Classifications

• • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
  • B21C37/00—Manufacture of metal sheets, rods, wire, tubes, profiles or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
  • B21C37/06—Manufacture of metal sheets, rods, wire, tubes, profiles 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
  • B21D13/00—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form
  • B21D13/08—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form by combined methods
• • 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
  • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
  • B21D22/02—Stamping using rigid devices or tools
  • B21D22/08—Stamping using rigid devices or tools with die parts on rotating carriers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D37/00—Tools as parts of machines covered by this subclass
  • B21D37/02—Die constructions enabling assembly of the die parts in different ways
• • 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
  • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D7/00—Bending rods, profiles, or tubes
  • B21D7/08—Bending rods, profiles, or tubes by passing between rollers or through a curved die

Definitions

• This invention relates to the forming of deformable sheet materials from its original profile to a desired profile.
• One application of the invention is to the forming of sheet metal into a desired profile and the invention will be described in detail in relation to that application however it will be apparent that it is more generally applicable to deformable materials.
• Known systems for forming deformable materials such as sheet metal into a desired profile include roll forming processes. These involve passing the sheets through a sequence of roll sets each further deforming the sheet beyond the profile achieved at the previous roll set.
• the disadvantages of roll forming include redundant defomiation resulting from nonuniform strain paths as the strip passes each roli set. That leads to high residual stresses which result in product defects such as edge wave, flare, twist, etc.
• Another disadvantage of roll forming is that the distance between the first roll set and the last roil set is relatively large. Consequently the space needed to house a roll forming assembly is substantial particularly when forming complex profiles.
• Known systems using multiple roll sets also suffer from significant difficulties associated with initial alignment.
• a further disadvantage of roll forming is that tooling design is related to the designer's experience. "Trial and error " ' plays a dominate role in tooling design and alignment and for a new complex profile tooling design, this means the development time is unpredictable. Additionally a large amount of material can be wasted during the period of tooling design and alignment, which contributes to the cost of tooling development.
• the present invention seeks to provide a method and apparatus of forming a profile of a deformable sheet material which provides an alternative for overcoming some of the disadvantages of the prior art.
• the present invention provides an apparatus for forming the profile of deformable materials, said apparatus including:
• each set including a plurality of die elements respectively arranged to travel along corresponding endless paths;
• said paths each including a forming portion in which die elements of each set are opposed to define a forming space therebetween;
• the forming portion of each path being configured so that one or more dimensions of the forming space reduce along the length of the forming portion to simultaneously apply lateral forces to material progressing through the forming portion to shape sajd material to a determined profile.
• the present invention provides an apparatus for forming the profile of deformable materials, said apparatus including:
• At least one set of die elements including a plurality of die elements arranged to travel along an endless path
• a moving forming surface arranged to travel about a corresponding endless path; said paths each including a forming portion in which die elements are to opposed to said forming surface to define a forming space therebetween;
• the forming portion of each path being configured so that one or more dimensions of the forming space reduce along the length of the forming portion to simultaneously apply lateral forces to material progressing through the forming portion to shape said material to a determined profile.
• this invention provides a method of forming the profile of deformable materials, said method including: passing the material through a forming space between moving die elements;
• the die elements being configured in at least two sets, each set including a plurality of die elements respectively arranged to travel along corresponding endless paths;
• said paths each including a forming portion in which die elements of each set are opposed to define said forming space therebetween;
• the forming portion of each path being configured so that one or more dimensions of the space reduce along the length of the forming portion to simultaneously apply lateral forces to material progressing through the forming portion to shape said material to a determined profile.
• this invention provides a method of forming the profile of delormable materials, said method including:
• the die elements being configured in at least one set including a plurality of die elements arranged to travel along an endless path:
• said moving forming surface being ai ranged to travel about a corresponding endless path
• said paths each including a forming portion in which die elements are opposed said forming surface to define said forming space therebetween;
• the forming portion of each path being configured so that one or more dimensions of the space reduce along the length of the forming portion to simultaneously apply lateral forces to material progressing through the forming portion of shape said materia! to a determined profile.
