VARIABLE THICKNESS ROLL-FORMED BLANK AND ROLL-FORMING SYSTEM AND METHOD
A variable thickness roll forming system for forming a variable thickness blank including at least two sets of cylindrical shaped rollers. Each of the sets of rollers include: a first roller including a face which is linear where the first roller contacts the metal sheet; and a second roller including multiple shaping faces positioned about a perimeter and directed toward the face of the first roller. Each roller set incrementally alters a thickness of a metal sheet in a direction transverse to a metal sheet feed direction when the metal sheet is passed between the first and second rollers. The metal sheet after passing between the first and second rollers forms a roll formed blank having a first portion and a second portion positioned in the direction transverse to the feed direction with respect to the first portion, the first portion thicker than the second portion.
The present disclosure relates generally to roll forming of metal blank materials.
BACKGROUNDThe statements in this section merely provide background information related to the present disclosure and may or may not constitute prior art.
Known roll forming processes provide for altering a thickness of a metal blank in a longitudinal direction parallel to a feed direction of a metal sheet, and for constructing metal blanks from multiple plates of differing thicknesses as desired. Known roll forming processes do not provide for incrementally varying a thickness of a plate across a transverse direction of the plate, and therefore require a second or subsequent manufacturing, welding, or brazing steps to add further material of a differing thickness.
Thus, while current roll forming processes achieve their intended purpose, there is a need for a new and improved system and method for preparing roll formed blanks.
SUMMARYAccording to several aspects, a variable thickness roll forming system for forming a variable thickness blank includes at least two sets of cylindrical shaped rollers. Each of the at least two sets of rollers includes a first roller including a face which is linear where the first roller contacts the metal sheet; and a second roller including multiple shaping faces positioned about a perimeter and directed toward the face of the first roller. Each of the at least two sets of rollers incrementally alters a thickness of a metal sheet in a direction transverse to a feed direction of the metal sheet when the metal sheet is passed between the first roller and the second roller. The metal sheet when passed between the first roller and the second roller forms a roll formed blank having a first portion and at least a second portion positioned in the direction transverse to the feed direction of the metal sheet with respect to the first portion, the first portion having a thickness greater than a thickness of the second portion.
In another aspect of the present disclosure, the multiple shaping faces of the second roller include a first shaping face which defines a first spacing distance between the first shaping face and the face of the first roller.
In another aspect of the present disclosure, the first spacing distance is equal to an initial thickness of the metal sheet.
In another aspect of the present disclosure, the second roller further includes a second shaping face defining a second spacing distance between the second shaping face and the face of the first roller which is less than the initial thickness of the metal sheet.
In another aspect of the present disclosure, the second roller further includes a third shaping face defining a third spacing distance between the third shaping face and the face of the first roller which is less than the initial thickness of the metal sheet.
In another aspect of the present disclosure, the second spacing distance defines a thickness of the second portion of the roll formed blank.
In another aspect of the present disclosure, the third spacing distance defines a thickness of a third portion of the roll formed blank oppositely positioned about the first portion with respect to the second portion.
In another aspect of the present disclosure, a first translational roller is positioned between a first roller set of the multiple roller sets and a second roller set of the multiple roller sets.
In another aspect of the present disclosure, the first translational roller when displaced toward the metal sheet in a displacement direction substantially transverse to the metal sheet deforms and thereby laterally lengthens a portion of the metal sheet between the first roller set and the second roller set.
In another aspect of the present disclosure, a second translational roller is positioned between the first roller set and the second roller set and positioned oppositely about the metal sheet with respect to the first translational roller, the second translational roller when displaced toward the metal sheet in a direction opposite to the displacement direction of the first translational roller deforming and thereby lengthening a further portion of the metal sheet.
