as for interior cross car structural beam, frame components, exterior cross car structural beams, roof bows, windshield header, rocker panels/sills, door beams, engine cradles, and instrument panel supports. It is contemplated that the present concept would be more cost competitive and have a more efficient/higher through-put than hydro-forming processes and also provide design flexibility over stamping processes.
- FIG. 9 A flow chart (Fig. 9) and apparatus (Fig. 9A) are illustrated similar to Figs. 1 and IA respectively, but modified and adapted for hot stamping ahead of the roll forming portion of the machine.
- uncoiled sheet material 32 capable of being hot stamped and quenched for high material strength is heated to a temperature of at least about 850 0 C (and preferably to about 88O 0 C to 95O 0 C, depending on material chemistry) in a step (100) by heaters 101.
- the duration of the heating process can be varied, depending on the BTU capability of the heaters, and depending on whether the process is a stop-start roll forming process or a continuous process.
- a length of the heaters is extended as necessary to match a speed of the machine/process.
- the heaters 101 are positioned immediately prior to the step 33 of piercing and shaping of the sheet 32, at a location adjacent and upstream of the stamping press 34.
- the dies 35/36 are cooled by a coolant system 103 and/or water/coolant is applied by a quenching system 103 to the formed sheet while the formed sheet is still between the dies 35/36 or as the formed sheet exits the dies 35/36.
- the timing of cooling is critical. Cooling must be done before the material temperature drops unacceptably. Typically, the quenching is done during or within seconds of the forming operation, such as by cooled dies and/or coolant applied to the steel while compressed between the dies.
- a typical steel suitable for the hot stamping process is Usinor pre-coated
- USIBOR 1500 The material as received and formed in the press 34 is preferably at a yield strength greater than 370 MPa, preferably at a tensile strength greater than 550 MPA, and has an elongation of greater than 14% .
- the properties of the "as-received" USIBOR 1500 are very suitable for press forming, because the material is able to be drawn (i.e. "stretched” or extruded such that a thickness of the material is reduced). At the same time, the post quench properties of this material are significantly higher; with a yield in the range of 1000 MPa, a tensile strength in the range of 1500MPa, and an elongation in the range of 5%.
- the uniqueness of the present concept includes the ability to combine the benefits of two very different manufacturing processes to produce a more competitive part.
- Benefits include the ability to change cross section along the length of a part.
- Higher part strength and reduced part weight represent benefits that are gained when material properties are increased and cross sections are tubular.
- the stamping process either cold stamping or hot stamping has the ability to vary shape across the part length.
- the hot stamped process has the added ability to work with as received mild steel which is suitable for forming and then transform the material during the processing into a material with extremely high properties. This transformation is achieved after the quenching of the heated and formed steel. This avoids the problems associated with work-hardening which can occur when high strength materials are stamped ... since the sheet material becomes high strength only when quenched after the stamping operation.
- roll forming is used to receive the stamped sheet and finish the forming of the part.
- the gradual forming stages associated with the roll forming process are capable of forming materials of very high strength level, including high strength and ultra high strength steels. This makes roll forming a desirable method for final forming of open or tubular pressed forms that are formed hot in a stamping press.
- the hot stamped process provides greater capability over cold stamping since forming is done with one material grade/strength and the final part is at another higher grade/strength.
- Material as received for the hot stamping processes is generally classified as mild steel and possesses properties very suitable for stamp forming.