• the die elements can be of any suitable shape required to form the desired profile.
• a moving forming surface it is preferably formed from an elastic material such as a suitable plastics or rubber material.
• the moving forming surface can be made up of a series of discrete blocks each corresponding to one or more die elements or an endless band.
• the dies in each set are arranged for synchronized movement with respect to the dies in the or each other set.
• a number of sequential sets of the apparatus are used to replace the traditional roll sets in a roll forming system.
• the forming process may partially use roll sets and partly the apparatus of the present invention.
• the apparatus of the present invention allows the use of a lesser number of distinct forming stations, each of which provide a continuous deformation equivalent to that performed by a subset of the roll sets of the prior art process.
• the present invention thus provides a hybrid system having a number of distinct forming stages in which continuous forming of the profile takes place.
• a large amount of the design processes, for example "flower" diagrams, used in roll forming are applicable to the design of the system.
• the methods and apparatus of this invention represent significant improvements over conventional roll forming and will result in significantly lower levels of redundant plastic energy and residual stresses in the profile and hence less product defects. Additionally one set of the apparatus of this invention can be used in place of a number of roll sets thus reducing the overall footprint compared to !he conventional roll forming approach.
• the apparatus of this invention additionally have less slippage between dies and material in forming direction, some products having high profile and narrow and deep groves that are difficult to be roll-formed can be produced using this method.
• the apparatus of the invention also provides greater control of the material being formed particularly in controlling the stretching in forming direction. This results in the desired profile being formed without the need for straightening as is often required in prior art roll forming processes.
• Another advantage of the present invention is a significant reduction in the need for initial alignment required in the prior art processes.
• the present invention also allows the profile to be changed without undertaking a realignment process.
• the die sets can be changed, for example, by changing a chain of dies without concern about alignment. This considerably reduces downtime of the apparatus and improves productivity.
• the present invention also provides for significantly simpler and improved safety arrangements. Firstly, there are less "pinch points" in the apparatus which need to be shielded against accidental access. Secondly the configuration, being compact, readily lends itself to being enclosed.
• auxiliary operations used in conventional roll forming are also applicable in the method of the present invention in a similar manner.
• the present invention provides a more gentle and smooth way to enclose the gap to be welded.
• the forming portions of the tracks are preferably formed as a large radius curve. This results in the forming process being comparable to a roll forming process using rolls of very large radius.
• each of the opposed forming portions can be formed as a large curvature radius.
• the radius may be the same or different depending upon the application. In some applications one of the ladii may be infinite (zero curvature), that is, the path is substantially flat.
• the curvature centres of radii may be set on respectively opposite sides of the forming portions or may be on the same side of one of the forming portions and different radii used to achieve a convergence between the tracks in the forming portion.
• the forming portion ma)' be made up of a variable radius. That is, the radius is not constant throughout the forming portion.
• the present invention also has application to forming the profile of deformable tubular sections.
• it is suitable for forming metal tubes of various cross section i ' orra tube with a circular cross section.
• the present invention provides an apparatus for forming the profile of deformable tubular sections, said apparatus including:
• each set including a plurality of die elements respectively arranged to travel along corresponding endless paths;
• said paths each including a forming portion in which die elements of each set are opposed to define a forming space therebetween;
• each said track being configured so that one or more dimensions of the space reduce along the length of the forming portion to simultaneously apply lateral forces in to a section progressing through the forming portion to shape said section to a determined profile.
• this invention provides a method of forming the profile of deformabie tubular sections said method including
• the die elements being configured in at least two sets, each set including a plurality of die elements respectively arranged to travel along corresponding endless paths;
• said paths each including a forming portion in which die elements of each set are opposed to define said forming space therebetween;
• each said path being configured so that one or more dimensions of the space reduce along the length of the forming portion to Simultaneously apply lateral forces to a section progressing through the forming portion to shape said section to a determined profile.