According to several aspects, a variable thickness roll forming system for forming a variable thickness blank includes multiple sets of cylindrical shaped rollers. Each of the multiple sets of rollers includes: a first roller having a face which is linear where the first roller contacts a metal sheet; and a second roller having multiple shaping faces positioned about a perimeter and directed toward the face of the first roller. Each of the sets of rollers incrementally alters a thickness of the metal sheet in a direction transverse to a feed direction of the metal sheet when the metal sheet is passed between the first roller and the second roller. The metal sheet when passed between the first roller and the second roller forms a roll formed blank having a central portion, a first outer portion and a second outer portion located opposite about the central portion with respect to the first outer portion, the central portion having a thickness greater than a thickness of each of the first outer portion and the second outer portion.
In another aspect of the present disclosure, the thickness of the central portion after passing through a final one of the sets of rollers is substantially equal to an initial thickness of the metal sheet.
In another aspect of the present disclosure, the thickness of each of the first outer portion and the second outer portion is substantially equal after passing through the final one of the sets of rollers.
In another aspect of the present disclosure, the thickness of the first outer portion is greater than the thickness of the second outer portion after passing through the final one of the sets of rollers.
In another aspect of the present disclosure, the thickness of the first outer portion is less than the thickness of the second outer portion after passing through the final one of the sets of rollers.
In another aspect of the present disclosure, a first translational roller is positioned between a first roller set of the sets of cylindrical shaped rollers and a second roller set of the sets of cylindrical shaped rollers, the first translational roller altering a length and a thickness of the metal sheet in a direction parallel to the feed direction of the metal sheet when the first translational roller is pressed into contact with the metal sheet between the first roller set and the second roller set.
In another aspect of the present disclosure, a second translational roller is positioned between the first roller set of the sets of cylindrical shaped rollers and the second roller set of the sets of cylindrical shaped rollers and oppositely about the metal sheet with respect to the first translational roller.
According to several aspects, a method for forming a variable thickness blank includes: aligning multiple sets of cylindrical shaped rollers, each of the multiple sets of rollers including: a first roller having a face which is linear where the first roller contacts the metal sheet; and a second roller having multiple shaping faces positioned about a perimeter and directed toward the face of the first roller; and passing a metal sheet through each of the sets of rollers to incrementally induce multiple thickness changes of the metal sheet in a direction transverse to a feed direction of the metal sheet when the metal sheet is passed between the first roller and the second roller of each of the sets of rollers.
In another aspect of the present disclosure, the method includes: setting a first spacing distance between a first shaping face of the multiple shaping faces of the second roller and the face of the first roller substantially equal to an initial thickness of the metal sheet; setting a second spacing distance between a second shaping face of the multiple shaping faces of the second roller and the face of the first roller less than an initial thickness of the metal sheet; and setting a third spacing distance between a third shaping face of the multiple shaping faces of the second roller and the face of the first roller less than the initial thickness of the metal sheet.
In another aspect of the present disclosure, the method includes positioning the first, second and third shaping faces wherein the metal sheet when passed between the first roller and the second roller forms a roll formed blank having a central portion, a first outer portion and a second outer portion located opposite about the central portion with respect to the first outer portion, the central portion having a thickness greater than a thickness of the first outer portion and the second outer portion.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
Referring to
Each of the roller sets incrementally changes a thickness in at least a transverse direction 24 of the metal sheet 12. In the example shown using the first roller set 14 and the second roller set 16, a roll formed blank 25 of the metal sheet 12 after passing through both the first roller set 14 and the second roller set 16 may include a central portion 26, a first outer portion 28, and a second outer portion 30 located opposite about the central portion 26 with respect to the first outer portion 28. According to several aspects, the central portion 26 may have a first finished thickness 32 which may equal the initial thickness 22. The first outer portion 28 may have a second finished thickness 34 less than or equal to the first finished thickness 32. The second outer portion 30 may have a third finished thickness 36 less than or equal to the first finished thickness 32 and equal to or different from the second finished thickness 34. Other variations in thickness of the central portion 26, the first outer portion 28, and the second outer portion 30 can also be provided, and roll formed blanks 25 may also have only two of the thickness portions, or may have more than three thickness portions.