- the hot steel is formed and then quenched in the die (or immediately quickly thereafter), which produces a martensitic grain structure and material properties more common to martensitic steels with tensile strengths greater than 1500 MPa.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Bending Of Plates, Rods, And Pipes (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2006302593A AU2006302593A1 (en) | 2005-10-04 | 2006-10-03 | Continuous process of roll-forming stamped sheet |
EP06804304A EP1941111A2 (en) | 2005-10-04 | 2006-10-03 | Continuous process of roll-forming stamped sheet |
CA002624960A CA2624960A1 (en) | 2005-10-04 | 2006-10-03 | Continuous process of roll-forming stamped sheet |
JP2008534623A JP2009509775A (en) | 2005-10-04 | 2006-10-03 | Continuous process for roll forming stamped sheets |
Applications Claiming Priority (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US72339305P | 2005-10-04 | 2005-10-04 | |
US60/723,393 | 2005-10-04 | ||
US11/330,301 US20070095001A1 (en) | 2005-10-04 | 2006-01-11 | Continuous process of roll-forming pre-stamped varying shapes |
US11/330,301 | 2006-01-11 | ||
US11/441,436 US20070074556A1 (en) | 2005-10-04 | 2006-05-25 | Continuous process of roll-forming stamped sheet |
US11/441,436 | 2006-05-25 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2007044327A2 true WO2007044327A2 (en) | 2007-04-19 |
WO2007044327A3 WO2007044327A3 (en) | 2008-07-24 |
Family
ID=37943319
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2006/038609 WO2007044327A2 (en) | 2005-10-04 | 2006-10-03 | Continuous process of roll-forming stamped sheet |
Country Status (4)
Country | Link |
---|---|
US (1) | US20070074556A1 (en) |
EP (1) | EP1941111A2 (en) |
AU (1) | AU2006302593A1 (en) |
WO (1) | WO2007044327A2 (en) |
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US8151614B2 (en) * | 2007-10-17 | 2012-04-10 | Shape Corp. | Variable adjustable cutoff device for roll formers |
US20120131974A1 (en) * | 2007-12-12 | 2012-05-31 | Allied Tube & Conduit Corporation | Arching metallic profiles in continous in-line process |
DE102007061475B3 (en) * | 2007-12-20 | 2009-09-24 | Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.), Kobe | Method of producing formed components from high strength and ultra high strength steels |
US7866716B2 (en) | 2008-04-08 | 2011-01-11 | Flex-N-Gate Corporation | Energy absorber for vehicle |
US8307685B2 (en) * | 2008-04-09 | 2012-11-13 | Shape Corp. | Multi-directionally swept beam, roll former, and method |
US20170183757A1 (en) * | 2008-10-02 | 2017-06-29 | Ms Autotech Co., Ltd. | Hot stamping method for manufacturing vehicle body parts |
CN101758382A (en) * | 2008-12-23 | 2010-06-30 | 上海和达汽车配件有限公司 | Vehicle reinforcing plate processing technique equipment and method thereof |
US8333095B2 (en) * | 2009-09-21 | 2012-12-18 | Shape Corp. | Roll former with three-dimensional sweep unit |
EP2839895B1 (en) * | 2010-09-23 | 2018-06-13 | Shape Corp. | Apparatus and method for forming a tubular beam with single center leg |
EP2830789A1 (en) * | 2012-03-25 | 2015-02-04 | Technische Universität Dortmund | Process and apparatus for the incremental bending of profile tubes, in particular of profile tubes having cross sections which vary over the longitudinal axis |
HUE042774T2 (en) * | 2014-09-22 | 2019-07-29 | Arcelormittal | Methods for producing a three-dimensional vehicle door frame inner reinforcement element, for producing a vehicle door frame and for producing a vehicle reinforcement structure |
US10065587B2 (en) | 2015-11-23 | 2018-09-04 | Flex|N|Gate Corporation | Multi-layer energy absorber |
WO2017098304A1 (en) * | 2015-12-09 | 2017-06-15 | Arcelormittal | Method for producing an automotive structural part comprising a lowerside sill and a lower front pillar |
CN105478488A (en) * | 2016-01-19 | 2016-04-13 | 北新集团建材股份有限公司 | Light steel keel rolling machine equipment |
WO2020112728A1 (en) | 2018-11-27 | 2020-06-04 | Shape Corp. | Galvanized multi-tubular beam and method of continuously forming the same |
CN112317610B (en) * | 2020-09-15 | 2022-11-11 | 深圳市信维通信股份有限公司 | Sheet metal forging and thinning process |
IT202100011909A1 (en) * | 2021-05-10 | 2022-11-10 | Effevi S R L | Method for producing a profile for a fence |
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Also Published As
Publication number | Publication date |
---|---|
AU2006302593A1 (en) | 2007-04-19 |
US20070074556A1 (en) | 2007-04-05 |
WO2007044327A3 (en) | 2008-07-24 |
EP1941111A2 (en) | 2008-07-09 |
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