• the dies in each set are arranged for synchronized movement with respect to the dies in the or each other set.
• the paths in the forming portions can be arranged such that die elements act substantially directly opposite each other against respective sides of the tubular section or can be offset or inclined to some extent provided they substantially apply lateral forces to a section.
• die elements act substantially directly opposite each other against respective sides of the tubular section or can be offset or inclined to some extent provided they substantially apply lateral forces to a section.
• three sets of die elements acting at approximately 120 degrees to each other could be used.
• four sets of die elements are used to form two substantially directly opposed pairs in the forming region.
• the forming region of the apparatus is preferably relatively long compared to the deformation required to achieve the determined profile.
• the forming portion can be of the order of 1.5 to 2 metres long.
• the dies can be of any desired shape.
• flat dies are used in opposed pairs to form a rectangular hollow section.
• the dies can be respectively concave, convex, male or female in various configurations to provide the desired determined side profile.
• opposed female and male die profiles may be used to produce a profile with a longitudinally extending groove on one surface.
• a pair of convex dies could be used to provide an elliptical profile.
• Other configurations of dies can be used to produce a wide variety of profiles.
• the sets of dies are driven substantially at the same rate.
• a use of appropriate dies and adjusting the phase of movement of the respective sets of dies can be used to control the deformation of the material to be formed in order to get a better quality of product.
• the die elements in one form of trie invention are arranged in the form of an endless chain with each die element forming or attached to a link connected to the adjacent links.
• the die elements may be fitted to an appropriate track so as to move around the predetermined endless path.
• the individual die elements ma)' or may not be interconnected.
• the pitch between each die in the forming portion of the track is small compared to the radius of the track .
• the pitch-radius ratio is over 1 :500. That is the maximum gap between the adjacent dies is only 1 /500th of the height or even smaller.
• the pitch height is also proportional to the pitch-radius ratio of the pitch.
• the die elements can be driven so as to draw a section to be formed through the forming portion.
• this can be achieved by drive sprockets operating on the chain.
• separate driving rolls or other suitable mechanisms can be employed to either drive the sections through the apparatus or pull the section through the apparatus.
• the apparatus produces a tubular section of constant profile in a continuous process.
• the profile of the sets of dies corresponds to a section having a varying profile. This is a batch process in which lengths of the section having for example tapered profile or formed with ribs or grooves or even profiles varying in shape along the length of the section can be produced.
• Figure 1 is a schematic elevation of an apparatus for forming the profile of deformable .sheet material according to an embodiment of the invention
• Figure 2 is a schematic perspective view of the apparatus shown in Figure 1 ;
• Figure 3(a) is a schematic perspective view of an apparatus for forming the profile of deformable tubular sections according to an embodiment of the invention
• Figure 3(b) is a schematic elevation of part of the apparatus shown in Figure 3(a);
• Figure 4(a) schematically illustrates a configuration of dies suitable for use in the embodiment of Figures 1 and 2 ;
• Figures 4(b) and 4(c) schematically illustrates a configuration oi dies suitable for use in the embodiment of Figure 3;
• Figures 5(a) to 5(c) schematically illustrate a modification to the embodiment of Figures 1 and 2
• Figures 6(a) to 6(c) schematically show different driving mechanisms applicable to the embodiments of both Figures 1 and 2 and Figure 3 ;
• Figures 7(a) to 7(d) schematically show track configurations applicable to the embodiments of both Figures 1 and 2 and Figure 3 ;
• Figure 8 schematically shows the relationship between maximum gap between adjacent dies and the radius of the forming portion of the track applicable to the embodiments of both Figures 1 and 2 and Figure 3 ;
• Figures 9(a) to 9(c) shows some of the profiles that can be formed from a circular section using the embodiment of Figure 3;
• Figure 10 schematically shows a set of dies used in a extensive application of the apparatus of Figures 1 and 2.
• the apparatus i includes two track frames 2, 3 that mount respective sets 4, 5 of die elements 6.