Referring to
Using an exemplary initial thickness 22 of the planar body 20 of the metal sheet 12 of 2.00 mm, according to several aspects, the second spacing distance 50 and the third spacing distance 54 may be equal, and in a non-limiting example may be 1.98 mm. These spacing distances create an initial thickness reduction of 0.02 mm where the metal sheet 12 passes between the face 42 of the first roller 38 and each of the second shaping face 48 and the third shaping face 52. The initial thickness 22 may be unchanged or may have a thickness reduction less than 0.02 mm where the metal sheet 12 passes between the face 42 of the first roller 38 and the first shaping face 44 of the second roller 40.
Referring to
Given the exemplary initial thickness 22 of the planar body 20 of the metal sheet 12 of 2.00 mm, according to several aspects, the fifth spacing distance 68 and the sixth spacing distance 72 may be equal, and in a non-limiting example may be 1.96 mm. After the metal sheet 12 passes through the first roller set 14, the spacing distances of the second roller set 16 create an additional thickness reduction of 0.02 mm where the metal sheet 12 passes between the face 60 of the third roller 56 and each of the fifth shaping face 66 and the sixth shaping face 70. The initial thickness 22 may continue to be unchanged where the metal sheet 12 passes between the face 60 of the third roller 56 and the fourth shaping face 62 of the fourth roller 58.
It should be apparent that additional incremental thickness reductions can be made by passing the metal sheet 12 through additional roller sets, as will be discussed in greater detail in reference to
Referring to
In an exemplary aspect, each of the successive roller sets of the roller set gang 74 incrementally reduces the second finished thickness 34 and the third finished thickness 36 by an additional 0.02 mm. After passing through the initializing roller set 76, each of the successive ten thickness reducing roller sets of the roller set gang 74 reduces a thickness in at least one portion of the metal sheet 12 by 0.02 mm, thereby providing a total thickness reduction of 0.2 mm (10 roller sets each creating a reduction of 0.02 mm). In this example, after passing through an eleventh and final roller set 78 the central portion 26 of the metal sheet 12 retains the first finished thickness 32 which is equal to the initial thickness 22, the first outer portion 28 has as the second finished thickness 34 a final thickness of 1.8 mm, and the second outer portion 30 has as the third finished thickness 36 a final thickness of 1.8 mm.
In the above examples, the initial thickness of 2.00 mm and the thickness reduction of 0.02 mm at each passage between a roller set are exemplary values. The thickness reduction that is desired can be varied depending on the number of roller sets, the initial thickness 22, the material of the metal sheet 12, a desired feed rate of the metal sheet 12, the total thickness reduction desired, and other factors.
Referring to
By displacing the translational roller 80 toward the metal sheet 12 in a displacement direction 100, contact with the metal sheet 12 and further controlled downward displacement of the translational roller 80 deforms and thereby longitudinally stretches a length 102 of the metal sheet 12 between the fixed first roller set 82 and the second roller set 84. A rotational speed of the rollers of the fixed second roller set 84 can also be varied (e.g., increased) from a rotational speed of the rollers of the fixed first roller set 82 to permit longitudinal stretching of the length 102 between the fixed first roller set 82 and the fixed second roller set 84.
Referring to
By displacing the first translational roller 106 toward the metal sheet 12 in a displacement direction 126, and by displacing the second translational roller 108 toward the metal sheet 12 in a displacement direction 128 opposite to the displacement direction 126, contact with the metal sheet 12 and further controlled displacement of the translational rollers 106, 108 deforms and thereby increases each of a first length 130 and a second length 132 of the metal sheet 12 between the first roller set 110 and the second roller set 112. A rotational speed of the rollers of the second roller set 112 can also be varied (e.g., increased) from a rotational speed of the rollers of the first roller set 110 to permit longitudinal lengthening of the first and second lengths 130, 132 between the first roller set 110 and the second roller set 112.
Roller translation can directly be controlled using a feedback control system (not shown) designed for the above applications. A thickness reduction achieved for each of the above systems is mapped directly to a displacement in the roll of the metal sheet 12. A blank length can also be controlled by at least one of increasing the metal sheet feed speed, reducing the center-to-center spacing 98, 124 between the fixed roller sets, or decreasing a roller diameter of the translational rollers.
Referring to
A flanged part 138 can be also created. The central portion 26 having a greater thickness than the first outer portion 28 and the second outer portion 30 can provide increased stiffness over an entire length of the flanged part 138. The first outer portion 28 and the second outer portion 30 can each define flanges that can be further modified such as to provide for a flange cutout 140 to suit installation requirements.
An assembly 142 can be created for exemplary use as a vehicle door frame. The central portion 26 can be used as a rigid web, while the first outer portion 28 can be reformed to support a window assembly, while the second outer portion 30 can be formed as a flange to longitudinally stiffen the assembly 142.
A tubular structure 144 can be created using for example two roll formed blanks 25 of the present disclosure. A first central portion 26(1) can be spaced apart from a second central portion 26(2) by joined, for example welded, first outer portions 28(1), 28(2) and joined second outer portions 30(1), 30(2).
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The variable thickness roll forming system 10 of the present disclosure offers several advantages. These include the ability to accurately provide incremental thickness reductions in a metal blank while maintaining a cost effective minimum feed speed for all of the roller sets. This is in lieu of imparting all of the desired thickness reduction using only a single roller set, which may reduce an overall feed speed compared to a feed speed achieved by only applying an incremental thickness reduction over multiple roller sets.
The description of the present disclosure is merely exemplary in nature and variations that do not depart from the gist of the present disclosure are intended to be within the scope of the present disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure.
Claims
1. A variable thickness roll forming system for forming a variable thickness blank, comprising:
- at least two sets of cylindrical shaped rollers, each of the at least two sets of rollers including: a first roller including a face which is linear where the first roller contacts a metal sheet; and a second roller including multiple shaping faces positioned about a perimeter and directed toward the face of the first roller;
- each of the at least two sets of rollers incrementally altering a thickness of the metal sheet in at least a direction transverse to a feed direction of the metal sheet when the metal sheet is passed between the first roller and the second roller;
- wherein the metal sheet when passed between the first roller and the second roller forms a roll formed blank having a first portion and at least a second portion positioned in the direction transverse to the feed direction of the metal sheet with respect to the first portion, the first portion having a thickness greater than a thickness of the second portion.
2. The variable thickness roll forming system of claim 1, wherein the multiple shaping faces of the second roller include a first shaping face which defines a first spacing distance between the first shaping face and the face of the first roller.
3. The variable thickness roll forming system of claim 2, wherein the first spacing distance is equal to an initial thickness of the metal sheet.
4. The variable thickness roll forming system of claim 3, wherein the second roller further includes a second shaping face defining a second spacing distance between the second shaping face and the face of the first roller which is less than the initial thickness of the metal sheet.
5. The variable thickness roll forming system of claim 4, wherein the second roller further includes a third shaping face defining a third spacing distance between the third shaping face and the face of the first roller which is less than the initial thickness of the metal sheet.
6. The variable thickness roll forming system of claim 5, wherein:
- the second spacing distance defines a thickness of the second portion of the roll formed blank; and
- the third spacing distance defines a thickness of a third portion of the roll formed blank oppositely positioned about the first portion with respect to the second portion.
7. The variable thickness roll forming system of claim 1, wherein the thickness of the second portion is reduced by up to approximately 40% of the thickness of the first portion.
8. The variable thickness roll forming system of claim 1, further including a first translational roller positioned between a first roller set of the multiple roller sets and a second roller set of the multiple roller sets.
9. The variable thickness roll forming system of claim 8, wherein the first translational roller when displaced toward the metal sheet in a displacement direction substantially transverse to the metal sheet deforms and thereby laterally lengthens a length of the metal sheet between the first roller set and the second roller set.