• the die elements 6 have any suitable profile determined by the profile desired to be formed.
• respective male and female die sets suitable for forming a channel or a top-hat profile are shown.
• Each die element 6 is mounted on a chain link 7 respectively connected to the adjacent chain link 7 by a pin 8 in a conventional manner to form a roller chain.
• the track frames 2, 3 define respective endless paths or tracks around which the links 7 travel.
• Each of the paths has a forming portion 9, 10 in which the die elements 6 of each set are opposed to define a forming space 1 1 .
• the forming portions 9, 10 are configured so that (he dimensions of the space 1 1 between the forming portions reduce along its length. In this way transverse forces are simultaneously applied to a section passing through the forming portion.
• the die elements 6 move with the material synchronisely and the distance between the sets of elements 6 gradually reduces.
• Figure 3 shows an embodiment of the invention for forming the profile of a deformable hollow section from a pre-formed tubular section.
• the apparatus 1 includes four track frame elements 2, 2a, 3, 3a arranged in opposed pairs. Each track frame element mounts respective sets 4, 4a, 5, 5a of die elements 6.
• the die elements 6 have any suitable profile determined by the profile desired to be formed in the material.
• Each die element 6 is mounted on a chain link 7 respectively connected to the adjacent chain link 7 by a pin 8 in a conventional manner to form a roller chain.
• the track frames 2, 2a, 3, 3a define respective endless paths around which the links 7 travel.
• Each of the paths has a forming portion 9, 9a, 10, 10a in which the die elements 6 associated with each paii of track frames are opposed to define a forming space 1 1.
• the foimirig portions 9, 9a, 10, 1 0a are configured so that the dimensions of the space 1 1 between the forming portions reduce along its length, in this way transverse forces are simultaneously applied to a section passing through the forming portion. This can be visualised as the section to be formed being forced through a progressively smaller aperture as it progresses through the forming portion.
• Figures 4(a) to 4(c) show three different configurations of die elements 6 profiles at respective locations along the formed portion 10.
• Figure 4(a) shows a configuration applicable to the embodiment shown in Figures 1 and 2 for forming the profile of a deformable sheet materia! m.
• the die sets are made up of respective male and female opposed dies. As the dies move along the forming portions 9, 10 the distance between them decreases to reduce the forming space in the direction from right to left. This progressively forms the material to a desired profile.
• Figures 4(b) and 4(c) show a configuration of die sets used in the embodiment generally described in relation to Figure 3.
• four die sets arranged in opposed pairs are used to form a circular section h into a square section as the dies move together along the forming space.
• Figure 4(c) shows an arrangement in which three sets of dies displaced at 120° to form a circular section h to a triangular profile.
• Figure 5 shows an alternative to the apparatus shown in Figures 1 and 2.
• one lower set 12 of die elements 6 have the profile of the final die profile.
• Three upper sets 6 of progressive shaped complimentary die elements upon track frames 2 are sequentially positioned.
• this provides forming portions 9, 10 at three spaced apart locations.
• the forming portions of the tracks aie configured to progressively reduce the dimensions to the space 1 1 between the dies.
• the material m to be formed progressively proceeds from right to left as shown in the drawings and is formed to the desired profile by the sequential operation of the die sets.
• Figures 6(a) to 6(c) show some exemplary ways in which the apparatus can operate
• the system is provided wi!h driving sprockets which dri ve the two sets of die elements in phase so as to draw a section through the for ing portion
• a separate set of driving rolls is provided to propel this section through the forming portion.
• Figure 6(c) shows a similar configuration in which a separate set of driving rolls are used to push a section through the forming portion.
• Figures 7(a) to 7(d) show some of the possible configurations of the track in the forming portion of the apparatus.
• each of the opposed forming portions has a large radius and the centre of the radii are respectively on the opposite sides of the forming space.
• Figure 7(b) shows configuration in which one of the forming portions has a large radius and another has an infinite radius or in other words is flat.