10. The variable thickness roll forming system of claim 9, further including a second translational roller positioned between the first roller set and the second roller set and positioned oppositely about the metal sheet with respect to the first translational roller, the second translational roller when displaced toward the metal sheet in a direction opposite to the displacement direction of the first translational roller deforming and thereby lengthening a further portion of the metal sheet.
11. A variable thickness roll forming system for forming a variable thickness blank, comprising:
- multiple sets of cylindrical shaped rollers, each of the multiple sets of rollers including: a first roller having a face which is linear where the first roller contacts a metal sheet; and a second roller having multiple shaping faces positioned about a perimeter and directed toward the face of the first roller;
- each of the sets of rollers incrementally altering a thickness of the metal sheet in a direction transverse to a feed direction of the metal sheet when the metal sheet is passed between the first roller and the second roller;
- wherein the metal sheet when passed between the first roller and the second roller forms a roll formed blank having a central portion, a first outer portion and a second outer portion located opposite about the central portion with respect to the first outer portion, the central portion having a thickness greater than a thickness of each of the first outer portion and the second outer portion.
12. The variable thickness roll forming system of claim 11, wherein the thickness of the central portion after passing through a final one of the sets of rollers is substantially equal to an initial thickness of the metal sheet.
13. The variable thickness roll forming system of claim 12, wherein the thickness of each of the first outer portion and the second outer portion is substantially equal after passing through the final one of the sets of rollers.
14. The variable thickness roll forming system of claim 12, wherein the thickness of one of the first outer portion and the second outer portion is greater than the thickness of the other one of the first outer portion and the second outer portion after passing through the final one of the sets of rollers.
15. The variable thickness roll forming system of claim 11, wherein the thickness of the first outer portion and the thickness of the second outer portion are reduced by up to approximately 40% of the thickness of the central portion after passing through a final one of the sets of rollers.
16. The variable thickness roll forming system of claim 11, further including a first translational roller positioned between a first roller set of the sets of cylindrical shaped rollers and a second roller set of the sets of cylindrical shaped rollers, the first translational roller altering a length and a thickness of the metal sheet in a direction parallel to the feed direction of the metal sheet when the first translational roller is pressed into contact with the metal sheet between the first roller set and the second roller set.
17. The variable thickness roll forming system of claim 16, further including a second translational roller positioned between the first roller set of the sets of cylindrical shaped rollers and the second roller set of the sets of cylindrical shaped rollers and oppositely about the metal sheet with respect to the first translational roller.
18. A method for forming a variable thickness blank, comprising:
- aligning multiple sets of cylindrical shaped rollers, each of the multiple sets of rollers including: a first roller having a face which is linear where the first roller contacts the metal sheet; and a second roller having multiple shaping faces positioned about a perimeter and directed toward the face of the first roller; and
- passing a metal sheet through each of the sets of rollers to incrementally induce multiple thickness changes of the metal sheet in a direction transverse to a feed direction of the metal sheet when the metal sheet is passed between the first roller and the second roller of each of the sets of rollers.
19. The method for forming a variable thickness blank of claim 18, further including:
- setting a first spacing distance between a first shaping face of the multiple shaping faces of the second roller and the face of the first roller substantially equal to an initial thickness of the metal sheet;
- setting a second spacing distance between a second shaping face of the multiple shaping faces of the second roller and the face of the first roller less than an initial thickness of the metal sheet; and
- setting a third spacing distance between a third shaping face of the multiple shaping faces of the second roller and the face of the first roller less than the initial thickness of the metal sheet.
20. The method for forming a variable thickness blank of claim 19, further including positioning the first, second and third shaping faces wherein the metal sheet when passed between the first roller and the second roller forms a roll formed blank having a central portion, a first outer portion and a second outer portion located opposite about the central portion with respect to the first outer portion, the central portion having a thickness greater than a thickness of the first outer portion and the second outer portion.
Type: Application
Filed: Jun 30, 2017
Publication Date: Jan 3, 2019
Inventors: Suhant Prajwal Reddy Ranga (Novi, MI), Stephan Röhner (Dortmund)
Application Number: 15/639,501