• Figure 7(c) shows a configuration m which the centres of the radii are both on one side of the forming space and large radii are used for the respective forming portions to provide converging paths between the opposed dies.
• Figure 7(d) shows a configuration in which the radii of the forming portion is not constant to provide a converging track between the opposed dies.
• Figure 8(a) schematically shows the relationship between the maximum gap between adjacent dies on the chain and the radius of the portion of the track.
• the pitch to radius ratio is large and preferably over 1 :500.
• the maximum gap between the adjacent dies is approximately the product of the height and the length divided by the radius of the track.
• the distance s the chord height between cord c extending through the mid point of the upper die surface and the adjacent die corners is a measure of the relative angle between the die blocks. It is approximately equal to the square of the length of each die divided by quad the radius. It will be apparent that larger gaps may occur in portions of the track other than the forming portion without in any way affecting the operation of the apparatus.
• Figures 9(a) to 9(c) schematically shows some of the profiles that can be formed from a circular section using the apparatus of this invention.
• Figure 9(a) shows a triangular profile.
• Figure 9(b) shows a rectangular profile and
• Figure 9(c) a stepped profile. It will be apparent however that appropriate selection of die shapes can produce a wide range of profiles.
• Figure 10 shows a modified form of the die sets suitable for use in the invention as described in figures 1 and 2.
• the uie elements 6 are not uniform but form a taper.
• a profile having a longitudinal taper or other desired non linear form can be formed.
• Embodiments of this invention can be in the form of standalone equipment lined before or after a forming process such as roil forming to process auxiliary operations such as blanking, punching, dooming, coining, shearing and the like. Because the forming dies' velocity is so close the strip's velocity, the auxiliary operation is processed continuously without the interference with the strip that occurs in the rotary punching or dooming.
• a forming process such as roil forming
• auxiliary operations such as blanking, punching, dooming, coining, shearing and the like.
• Figures 1 1 (a) and 1 1 (b) schematically show die configurations for performing punching and dooming respectively.
• opposed dies corresponding shaped to perform the operation more through a forming function in which the dimension of the forming space reduce along the length of the forming portion.
• one part of the die elements are rigid to ensure the profile to be formed but the another can be elastically deformable such as using polyurethane.
• the deformable die elements can provide adequate compressing force to the material to be formed and/or compensate the variation of material properties and thickness.
• Embodiments of the invention can also be used to form a part having limited length that requires multiple passes to form.
• the forming dies for each pass (for example, 8 passes as shown) are arranged in one set and the motions of the sets are synchronised.
• the blank is fed into the former a corresponding number of times to achieve the iinal profile in one machine.
• This arrangement is to save the capita! and space, and another is this type former can be placed beside an assembly line for multi component product and after forming a workpart on-site, the part can be assembled to the product directly.
• a guiding system can be a separate apparatus or embedded in the die-blocks.
• using magnetic die blocks in one die set can sufficiently control the steel strip moving straight forward.
• Other method such as guide plates assembled on the die-blocks may also be applied to guide the strip going straight.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Bending Of Plates, Rods, And Pipes (AREA)
• Press Drives And Press Lines (AREA)
• Shaping Metal By Deep-Drawing, Or The Like (AREA)
• Moulds For Moulding Plastics Or The Like (AREA)
• Shaping Of Tube Ends By Bending Or Straightening (AREA)

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• 2011
  • 2011-06-20 JP JP2013514499A patent/JP5860041B2/ja active Active
  • 2011-06-20 EP EP11794966.9A patent/EP2582474B1/en active Active
  • 2011-06-20 AU AU2011267770A patent/AU2011267770B2/en active Active
  • 2011-06-20 CN CN201180037732.2A patent/CN103313806B/zh active Active
  • 2011-06-20 WO PCT/AU2011/000744 patent/WO2011156873A1/en not_active Ceased
  • 2011-06-20 US US13/805,084 patent/US9676018B2/en active Active

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